CN103694693A - 一种焊接溢料改善的增强聚酰胺复合材料及其制备和应用 - Google Patents
一种焊接溢料改善的增强聚酰胺复合材料及其制备和应用 Download PDFInfo
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Abstract
本发明属于聚酰胺复合材料技术领域,公开了一种焊接溢料改善的增强聚酰胺复合材料及其制备方法和应用。该聚酰胺复合材料包含以下质量百分数的组分:聚酰胺45~85%;增强填料10~50%;焊接助剂0.5~5%;溢料改善剂0.1~5%;抗氧剂0.1~2%;热稳定剂0.1~1.5%;加工助剂0.1~1%;其它助剂0.4~4%。本发明通过添加焊接助剂,改善材料的导热性能,并通过添加溢料改善剂,改善材料的热稳定性,实现减少焊接溢料。得到的聚酰胺复合材料具有优异的焊接强度,常温下爆破强度可提高50%,溢料重量可降低47%,焊接时间减少40%,能满足不同行业的要求,因此具有广阔的应用前景。
Description
技术领域
本发明属于聚酰胺复合材料技术领域,特别涉及一种焊接溢料改善的增强聚酰胺复合材料及其制备方法和应用。
背景技术
塑料的焊接方法一般分为两大类:一类是内部加热法(通过材料的机械运动、内部摩擦发热),比如振动焊、旋转焊、超声波焊;另一类是外部加热法,如热气焊、热工具焊、高频焊、激光焊等。由于塑料焊接技术具有低成本、高速度、加工方便、原材料适用范围广、接合性和工艺性好、有利于大型复杂结构制造等综合优势,所以应用越来越广泛,技术越来越成熟。
玻璃纤维增强聚酰胺复合材料,广泛应用在日常用品、电子电气、汽车工业、交通运输、建筑业等领域中。但目前来看,增强聚酰胺材料的焊接普遍存在溢料较多的问题,影响了焊接件的外观和实际使用效果。如何改善增强聚酰胺材料的可焊接性,降低焊接时间,减少焊接过程中的溢料,改善焊接外观,以扩展其在各种行业中的应用,成为目前亟待解决的问题。
发明内容
为了克服上述现有技术的缺点与不足,本发明的首要目的在于提供一种焊接溢料改善的增强聚酰胺复合材料,该聚酰胺复合材料常温下爆破强度可提高50%,溢料重量可降低47%,焊接时间减少40%。
本发明另一目的在于提供一种上述焊接溢料改善的增强聚酰胺复合材料的制备方法。
本发明再一目的在于提供上述焊接溢料改善的增强聚酰胺复合材料在日常用品、电子电气、汽车工业、交通运输、建筑业中的应用。
本发明的目的通过下述方案实现:
一种焊接溢料改善的增强聚酰胺复合材料,包含以下质量百分数的组分:
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的聚酰胺为PA6和PA66中的至少一种。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的增强填料为无机填料和纤维增强剂中的至少一种。
优选地,所述的增强填料为碳酸钙、高岭土、滑石粉、硅灰石、云母、玻璃微珠、玻璃纤维和碳纤维中的至少一种。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的焊接助剂为铜粉、铝粉、镁粉、铁粉、银粉、石墨、纳米碳管、碳纤维和石墨烯中的至少一种,其主要作用为改善材料的导热性能,从而使焊接部分的热量分散更均匀,达到降低焊接时间提高焊接强度的目的。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的溢料改善剂为丙三醇、三羟甲基丙烷、季戊四醇、双季戊四醇、二乙二醇二甲醚、二丙二醇甲醚、聚己内酯二元醇、聚己内酯三元醇和聚己内酯四元醇中的至少一种。溢料改善剂的主要作用为改善材料在焊接时的稳定性,从而达到减少焊接溢料的目的。溢料改善剂的加入可以较明显的提升尼龙的热稳定性,减少尼龙在焊接过程中的分解,使焊接发生部分的尼龙能够保持较高的分子量,从而达到减少焊接溢料的目的。
优选地,所述的聚己内酯二元醇、聚己内酯三元醇和聚己内酯四元醇的分子量范围为2000~3000,此分子量范围的溢料改善剂能够较多的分布在材料近表面的位置,从而在焊接时发挥较好的效果,分子量过小容易在放置过程中失效,分子量过大则无法起到改善溢料的目的。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的抗氧剂为酚类、胺类、亚磷酸酯类、半受阻酚类、含丙烯酰基官能团类、硫代酯和杯芳烃中的至少一种。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的热稳定剂为铜盐和碱金属卤化物的组合。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的加工助剂为羟基改性乙撑双硬脂酸酰胺,其主要作用为提高加工性能。
