CN103233323A - 环状纤维预制件及其制备方法 - Google Patents

环状纤维预制件及其制备方法 Download PDF

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CN103233323A
CN103233323A CN2013101643780A CN201310164378A CN103233323A CN 103233323 A CN103233323 A CN 103233323A CN 2013101643780 A CN2013101643780 A CN 2013101643780A CN 201310164378 A CN201310164378 A CN 201310164378A CN 103233323 A CN103233323 A CN 103233323A
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ring
fabric
fiber
prefabricated component
needling
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CN103233323B (zh
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缪云良
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Jiangsu Tianniao High Technology Co., Ltd.
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JIANGSU TIANNIAO HIGH TECHNOLOGY Co Ltd
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Priority to US14/771,706 priority patent/US10202715B2/en
Priority to PCT/CN2014/000249 priority patent/WO2014180159A1/zh
Priority to EP14794154.6A priority patent/EP2982789B1/en
Priority to TR2019/07827T priority patent/TR201907827T4/tr
Priority to ES14794154T priority patent/ES2720209T3/es
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Abstract

本发明公开了一种环状纤维预制件及其制备方法。该预制件由包含环状复合织物的环状单元叠置针刺成型，且环状复合织物由同种扇形纤维织物与环状纤维网胎经预针刺定型。该预制件制备方法将扇形纤维织物拼接的环状纤维织物与环状纤维网胎预针刺固定连结成环状复合织物，后进行环状单元的针刺成型，实现所述的环状纤维预制件的制备。本发明有效消除了扇形拼接纤维织物后期针刺变形错位的现象，面内及层间均匀一致性好，具有纤维含量高、力学性能优异、原材料利用率高等优点，经C/C复合后摩擦材料的摩擦性能提高，综合性能优良。本发明可应用于飞机刹车盘复合材料预制件，也可用于高速列车和高级汽车刹车系统中摩擦材料预制件。

