CN103737946A - Forming method of resin matrix composite with double layers of foam sandwich structures - Google Patents
Forming method of resin matrix composite with double layers of foam sandwich structures Download PDFInfo
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- CN103737946A CN103737946A CN201410002892.9A CN201410002892A CN103737946A CN 103737946 A CN103737946 A CN 103737946A CN 201410002892 A CN201410002892 A CN 201410002892A CN 103737946 A CN103737946 A CN 103737946A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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Abstract
The invention discloses a forming method of a resin matrix composite with double layers of foam sandwich structures, the entire forming preparation of the resin matrix composite with double layers of foam sandwich structures is realized by adopting a liquid forming method, the forming method comprises the following steps: on a mold which can heat, employing a step-by-step dipping technology, dipping a lower-layer pre-formed body in a pre-formed body of the double layers of sandwich structures in a Z direction by using a resin film infusion method, and then guiding fluid resin by using a vacuum infusion molding process to dip upper-layer pre-formed body and a middle layer pre-formed body in the pre-formed body of the double layers of sandwich structures; after dipping, carrying out co-curing forming on the upper, middle and lower layers of pre-formed bodies and two foam sandwiches clamped between the upper, middle and lower layers of pre-formed bodies, so as to obtain the resin matrix composite with double layers of foam sandwich structures, wherein the upper, middle and lower layers of pre-formed bodies and the two foam sandwiches are thoroughly dipped by resin. The forming method has the advantages of simplicity in operation, environment protection, low cost, high functionality and the like, and is especially suitable for the forming preparation of a large-size composite material component.
Description
Technical field
The invention belongs to the processing technique field that dimension strengthens polymer matrix composites, relate in particular to a kind of forming method with the polymer matrix composites of sandwich structure.
Background technology
Sandwich structure is since 20th century, the forties occurred, its main feature is that bending rigidity is large, lightweight construction, be that sandwich structure has high specific strength and specific modulus, and endurance, shock resistance are good, sound insulation, the excellent performance such as heat insulation, and apparatus with shock absorbing effectively, simultaneously can also be by selecting suitable panel, core and adhesive, meet the requirement under various service conditions, be therefore important in aerospace engineering " structural material " always.
The moulding of sandwich structure is general, and what adopt is that panel, core are carried out to bonding solidifying after preformed respectively again, the more and bad assurance of bonding quality of operation.For single layer foam sandwich structure composite material, in the middle of some specialities can adopt the method for foaming bonding both sides panel continuously shaped, various types of structures all can also adopt the molding (VIMP) of vacuum importing cheaply technological forming, and (Vacuum infusion molding process is coated with flexible vacuum bag film in one side rigid die, sealing fibre reinforced materials, utilize negative pressure of vacuum to get rid of the gas in die cavity, and drive resin flows to realize resin to fiber and textile impregnation thereof by negative pressure of vacuum, and under room temperature or heating condition direct curing molding): the fabric that lower floor's lay is dry, middle level lay fluting open celled foam core, the fabric that upper strata lay is dry, then adopt the encapsulation of vacuum bag film, resin-dipping, solidify, one-shot forming, in this technique, the designability of panel laying is strong, panel and core are bonding good, product properties is good, promoted effectively the engineering application (referring to table 1) of single layer foam sandwich structure.
Table 1: several typical case's application of individual layer sandwich structure
Along with individual layer sandwich structure is more and more extensive in engineering application, people have also found the some shortcomings that it exists gradually, for example: opposing low velocity impact poor performance.When it is manufacturing the low velocity impact that is subject to exotic in moulding, transportation, operation and maintenance process (as instrument drops, hail impact etc.), by the damage of the various ways such as counter plate causes that MATRIX CRACKING and fibrous fracture, panel and core body boundary emaciated face are glued, thereby cause the reduction of structural-load-carrying capacity, especially significantly declining will appear in compression or shearing bearing capacity, even lose efficacy.The follow-up destruction that damage causes structure is also very serious, for example, after outer panels is destroyed, has water or other materials to infiltrate core and also can cause structural failure.In addition individual layer sandwich structure also can be applicable to military equipment, as helicopter wing, once but structure destroyed, cannot continue to use, need Immediate reconstruction.