本发明的焊接溢料改善的增强聚酰胺复合材料,所述的其它助剂包括润滑剂、抗紫外剂和着色剂等中的至少一种。
一种上述焊接溢料改善的增强聚酰胺复合材料的制备方法,包括以下步骤:把聚酰胺、焊接助剂、溢料改善剂、抗氧剂、热稳定剂、加工助剂、其它助剂按比例加入混合机混合均匀,加入双螺杆挤出机中,增强填料从二区侧喂料口加入,挤出造粒,得到焊接溢料改善的增强聚酰胺复合材料。
所述双螺杆挤出机的螺杆长径比为(40~75):1。
所述挤出造粒的工艺条件为:双螺杆挤出机转速为100~1000rpm;一区温度220~260℃,二区温度230~290℃,三区温度220~285℃,四区温度230~290℃,机头温度为235~295℃。
上述焊接溢料改善的增强聚酰胺复合材料在日常用品、电子电气、汽车工业、交通运输、建筑业中的应用。
本发明的机理为:
本发明通过添加焊接助剂,改善材料的导热性能,从而使焊接部分的热量分散更均匀,达到减少焊接时间提高焊接强度的目的。并通过添加溢料改善剂,减少材料在焊接过程中发生的分解,改善材料在焊接过程中的热稳定性,从而实现减少焊接溢料的目的。
本发明相对于现有技术,具有如下的优点及有益效果:
本发明所制备的增强聚酰胺复合材料,与常规制备的增强聚酰胺材料相比,具有优异的焊接强度,常温下爆破强度可提高50%,溢料重量可降低47%,焊接时间减少40%,能满足电子电器,汽车工业,交通运输,建筑业,生活日用品等行业对聚酰胺材料的焊接强度的要求,并且能够降低焊接时间,改善焊接外观,满足不同行业对焊接外观的要求,因此具有广阔的应用前景。
具体实施方式
下面结合实施例对本发明作进一步详细的描述,但本发明的实施方式不限于此。
实施例1:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例2:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例3:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例4:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例5:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例6:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例7:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例8:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
实施例9:焊接溢料改善的增强聚酰胺复合材料的制备
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
下面以不加焊接助剂溢料改善剂的聚酰胺复合材料进行对比。
对比例1
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例2
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例3
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例4
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例5
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例6
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例7
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例8
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对比例9
按重量百分比称取各种原材料,除增强填料外的原料在高速混合器中干混5分钟;将混合好的原料置于双螺杆机中,经熔融挤出,造粒。其中螺筒内温度为:一区250℃,二区280℃,三区280℃,四区290℃,机头290℃,双螺杆挤出机转速为400rpm,增强填料从二区侧喂料口加入。
对实施例1~9和对比例1~9制备得到的聚酰胺复合材料进行性能测试,性能检测结果见表1和表2。
表1焊接溢料改善的增强聚酰胺复合材料的性能指标
实施例 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