Description

环状纤维预制件及其制备方法
 
技术领域
本发明涉及摩擦材料技术领域，尤其是一种纤维预制件，如飞机碳/碳刹车盘用环状纤维预制件，也可以用于高速列车、高级汽车等摩擦材料预制件。
背景技术
刹车盘，现有技术一般采用由碳基体和预氧化纤维增强或碳纤维增强复合制备，相比于以前的粉末冶金材料制备的刹车盘，具有机械性能好、热库性能强、摩擦性能优异、产品可设计性强等优点。生产复合材料刹车盘首要是制备出结构性能优异且易于后期基体增密的环形纤维预制件。
现有技术公开了一种通过圆式针刺台针刺叠置环形层获得的环状纤维预制件，其中环形层是由无纬织物上切割长纤维呈径向及切线方向分布的两种扇形单元交错拼接成（US5323523，US5705264，US4955123），该方法材料损失比从完整的方形或圆形件上进行切割要少，但其提供的切割方式带来的损耗仍然不可忽视。以上发明中两种类型扇形部分交错叠置，面内和层间均匀一致性差，且当扇形单元拼接数量为奇数时，预制体平面内势必出现不均匀的两种纤维连接结构，破坏预制件的整体一致性，最终影响摩擦材料的稳定性；同时，制动力切线方向长纤维含量少而不均匀，经C/C复合后摩擦材料的耐磨损及抗振性差；还可以明显看出，发明中扇形单元采用搭接的方式，该方案易造成面内和层间的不均匀，搭接处相较之下密实且层厚，堵塞了后期碳基体沉积通道，加大了复合工艺控制难度，使复合后摩擦材料内部存在明显的性能差异，工作稳定性差，且单层扇形单元数量越多，预制件厚度越大，差异越明显越突出，整体结构及性能越难控制。
已报道的另一种常见制备方法是由纤维织物叠合经针刺连接后裁切成环状纤维预制件（美国专利US5869411、中国专利96121709、95191073及CN02138191.7），但上述方法成型的环状纤维预制件均需按照使用形状和尺寸去除材料，这使得原材料的有效利用率仅为30%-55%，造成材料的严重浪费；且碳纤维采用0°/900纤维叠置，在制动力切线方向转动面上长纤维量相对较少，影响产品质量的一致性和稳定性。
另外，采用预氧化纤维制备环形纤维预制件是目前公开的、较成熟工艺（CN101575766、CN1945048、CN101503844、CN02138191.7），其优势在于其纺织操作性强，制成短纤维薄毡与长纤维织物交替铺层针刺获得一定预期特征的预制件。然而，该技术有一些缺点。首先，以上方法也需去除材料获得环状纤维预制件，材料利用率低；其次，预氧化纤维需施加张力碳化才能获得较好的强度，但与碳纤维的力学特征相比显著降低并显示出更广泛的分散作用，且预氧化纤维预制件碳化变形较大，与碳纤维组合使用时，由于两者具有不同的热膨胀系数使得后续高温碳化过程造成内应力分布不均匀，增加了工艺控制难度，影响材料的使用性能。
上述不足仍有值得改进的地方。
发明内容
本发明针对现有技术的不足，提出一种环状纤维预制件，该预制件整体均匀性好，结构稳定，具有纤维含量高、力学性能优异、原材料利用率高等优点，经C/C复合后复合材料的摩擦性能提高，综合性能优良。
还提出了上述环状纤维预制件的制备方法，有效消除了扇形拼接纤维织物后期针刺变形错位的现象，克服了扇形纤维织物搭接方式引起的经C/C复合后摩擦材料结构稳定性差的不足，提高了预制件面内及层间的均匀一致性，整体结构稳定、性能优良。
为了实现上述发明第一目的，本发明提供以下技术方案：一种环状纤维预制件，该预制件是由环状单元叠置针刺成型的准三维立体织物，环状单元为由环状的纤维织物与环状的纤维网胎经预针刺定型的环状复合织物，或为该环状复合织物与环状的纤维网胎叠置针刺构成环状物；环状纤维网胎由短切纤维薄毡或短切预氧化纤维薄毡制成。
进一步地，环状纤维织物由2～6个相同扇形的纤维织物拼接构成。
进一步地，环状复合织物中长纤维含量为50%～90%。
进一步地，纤维织物的面密度为120～450g/m2，纤维规格为50K、48K、24K、12K、6K、3K、1K。
进一步地，短切碳纤维薄毡或短切预氧化纤维薄毡的面密度为20～300g/m2，纤维规格为320K、50K、48K、24K、12K。 
进一步地，该环状纤维预制件层间密度为10～18层/cm，长纤维含量为45～85%。
进一步地，该预制件体积密度为0.35～0.70g/cm3。
为了实现上述发明第二目的，本发明提供以下技术方案：采用预针刺定型的针刺成型工艺，将环状的纤维织物与环状的纤维网胎预针刺固定连结成环状复合织物，然后由环状复合织物或其与环状网胎叠置针刺构成环状单元，由环状单元叠置针刺成型准三维立体织物，即环状纤维预制件。
