CN103895152A - 复合体及其制备方法 - Google Patents

复合体及其制备方法 Download PDF

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CN103895152A
CN103895152A CN201210588381.0A CN201210588381A CN103895152A CN 103895152 A CN103895152 A CN 103895152A CN 201210588381 A CN201210588381 A CN 201210588381A CN 103895152 A CN103895152 A CN 103895152A
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plastics
fiber prepreg
composite part
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秦姚姚
周书祥
徐秋江
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Shenzhen Futaihong Precision Industry Co Ltd
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Priority to TW102102765A priority patent/TWI542471B/zh
Priority to US13/924,709 priority patent/US20140186609A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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    • B29C2045/1486—Details, accessories and auxiliary operations
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

一种复合体，其包括纤维复合材料件及结合于该纤维复合材料件表面的塑料件，该塑料件注塑形成于该纤维复合材料件上，该纤维复合材料件由含浸环氧树脂的纤维束热压成型；在该纤维复合材料件和该塑料件之间设置有一水解的硅烷偶联剂层和一胶粘剂层，其中水解的硅烷偶联剂层与该纤维复合材料件直接结合，胶粘剂层与塑料件直接结合，该胶粘剂层含有单组份聚氨酯。此外，本发明还提供一种所述复合体的制备方法。该复合体中纤维复合材料件与塑料件的结合牢固。