In order to address the above problem, people have proposed double-layer sandwich structure.Double-layer sandwich structure as shown in Figure 1, is mainly comprised of top panel 1, lower panel 2, upper foam sandwich 3, lower floor's foam core 4 and wainscot 5.Double-layer sandwich structure not only has the general characteristic of individual layer sandwich structure, and it is special also to have advantages of, is mainly reflected in following three aspects:
(1) double-layer sandwich structure is introduced wainscot 5, has improved its hardness in crash direction, and wainscot 5 can also disperse effect of impact to whole sandwich structure simultaneously, so double-layer sandwich structure has better anti-collision performance.Result of study both domestic and external shows: under higher impact velocity, the degree of injury of multilayer sandwich structure is less than individual layer sandwich structure; After impact, multilayer sandwich structure has higher remnant compressive strengths than individual layer sandwich structure.
(2) there is transition state in the damage type of double-layer sandwich structure, is not that outer panels will lose efficacy once damaging total.Therefore, at some, in emergency circumstances do not need Immediate reconstruction, still can continue to use.
(3) because upper and lower core in double-layer sandwich structure can be the same or different, so can design according to various demands, reach the object of rationally utilizing material, thereby greatly expanded the scope of application of sandwich structure.
With regard to manufacture craft, single layer foam sandwich structure can adopt Vacuum infusion molding process moulding cheaply, in actual forming process, by core perforate (leading glue hole), slot, the dipping of take in face can soak into the upper and lower preform in individual layer sandwich structure as main traditional VIMP technique, and then integral solidifying goods; But for two-ply foam sandwich structure, isolation due to two-ply foam core, traditional VIMP technique that can not adopt this class formation realizes low-cost whole preparation, the same with individual layer sandwich structure, perforate in foam core material (leading glue hole) fluting, the dipping of take in face can soak into upper strata and the middle level preform in double-layer sandwich structure as main traditional VIMP technique, but can not soak into lower floor's preform completely, cannot the qualified double-layer sandwich composite structure of preparation quality.Particularly, after resin system adds solid fireproof filler, resin flows performance declines, and is more difficult to soak into lower floor's preform, can not the good large scale double-layer sandwich composite structure of global formation anti-collision performance.
Visible, though double-layer sandwich structural behaviour is good, its manufacturing process is remarkable, need to be by bonding, curing molding after three deck panels, the preformed of two-layer sandwich difference, operation is many, process costs is high, and bonding quality is difficult to guarantee, these drawbacks limit applying of double-layer sandwich structure.
Summary of the invention
The technical problem to be solved in the present invention is to overcome the deficiencies in the prior art, provides a kind of simple to operate, environmental protection, cost low, functional strong, the forming method that is particularly suitable for the two-ply foam sandwich structure polymer matrix composites of large-sized composite material member.
For solving the problems of the technologies described above, the technical scheme that the present invention proposes is a kind of forming method of two-ply foam sandwich structure polymer matrix composites, it is characterized in that, adopt liquid molding method to realize the global formation preparation of two-ply foam sandwich structure polymer matrix composites, comprise the following steps: on can heating work mould, adopt impregnation technology step by step, utilize lower floor's (bottom) preform in resin molding infiltration method (RFI) Z-direction dipping double-layer sandwich structure preform, adopt again vacuum to import method of molding (VIMP) and import upper strata preform and the middle level preform in liquid resin dipping double-layer sandwich structure preform, after having flooded, the upper, middle and lower layer preform of impregnated with resin and the middle two layers of foam sandwich being mingled with are carried out to co-curing moulding, obtain two-ply foam sandwich structure polymer matrix composites.
In above-mentioned forming method, preferably, described double-layer sandwich structure preform is seated in a resin molding (resin molding is preferably the functional form resin molding with fire-retardant or anti-ultraviolet ageing function) surface, and described double-layer sandwich structure preform comprises lower floor's reinforcing material, lower floor's foam core, middle level reinforcing material, upper foam sandwich and upper strata reinforcing material from the bottom to top successively.