进一步地，该制备方法的具体步骤包括：
（1）将纤维织物裁剪为扇形，并拼接成环状的纤维织物；
（2）步骤（1）环状的纤维织物与环状的纤维网胎预针刺定型，获得环状复合织物，针刺密度为2～6针/cm2；或将该环状复合织物与环状的纤维网胎叠置针刺构成环状物；
（3）步骤（2）的环形复合织物或环状物进行叠置，旋转错开拼接缝；并经针刺工艺在叠置层之间引入Z向纤维，针刺密度为15～35针/cm2；即得到环状纤维预制件。
该制备方法采用预针刺定型的针刺成型工艺，将扇形纤维织物拼接的环状纤维织物与环状纤维网胎预针刺固定连结成环状复合织物，后进行环状单元的针刺成型，实现所述的环状纤维预制件的制备，具体制备步骤包括：
（1）幅宽设计，其作用是满足产品尺寸的要求，在一定的裁切方案下减少周边材料的损耗及有效控制尾料的利用率。根据产品尺寸和扇形纤维织物裁剪角度要求设计纤维织物及网胎的幅宽，控制距裁剪边缘的材料余量在10mm以内。
（2）纤维织物与网胎制备，根据产品性能及结构要求选择一定规格的纤维材料制备所需面密度的纤维织物及网胎。
（3）扇形裁剪，其作用与现有技术相同，根据产品规格及结构性能要求设计扇形纤维织物的尺寸和数量，由设定的裁剪方案获得扇形纤维织物。例如制作φ500mm×φ300mm的环状纤维预制件，如图4所示a、b、c三种不同方式进行裁剪，原材料利用率分别为40%-55%、50%-65%、60%-75%。实践表明扇形角度越小、批次生产产品数量越多，原材料利用率越高。该方法简单易操作，控制容易，适于自动化制备，可以避免方形件或圆形件裁切成环形件造成的大量材料损失。另外，为实现产品结构及性能的设计要求，保留足够多的一定轨迹分布的连续长纤维含量，可按图5所示进行扇形裁剪，其扇形中轴线与纤维织物经向夹角N可以为0°或90°或两者之间任意值。
（4）预针刺定型，由扇形纤维织物拼接成圆环状，与环状网胎预针刺定型获得环状复合织物，针刺密度为2-6针/cm2。该方法消除了扇形拼接的环状纤维织物在后针刺过程中引起的变形及错位现象，且预针刺实现了平面多片扇形纤维织物间及与环状纤维网胎的固定与连接，同时采用同种扇形纤维织物拼成圆环状，均有效提高了预制件面内及层间的均匀一致性，整体结构稳定，复合后摩擦材料结构功能稳定好。
（5）旋转叠置，环形复合织物的叠置按设计角度旋转错开拼接缝，如图6所示；同时，环状单元由扇形拼接的环形纤维网胎与环状复合织物构成时，叠置相邻层扇形拼接缝错开；以上方法可以消除拼接缝重叠对预制件力学性能的影响，同时增强预制件材料的各向同性，满足制动器抗震性的要求。
（6）针刺成型，经针刺工艺引入Z向纤维，实现多层环状单元间的连接，针刺密度为15-35针/cm2。试验表明圆式针刺台装置复杂，技术难度大，易造成多次多处重复针刺，影响材料性能；而采用大规格平面针刺可以实现批量化生产，自动化程度高；同时通过旋转预制件，改变刺针排布方式，可以避免同一部分重复针刺造成的性能二次衰减，实现Z向纤维分布的均匀性，增强预制件材料的各向同性，材料整体一致性好。
（7）可重复所述步骤（5）和（6），即获得本发明所述的环状纤维预制件，成型环状纤维预制件经C/C复合后可按照设计要求将其加工成所需形状和尺寸。
众所周知，预制件材料的各向同性的好坏决定了材料的结构可靠性和性能稳定性，于是为了合理客观表征预制件的性能，性能测试样件的选取和准备显得至关重要。本发明中涉及的预制件力学性能主要包括面内拉伸性能和层间抗拉抗剪性能，面内拉伸性能主要包括轴径向方向和制动力平面切线方向，其中层间结合强度可以通过不同部位Z向纤维的连接强度表征，层间抗剪切性能可以通过T型剥离强度表征，这里如图7所示制备测试样件，为后期复合材料的整体性能提供参照作用。