Description

复合体及其制备方法
技术领域
本发明涉及一种复合体及其制备方法，尤其涉及一种纤维复合材料与塑料的复合体及其制备方法。
背景技术
纤维预浸布是由纤维束含浸未熟化的树脂所构成，是目前最常用来制作高性能复合材料的原材料。使用纤维预浸布成型的产品具有质轻、强度高、耐化学腐蚀等优点。纤维预浸布成型产品的方法常使用heat-press技术，该技术通常包括如下步骤：根据需要对纤维预浸布进行裁剪；将纤维预浸布放入成型模具中；模具压合并在模具内加热加压；最后开模，冷却即制得所述纤维复合材料产品。
然而，纤维预浸布通常用来成型平板状结构的产品，且通常无法直接成型出其他的功能性的零部件。现有的方法是将成型后的纤维复合材料产品的表面粘附固体或液体的粘结层，然后将零部件粘附于粘结层表面使二者结合于一体。然而，该种方法，纤维复合材料产品与零部件的结合强度不高，使用过程中二者容易脱离。
发明内容
有鉴于此，有必要提供一种复合体，其含有纤维复合材料件及塑料件，且二者结合牢固。
另外，还有必要提供一种上述复合体的制备方法。
一种复合体，其包括纤维复合材料件及结合于该纤维复合材料件表面的塑料件，该塑料件注塑形成于该纤维复合材料件上，该纤维复合材料件由含浸环氧树脂的纤维束热压成型；在该纤维复合材料件和该塑料件之间设置有一水解的硅烷偶联剂层和一胶粘剂层，其中水解的硅烷偶联剂层与该纤维复合材料件直接结合，胶粘剂层与塑料件直接结合，该胶粘剂层含有单组份聚氨酯。
一种复合体的制备方法，其包括如下步骤：
提供纤维预浸布，该纤维预浸布中含有纤维束及浸润纤维束的未熟化的环氧树脂；
在纤维预浸布表面涂布一层水解的硅烷偶联剂溶液并干燥形成一硅烷偶联剂层；
在该硅烷偶联剂的表面继续涂布胶粘剂形成胶粘剂层，该胶粘剂主要含有单组份聚氨酯；
将经上述处理的纤维预浸布放置于注塑模具内，注塑模具压合且注塑模具内加热加压，注射熔融的塑料材料于纤维预浸布形成有胶粘剂层的表面，冷却后成型为塑料件，同时纤维预浸布中的环氧树脂也固化成型使纤维预浸布成型为纤维复合材料件。
本发明的复合体，先在纤维预浸布的表面涂覆水解的硅烷偶联剂，再在硅烷偶联剂的表面进一步涂覆含单组份聚氨酯的胶粘剂，再将经上述处理的纤维预浸布放入注塑模具中注塑塑料件于纤维预浸布的表面，同时纤维预浸布本身也固化成型为纤维复合材料件，使纤维复合材料件与塑料件结合牢固。
附图说明
图1为本发明一较佳实施例复合体的剖面示意图。
主要元件符号说明
复合体 10
纤维复合材料件 11
塑料件 13
硅烷偶联剂层 15
胶粘剂层 17
如下具体实施方式将结合上述附图进一步说明本发明。
具体实施方式
请参阅图1，本发明一较佳实施方式的复合体10，其包括纤维复合材料件11及结合于该纤维复合材料件11表面的塑料件13。该纤维复合材料件11由含浸环氧树脂的纤维束热压成型，该纤维束可为碳纤维束、玻璃纤维束或聚酰胺纤维束。该塑料件13由常见的热塑性树脂注塑形成，该纤维复合材料件11与该塑料件13为一体化同时成型，该纤维复合材料件11与该塑料件13于同一模具（图未示）中固化成型。
在该纤维复合材料件11和该塑料件13之间设置有一水解的硅烷偶联剂层15和一胶粘剂层17，其中水解的硅烷偶联剂层15与该纤维复合材料件11直接结合，胶粘剂层17与塑料件13直接结合。该胶粘剂层17含有单组份聚氨酯。
该胶粘剂层17中还含有适量的常用于胶粘剂的常规乳化剂、pH调整剂。
经实验测试，本发明的复合体10，纤维复合材料件11与塑料件13间的拉拔力达到3.28Mpa，而未设置有水解的硅烷偶联剂层的复合体的纤维复合材料与塑料间的拉拔力仅为2.64Mpa。可见，本实施例中复合体10的纤维复合材料件11与塑料件13结合牢固。
本明的复合体10的制备方法，其包括如下步骤：
（1）提供纤维预浸布（图未示），该纤维预浸布中含有纤维束及浸润该纤维束的未熟化的环氧树脂。该纤维束可为碳纤维束、玻璃纤维束或聚酰胺纤维束。
（2）使用高频交流电压对该纤维预浸布进行表面电晕放电处理，使纤维预浸布周围的气体产生低温等离子体。该低温等离子体使纤维预浸布表面的环氧树脂分子结构重新排列，产生更多的极性部位，增加纤维预浸布表面的附着能力。该高频交流电压的电压值达到5000-15000V/m2，工作频率为15-24kHZ。
（3）在纤维预浸布表面涂布一层水解的硅烷偶联剂溶液并干燥形成一硅烷偶联剂层15。
配置硅烷偶联剂溶液的方法是：将硅烷偶联剂与有机溶剂按照3-5：95-97的质量比例混合均匀，并缓慢添加相对硅烷偶联剂质量的3%-5%的去离子水使硅烷偶联剂水解。该有机溶剂优选为乙醇，但不限于乙醇。所述干燥处理为在80-120℃的温度条件烘烤15-60分钟。
干燥过程中，该硅烷偶联剂水解产生的活性硅羟基【-Si(OH)3 】与环氧树脂中的羟基（-OH）脱水缩聚，从而形成Si-O键分布于纤维预浸布表面，硅烷偶联剂的另外一端的有机链（含活性基团硅羟基）裸露，从而增加了纤维预浸布表面的活性。
（4）在所述硅烷偶联剂层15的表面继续涂布胶粘剂形成胶粘剂层17。
该胶粘剂主要含有单组份聚氨酯，并含有适量的常用于胶粘剂的常规乳化剂、pH调整剂及稀释剂。该胶粘剂的固含量为40%-60%。
该胶粘剂中含有的活性基团(氨基)可与该硅烷偶联剂有机链上的活性基团(硅羟基)反应结合，通过分子间的作用提高了胶粘剂与纤维预浸布的附着力。所述硅烷偶联剂在纤维预浸布与胶粘剂之间起到一个桥接的作用，可使纤维预浸布与塑料件达到更牢固的结合。
此外，单组份聚氨酯含有异氰酸端基（-NCO），其可逐渐渗透穿过较薄的硅烷偶联剂层，直接跟纤维预浸布中的环氧树脂发生聚合反应。反应式为：胶粘剂-NCO + HO-环氧树脂→胶粘剂-NHCOO-环氧树脂。
如此，通过胶粘剂与硅烷偶联剂层及纤维预浸布中的环氧树脂的反应，可有效提高粘合强度。
（5）将纤维预浸布植入注塑模具注塑成型塑料件。
将经上述处理的纤维预浸布放置于注塑模具内（未图示），注塑模具压合且注塑模具内加热加压，注射熔融的热塑性的塑料材料于纤维预浸布形成有胶粘剂层17的表面，冷却后成型为塑料件13，同时纤维预浸布中的环氧树脂也在模具中固化成型使纤维预浸布成型为纤维复合材料件11。该塑料件13可为卡扣或螺柱等零部件。由于胶粘剂的粘合作用，所述塑料件13能牢固地结合于纤维复合材料件11的表面。
本发明较佳实施例复合体10，先在纤维预浸布的表面涂覆水解的硅烷偶联剂，再在硅烷偶联剂的表面进一步涂覆含单组份聚氨酯的胶粘剂，再将经上述处理的纤维预浸布放入注塑模具中注塑塑料件13于纤维预浸布的表面，同时纤维预浸布本身也固化成型为纤维复合材料件11，使纤维复合材料件11与塑料件13一体化同时成型，因而该纤维复合材料件11与塑料件13结合牢固。
另外，本领域技术人员还可在本发明权利要求公开的范围和精神内做其它形式和细节上的各种修改、添加和替换。当然，这些依据本发明精神所做的各种修改、添加和替换等变化，都应包含在本发明所要求保护的范围之内。