In above-mentioned forming method, preferably, the vacuum leading device that described vacuum imports in method of molding is arranged on the top of described double-layer sandwich structure preform, and utilizes vacuum bag film that described double-layer sandwich structure preform and resin molding are encapsulated in the lump in vacuum importing method of molding.
In above-mentioned forming method, preferably, utilize before resin molding infiltration method Z-direction dipping double-layer sandwich structure preform, first by vacuumize make work mould keep vacuum state (preferably relative vacuum degree is not less than 0.95 atmospheric pressure/atm, be that absolute vacuum is not more than 0.05 atmospheric pressure), then after making resin molding infiltration by heating work mould, Z-direction is flooded double-layer sandwich structure preform (preferably temperature control is 60 ℃~70 ℃).
In above-mentioned forming method, preferred, adopt vacuum to import method of molding and import before liquid resin dipping double-layer sandwich structure preform, close the heating system of described work mould.
In above-mentioned forming method, preferred, by heating work mould again, carry out described co-curing moulding, temperature during co-curing moulding is controlled at 60 ℃~70 ℃, and vacuum degree control is not less than 0.95 atmospheric pressure/atm in relative vacuum.
Compared with prior art, the invention has the advantages that:
(1) the present invention adopts timesharing impregnation technology in Z-direction/face to prepare double-layer sandwich composite structure, belongs to liquid phase global formation, and its processing step and VIMP technique are similar, not only easy and simple to handle, and preparation cost is low;
(2) can lay in resin molding infiltration method of the present invention all in functional form resin moldings such as fire-retardant, anti-ultraviolet ageings, thereby the lower surface that makes double-layer sandwich composite has the function such as fire-retardant, anti-ultraviolet ageing accordingly, makes double-layer sandwich composite structure can meet varying environment instructions for use;
(3) the whole vacuum bag that adopts of the present invention is molded, the fiber volume fraction of each deck panels is higher, in addition double-layer sandwich structure has higher shock resistance than individual layer sandwich structure, and the composite element that thus prepared by technique can be used for the main force support structures such as spacecraft, track traffic, boats and ships;
(4) adopt appearance and size, the form and position tolerance of the double-layer sandwich composite structure of the whole preparation of the present invention guaranteed by rigidity former, easily meet design requirement.
Accompanying drawing explanation
Fig. 1 is the structural representation of existing double-layer sandwich structure.
Fig. 2 is the impregnation technology schematic diagram of forming method of the present invention.
Fig. 3 is bilayer that in the embodiment of the present invention 1, moulding obtains and the photo of individual layer core filled composite material slab construction sample; Be followed successively by from left to right upper and lower foam core aspect ratio at 5:15,10:10,15:5 two-ply foam core filled composite material sample and single layer foam core filled composite material.
Marginal data:
1, top panel (after moulding); 2, lower panel (after moulding); 3, upper foam sandwich; 4, lower floor's foam core; 5, wainscot (after moulding); 6, lead glue hole; 7, middle level preform (before moulding); 8, resin molding; 9, upper strata preform (before moulding); 10, permeable medium; 111, gluing nozzle; 112, injected rubber hose; 121, excessive Jiao Zui; 122, excessive sebific duct; 13, vacuum bag film; 14, lower floor's preform (before moulding); 15, sealing joint strip.
The specific embodiment
Below in conjunction with Figure of description, the invention will be further described with concrete preferred embodiment, but protection domain not thereby limiting the invention.
embodiment 1: prepare two-ply foam sandwich structure polymer matrix composites dull and stereotyped.
A forming method for two-ply foam sandwich structure polymer matrix composites of the present invention as shown in Figure 2, specifically comprises the following steps:
1. mould is prepared:
On metal plate mould (the embedded Resistant heating system) working face of 500mm*500mm, after polishing, clear up, processing, apply releasing agent, standby.