本发明采用包含环状复合织物的环状单元叠置针刺获得厚度和体积密度预期要求的预制件。环状复合织物由同种扇形纤维织物与环状纤维网胎经预针刺定型，通过低密度针刺实现扇形拼接的环状纤维织物与环状纤维网胎的复合，该方法纤维损伤小，有效地将单层相邻扇形纤维织物进行固定和连结，消除了扇形拼接纤维织物后期针刺变形及错位的现象，克服了搭接方式带来复合后摩擦材料结构稳定性差的不足，提高了面内和层间的均匀性；单层环状纤维织物由同种扇形纤维织物构成，进一步提高了预制件整体的均匀性；另外，环状复合织物旋转叠置错开拼接缝，制备过程均采用相同材料为原材料，均提高了预制件的各向同性，与传统0°/90°铺层结构相比，纤维抱合力强，确保了面内纤维的力学特征良好；同时扇形裁剪拼接环形有效减少了从完整的圆形件或方形件上进行切割造成的材料损失，该方法可以提高制动力切线方向转动面上长纤维的含量，确保C/C复合后复合材料的耐摩擦性能好。综合来讲，该预制件结构稳定性好，性能优异、纤维含量高，原材料利用率高，预制件经C/C复合后复合材料的摩擦性能提高，综合性能好。该预制件层间密度为10-18层/cm，长纤维含量为45-85%，体积密度为0.35-0.70 g/cm3，原材料利用率为55%-75%。本发明可应用于飞机刹车盘复合材料预制件，也可用于高速列车和高级汽车刹车系统中摩擦材料预制件。
附图说明
图1为环状复合织物结构示意图，1为环状纤维网胎，2为表示环状纤维织物；
图2为环状纤维织物示意图，3为扇形纤维织物；
图3为环状纤维预制件结构示意图，4为环状复合织物，5为环状单元；
图4为扇形纤维织物裁剪示意图，a、b、c三种不同裁剪方案，6为纤维织物；
图5为扇形纤维织物裁剪角度示意图，N扇形纤维织物中轴线与纤维织物经向夹角；
图6为环状复合织物错开拼接缝示意图，a为三片扇形拼接成环，b为五片扇形拼接成环，c为六片扇形拼接成环，α设定旋转角度；
图7为环状纤维预制件性能测试取样示意图，XY为制动力切线方向拉伸测试，T为T型剥离性能测试，Z为层间结合强度，a五片拼接叠置旋转角度为14°，b六片拼接叠置旋转角度为15°。
具体实施方式
下面结合实施例和附图对本发明进行详细描述，本部分的描述仅是示范性和解释性，不应对本发明的保护范围有任何的限制作用。
实施例1
由48K预氧化纤维制备预氧化纤维平纹织物及短切预氧化纤维网胎，其面密度分别为420g/m2、90g/m2；设计扇形纤维织物尺寸为φ470mm×φ180mm（扇形角度为120°），按图4（b）所示裁剪方案获得；拼接3片扇形纤维织物成圆环状，短切预氧化纤维网胎直接裁剪成圆环状，经5针/cm2的针刺密度定型环状复合织物；环状复合织物交替叠置以25针/cm2的针刺密度进行针刺；按图6（a）所示旋转叠置环状复合织物，每八层环状单元为一个重复结构单元，设定拼接缝夹角为15°；最终获得尺寸为φ450mm×φ200mm×22mm的环状预氧化纤维预制件，其层间密度为12.7层/cm，长纤维含量为82%，体积密度为0.65g/cm3，原材料利用率为58%。
实施例2
由12K聚丙烯腈基碳纤维制成短切碳纤维网胎和无纬织物，其面密度分别为40g/m2，280g/m2；设计扇形纤维织物的尺寸为φ520mm×φ170mm（扇形角度为72°），按图4（a）所示裁剪方案获得；拼接5片扇形纤维织物成圆环状，短切碳纤维网胎直接裁剪成圆环状，经3针/cm2的针刺密度定型环状复合织物；环状复合织物及环状纤维网胎交替叠置组成环状单元，以30针/cm2的针刺密度进行针刺；按图6（b）所示叠置环状复合织物，每五层环状单元为一个重复结构单元，设定拼接缝夹角为14°；最终获得尺寸为φ500mm×φ190mm×24mm的环状碳纤维预制件，其层间密度为14.3层/cm，长纤维含量为78%，体积密度为0.53g/cm3，原材料利用率为62%；按图7（a）所示取样测试，该预制件制动力切线平面拉伸强度均值为3.12MPa，T型剥离强度均值为0.818KN/m，Z向连接强度均值为0.087MPa。
实施例3
分别采用50K和24K的聚丙烯腈基碳纤维为原料制备成无纬织物和短切纤维网胎，其面密度分别为180g/m2、90g/m2；设计扇形纤维织物的尺寸为φ540mm×φ80mm（扇形角度为60°），按图4（c）所示裁剪方案获得扇形纤维织物及扇形网胎；分别拼接6片扇形组成圆环状，环形纤维织物与环状纤维网胎拼接缝错开30°叠置，经2针/cm2的针刺密度成型环状复合织物；交错旋转叠置环状复合织物，以25针/cm2的针刺密度进行针刺；按图6（c）所示叠置环状复合织物，每四层环状复合织物为一个重复结构单元，设定拼接缝夹角为15°；最终获得尺寸为φ520mm×φ100mm×35mm的环状碳纤维预制件，其层间密度为17.7层/cm，长纤维含量为67%，体积密度为0.48g/cm3，原材料利用率为70%；按图7（b）所示取样测试，该预制件制动力切线平面拉伸强度均值为2.84MPa，T型剥离强度均值为0.832KN/m，Z向连接强度均值为0.088MPa。