Claims (9)

1.一种复合体，其包括纤维复合材料件及结合于该纤维复合材料件表面的塑料件，该塑料件注塑形成于该纤维复合材料件上，其特征在于：该纤维复合材料件由含浸环氧树脂的纤维束热压成型；在该纤维复合材料件和该塑料件之间设置有一水解的硅烷偶联剂层和一胶粘剂层，其中水解的硅烷偶联剂层与该纤维复合材料件直接结合，胶粘剂层与塑料件直接结合，该胶粘剂层含有单组份聚氨酯。
2.如权利要求1所述的复合体，其特征在于：该纤维复合材料件与该塑料件为一体化成型，且该纤维复合材料件与该塑料件于同一模具中固化成型。
3.如权利要求1所述的复合体，其特征在于：该纤维束为碳纤维束、玻璃纤维束或聚酰胺纤维束。
4.如权利要求1所述的复合体，其特征在于：该塑料件由热塑性树脂注塑形成。
5.一种复合体的制备方法，其包括如下步骤：
提供纤维预浸布，该纤维预浸布中含有纤维束及浸润纤维束的未熟化的环氧树脂；
在纤维预浸布表面涂布一层水解的硅烷偶联剂溶液并干燥形成一硅烷偶联剂层；
在该硅烷偶联剂的表面继续涂布胶粘剂形成胶粘剂层，该胶粘剂主要含有单组份聚氨酯；
将经上述处理的纤维预浸布放置于注塑模具内，注塑模具压合且注塑模具内加热加压，注射熔融的塑料材料于纤维预浸布形成有胶粘剂层的表面，冷却后成型为塑料件，同时纤维预浸布中的环氧树脂也固化成型使纤维预浸布成型为纤维复合材料件。
6.如权利要求5所述复合体的制备方法，其特征在于：该方法还包括在形成硅烷偶联剂层前使用高频交流电压对该纤维预浸布进行表面电晕放电处理。
7.如权利要求6所述复合体的制备方法，其特征在于：该高频交流电压的电压值达到5000-15000V/m2，工作频率为15-24kHZ。
8.如权利要求5所述复合体的制备方法，其特征在于：该硅烷偶联剂溶液中含有硅烷偶联剂、有机溶剂及去离子水，其中硅烷偶联剂与有机溶剂的质量比为3-5：95-97，去离子水的质量为硅烷偶联剂质量的3%-5%。
9.如权利要求5所述复合体的制备方法，其特征在于：所述硅烷偶联剂溶液的干燥处理为在80-120℃的温度条件烘烤15-60分钟。
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