2. material is prepared:
According to product, prepare requirement, be ready to respectively corresponding reinforcing material, RFI resin molding, liquid impregnating resin, and required flow-guiding screen, release cloth, suction collodion, vacuum bag film 13, sealing joint strip 15, the vacuum slot of Vacuum infusion molding process, walk the auxiliary material such as sebific duct, injected rubber hose, collection glue tank.
2.1 RFI resin moldings are prepared:
By 500g epoxy resin E-44 (a kind of light yellow viscous liquid, purchased from Epoxy Resin of Yueyang Petro-Chemical Industry General Plant) and 500g epoxy resin CYD-011(white transparent solid, purchased from Epoxy Resin of Yueyang Petro-Chemical Industry General Plant) be mixed after, add 40g 704 curing agent (a kind of brownish black liquid, main component is glyoxal ethyline and expoxy propane iso-octyl ether addition product, purchased from Tianjin chemical reagent Co., Ltd), stir, on flat plate mold, spread to the resin molding of the about 0.5mm of thickness.After room temperature is dried, cutting with a paper cutter, it is standby to cut 400mm*400mm resin molding.
2.2 reinforcing materials are prepared:
Alkali-free glass fibre 04 plain (purchased from Jiangsu Danyang Zhongya Glass Fiber Co., Ltd.) is cut into 400mm*400mm square and amounts to 18, in 105 ℃ of baking ovens, dry 10h, standby.
2.3 PVC foam core materials are prepared:
By commercial 40kg/m
3pVC foam profile plate (purchased from Tianjin Sa Weisi chemical industry composite Co., Ltd) cut into the 400mm*400mm square that 2 thickness are 10mm, standby.
3. resin molding lay:
At the thick resin molding 8 of ready die surface lay 0.5mm, the lay amount of resin molding 8 is to control (referring to Fig. 2) according to the required amount of resin of lower floor's composite material face of two-ply foam core filled composite material target product.
4. fibre bed lay:
At resin molding 8 surfaces of lay, successively required lower floor's reinforcing material (6 layer of 04 plain), the foam core 4(1 of the lower floor layer PVC foam of lay two-ply foam core filled composite material target product), middle level reinforcing material (6 layer of 04 plain), upper foam sandwich 3(1 layer PVC foam) and upper strata reinforcing material (6 layer of 04 plain).
5. vacuum bag film encapsulation:
According to VIMP technological requirement, in the good fibre bed of lay (comprising RFI resin molding, lower floor's reinforcing material, lower floor's foam core, middle level reinforcing material, upper foam sandwich and the upper strata reinforcing material of lay successively), lay release cloth and permeable medium 10 successively, after arranging that gluing nozzle 111 and excessive glue chew 121, at die edge, apart from the about 70mm~100mm of fibre bed external pasting sealing joint strip 15, and with vacuum bag film 13, all former, auxiliary material are sealed in vacuum bag.
6. vacuum line connects:
Connection glue injection pipe 112 on gluing nozzle 111, chews on 121 and connects the sebific duct 122 that overflows at excessive glue, connects after collection glue tank, then be connected with vavuum pump on the sebific duct 122 that overflows, and checks vacuum.Stop up after injected rubber hose, start vavuum pump, check the sealing of whole die cavity (vacuum bag film packaging area).After die cavity sealing is qualified, can start next operating procedure.
7. resin molding melting infiltration:
Start and maintain die cavity vacuum state, starting mold heating device, making mould be warming up to 60 ℃, after resin molding melting, under vacuum pressure, the resin molding dipping preform 14(of lower floor that makes to be laid in die surface is lower floor's plain fabric of fibre bed).
8. liquid resin vacuum imports:
By epoxy resin LT-5078A(purchased from exhibitions electronic material (Shanghai) Co., Ltd.) and corresponding curing agent LT-5078-2 by the ratio mixing of 100:30 after, injected rubber hose 11 is inserted in glue bucket, open injecting glue valve, glue is imported in sealing die cavity under vacuum pressure effect, by walking sebific duct, lead glue hole 6, after upper strata preform 9 and middle level preform 7 in shunting rapidly, the infiltration fibre bed such as permeable medium 10, close injecting glue valve.