爆破强度(bar,23℃) | 11.9 | 8.7 | 10.2 | 11.4 | 9.7 | 9.7 | 6.7 | 18.1 | 19.6 |
溢料重量(g) | 10.1 | 11.2 | 6.7 | 5.7 | 9.5 | 12.3 | 15.2 | 4.3 | 4.9 |
焊接时间(s) | 9.4 | 12.3 | 9.9 | 8.1 | 11.2 | 11.4 | 13.4 | 6.7 | 6.1 |
表2聚酰胺复合材料的性能指标
对比例 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
爆破强度(bar,23℃) | 10.1 | 8.1 | 8.2 | 9.4 | 9.1 | 10.4 | 4.7 | 12.1 | 13.6 |
溢料重量(g) | 12.1 | 13.2 | 12.7 | 13.2 | 14.5 | 15.3 | 30.6 | 16.3 | 17.9 |
焊接时间(s) | 10.3 | 13.2 | 13.9 | 10.1 | 12.2 | 13.4 | 17.4 | 9.4 | 10.2 |
焊接和爆破试验在自制的爆破盒制件上进行,焊接面积为7.64cm2,焊接深度为1.5cm,焊接后放置24h后进行爆破试验,以材料被从焊接位置爆开的最大气体压强作为其爆破强度。取焊接完成后的样件,小心的刮下焊接溢料,并迅速称重。
对比实施例1~9和对比例1~9可以看出,加入焊接助剂和溢料改善剂后,材料的常温爆破强度得到提升,且焊接时间和溢料重量得到了明显的降低,常温下爆破强度可提高50%,溢料重量可降低47%,焊接时间减少40%。
上述实施例为本发明较佳的实施方式,但本发明的实施方式并不受上述实施例的限制,其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。
Claims (10)
1.一种焊接溢料改善的增强聚酰胺复合材料,其特征在于包含以下质量百分数的组分:
2.根据权利要求1所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的聚酰胺为PA6和PA66中的至少一种;所述的增强填料为无机填料和纤维增强剂中的至少一种。
3.根据权利要求1所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的焊接助剂为铜粉、铝粉、镁粉、铁粉、银粉、石墨、纳米碳管、碳纤维和石墨烯中的至少一种。
4.根据权利要求1所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的溢料改善剂为丙三醇、三羟甲基丙烷、季戊四醇、双季戊四醇、二乙二醇二甲醚、二丙二醇甲醚、聚己内酯二元醇、聚己内酯三元醇和聚己内酯四元醇中的至少一种。
5.根据权利要求4所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的聚己内酯二元醇、聚己内酯三元醇和聚己内酯四元醇的分子量范围为2000~3000。
6.根据权利要求1所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的抗氧剂为酚类、胺类、亚磷酸酯类、半受阻酚类、含丙烯酰基官能团类、硫代酯和杯芳烃中的至少一种;所述的热稳定剂为铜盐和碱金属卤化物的组合;所述的加工助剂为羟基改性乙撑双硬脂酸酰胺。
7.根据权利要求1所述的焊接溢料改善的增强聚酰胺复合材料,其特征在于:所述的增强填料为碳酸钙、高岭土、滑石粉、硅灰石、云母、玻璃微珠、玻璃纤维和碳纤维中的至少一种;所述的其它助剂指润滑剂、抗紫外剂和着色剂中的至少一种。
8.一种根据权利要求1~7任一项所述的焊接溢料改善的增强聚酰胺复合材料的制备方法,其特征在于包括以下步骤:把聚酰胺、焊接助剂、溢料改善剂、抗氧剂、热稳定剂、加工助剂、其它助剂按比例加入混合机混合均匀,加入双螺杆挤出机中,增强填料从二区侧喂料口加入,挤出造粒,得到焊接溢料改善的增强聚酰胺复合材料。
9.根据权利要求8所述的焊接溢料改善的增强聚酰胺复合材料的制备方法,其特征在于:所述双螺杆挤出机的螺杆长径比为(40~75):1;所述挤出造粒的工艺条件为:双螺杆挤出机转速为100~1000rpm;一区温度220~260℃,二区温度230~290℃,三区温度220~285℃,四区温度230~290℃,机头温度为235~295℃。
10.根据权利要求1~7任一项所述的焊接溢料改善的增强聚酰胺复合材料在日常用品、电子电气、汽车工业、交通运输、建筑业中的应用。
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