Claims (9)

1.一种环状纤维预制件，该预制件是由环状单元叠置针刺成型的准三维立体织物，其特征在于：环状单元为由环状的纤维织物与环状的纤维网胎经预针刺定型的环状复合织物，或为该环状复合织物与环状的纤维网胎叠置针刺构成环状物；环状纤维网胎由短切纤维薄毡或短切预氧化纤维薄毡制成。
2.如权利要求1所述环状纤维预制件，其特征在于：环状纤维织物由2～6个相同扇形的纤维织物拼接构成。
3.如权利要求1所述环状纤维预制件，其特征在于：环状复合织物中长纤维含量为50%～90%。
4.如权利要求1或2所述环状纤维预制件，其特征在于：纤维织物的面密度为120～450g/m2，纤维规格为50K、48K、24K、12K、6K、3K、1K。
5.如权利要求1所述环状纤维预制件，其特征在于：短切碳纤维薄毡或短切预氧化纤维薄毡的面密度为20～300g/m2，纤维规格为320K、50K、48K、24K、12K。
6.如权利要求1所述环状纤维预制件，其特征在于：该环状纤维预制件层间密度为10～18层/cm，长纤维含量为45～85%。
7.如权利要求1所述环状纤维预制件，其特征在于：该预制件体积密度为0.35～0.70g/cm3。
8.一种权利要求1所述环状纤维预制件的制备方法，该制备方法采用预针刺定型的针刺成型工艺，将环状的纤维织物与环状的纤维网胎预针刺固定连结成环状复合织物，然后由环状复合织物或其与环状网胎叠置针刺构成环状单元，由环状单元叠置针刺成型准三维立体织物，即环状纤维预制件。
9.如权利要求8所述制备方法，其特征在于：该制备方法的具体步骤包括：
（1）将纤维织物裁剪为扇形，并拼接成环状的纤维织物；
（2）步骤（1）环状的纤维织物与环状的纤维网胎预针刺定型，获得环状复合织物，针刺密度为2～6针/cm2；或将该环状复合织物与环状的纤维网胎叠置针刺构成环状物；
（3）步骤（2）的环形复合织物或环状物进行叠置，旋转错开拼接缝；并经针刺工艺在叠置层之间引入Z向纤维，针刺密度为15～35针/cm2；即得到环状纤维预制件。
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CN115235289A (zh) * 2022-06-30 2022-10-25 江苏恒神股份有限公司 一种复合材料弹托及成型方法

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