9. integrally curing:
Maintain system vacuum, and mold system (together with also uncured composite) is sent into baking oven, baking oven is warming up to 70 ℃, and insulation 4h, makes to be sealed in the two-ply foam core filled composite material preform integrally curing in vacuum bag film.After fibre bed is solidified, closing molding heating system, makes mould and products temperature be reduced to room temperature.
10. the demoulding and post processing:
Remove vacuum bag film and release cloth, permeable medium, gluing nozzle, walk the auxiliary material such as sebific duct and excessive Jiao Zui, knock gently, two-ply foam core filled composite material flat board is removed from metal plate, remove overlap, obtain two-ply foam sandwich structure polymer matrix composites dull and stereotyped.
Adopt same technique, prepared respectively upper and lower foam core height and be respectively: the two-ply foam core filled composite material sample of 5:15,10:10,15:5 and single layer foam core filled composite material plane plate specimen are shown in Fig. 3.
embodiment 2: prepare double-layer sandwich structural composite material subway head-shield.
1. mould is prepared:
In the composite headstock hood die face of built-in resistor silk heating system, the cleaning of polishing applies releasing agent after processing, standby.
2. RFI resin molding is prepared:
By 5000g epoxy resin E-44 (a kind of light yellow viscous liquid, purchased from Epoxy Resin of Yueyang Petro-Chemical Industry General Plant) and 5000g epoxy resin CYD-011(white transparent solid, purchased from Epoxy Resin of Yueyang Petro-Chemical Industry General Plant) be mixed after, add respectively the ultra-fine Al of 8000g (OH)
3(white powder, Zhuzhou electric locomotive Guang Yuan scientific & technical corporation provides) and 1500g dimethyl methyl phosphonate (DMMP, water white transparency low-viscosity (mobile) liquid, purchased from Qingdao Lian Mei Chemical Co., Ltd.), 400g 704 curing agent (a kind of brownish black liquid, main component is glyoxal ethyline and expoxy propane iso-octyl ether addition product, purchased from Tianjin chemical reagent Co., Ltd), stir, on flat plate mold, spread to the resin molding of the about 1mm of thickness.After room temperature is dried, according to headstock hood shape, cutting with a paper cutter, it is standby to be cut into the resin molding of suitable size.
3. reinforcing material is prepared:
According to headstock hood reinforcing material consumption, alkali-free glass fibre continuous felt, alkali-free glass fibre multi-axial fabric (purchased from Jiangsu Danyang Zhongya Glass Fiber Co., Ltd.) are cut into sizeable square, in 105 ℃ of baking ovens, dry 10h, standby.
4. PVC foam core material is prepared:
By commercial 60kg/m
3pVC foam profile plate (purchased from Tianjin Sa Weisi chemical industry composite Co., Ltd) according to headstock hood shape, cut into the square that thickness is the suitable shape of 30mm, standby.
5. fibre bed lay:
On ready mould, successively after lay resin molding, 2 layers of continuous felt, 6 layers of multiaxial fabric, 1 layer of PVC foam, 2 layers of multiaxial fabric, 1 layer of continuous felt, 2 layers of multiaxial fabric, 1 layer of PVC foam and 6 layers of multiaxial fabric, according to walking adhesive process design, lay release cloth and flow-guiding screen in fibre bed, arrange gluing nozzle, walk sebific duct and excessive Jiao Zui.
6. vacuum bag film encapsulation:
In mold periphery, apart from fibre bed 100mm place adhesive seal adhesive tape, and with vacuum bag film, all materials such as fibre bed are all sealed in vacuum bag film, then connection glue injection and vacuum line, check vacuum.
7. RFI resin molding infiltration:
After vacuum is qualified, start mold heating device, make mould be warming up to 60 ℃, insulation makes after resin molding melting, under vacuum pressure, and the layer fabric reinforcement of infiltration fibre bed.
8. liquid resin infiltration:
By unsaturated polyester resin 9001-I-1, curing agent M50, promoter 5002-M-2(purchased from Nanjing DSM) according to 100:1.1:1.3 ratio, mix, after stirring evenly, injected rubber hose is inserted in glue bucket, open injecting glue valve, glue is imported in sealing die cavity under vacuum pressure effect, by upper strata and the middle level of walking in the shunting rapidly such as sebific duct, flow-guiding screen, infiltration fibre bed, strengthen after fabric, close injecting glue valve.
9. integrally curing:
Maintain system vacuum, and on vacuum bag film covering and heat insulating cotton-wadded quilt, start mold heating device, make mould be warming up to 70 ℃, insulation 6h, makes to be sealed in the double-layer sandwich composite material solidification in vacuum bag film.
10. the demoulding and post processing:
Remove vacuum bag film and other auxiliary material, knock gently, make double-layer sandwich composite headstock hood separated with composite material mould, remove overlap, obtain double-layer sandwich composite headstock hood product.
The present embodiment adopts timesharing impregnation technology in Z-direction/face, manufactured experimently two-ply foam core filled composite material locomotive head cover structure, product surface and inner no significant defect, the composite headstock hood excellent performance of making, bearing under the condition of equal load, than former individual layer Sandwich glass fibrous composite headstock hood loss of weight, surpassing 40%.The various double-layer sandwich composite structure of trial-production has all passed through load-carrying properties test, meets the requirement of design objective completely.
Claims (9)
1. the forming method of two-ply foam sandwich structure polymer matrix composites, it is characterized in that, adopt liquid molding method to realize the global formation preparation of two-ply foam sandwich structure polymer matrix composites, comprise the following steps: on can heating work mould, adopt impregnation technology step by step, utilize the lower floor's preform in resin molding infiltration method Z-direction dipping double-layer sandwich structure preform, then adopt vacuum to import upper strata preform and the middle level preform in method of molding importing liquid resin dipping double-layer sandwich structure preform; After having flooded, the upper, middle and lower layer preform of impregnated with resin and the middle two layers of foam sandwich being mingled with are carried out to co-curing moulding, obtain two-ply foam sandwich structure polymer matrix composites.
2. forming method according to claim 1, it is characterized in that: described double-layer sandwich structure preform is seated in a surface resin film, described double-layer sandwich structure preform comprises lower floor's reinforcing material, lower floor's foam core, middle level reinforcing material, upper foam sandwich and upper strata reinforcing material from the bottom to top successively.
3. forming method according to claim 2, it is characterized in that: the vacuum leading device that described vacuum imports in method of molding is arranged on the top of described double-layer sandwich structure preform, and utilizes vacuum bag film that described double-layer sandwich structure preform and resin molding are encapsulated in the lump in vacuum importing method of molding.
4. forming method according to claim 2, is characterized in that: described resin molding is the functional form resin molding with fire-retardant or anti-ultraviolet ageing function.
5. according to the forming method described in any one in claim 1~4, it is characterized in that: utilize before resin molding infiltration method Z-direction dipping double-layer sandwich structure preform, first by vacuumizing, make work mould keep vacuum state, then after making resin molding infiltration by heating work mould, Z-direction is flooded double-layer sandwich structure preform.
6. forming method according to claim 5, is characterized in that: described vacuum state refers to that relative vacuum degree is not less than 0.95 atmospheric pressure/atm.
7. forming method according to claim 5, is characterized in that: the described heating and temperature control of resin molding infiltration that makes by heating work mould is at 60 ℃~70 ℃.
8. forming method according to claim 5, is characterized in that: adopt vacuum to import method of molding and import before liquid resin dipping double-layer sandwich structure preform, close the heating system of described work mould.
9. forming method according to claim 6, it is characterized in that: by heating work mould again, carry out described co-curing moulding, temperature during co-curing moulding is controlled at 60 ℃~70 ℃, and vacuum degree control is not less than 0.95 atmospheric pressure/atm at relative vacuum degree.
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