CN105437622B - 一种工字型夹芯复合板材的制备工艺 - Google Patents
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Abstract
本发明公开了一种工字型夹芯复合板材的制备工艺，包括如下步骤：（1）、制得工字加强筋；（2）、制得夹芯复合板架构；（3）、添加阻燃剂和发泡。用该制备工艺制得的工字型夹芯复合板，不仅强度高、质量轻，同时能够避免物理连接缺陷，该面板与工字加强筋结构为面接触，与点接触及物理连接相比，大大增加粘接强度，同时又避免了焊接、铆接过程中产生的焊缝、连接缝问题，适宜用于列车内门和绿色家居用门。
Description
技术领域
本发明涉及一种工字型夹芯复合板材的制备工艺，该工字型夹芯复合树脂板材适宜用于列车内门、绿色家居用门。
背景技术
随着工业的不断发展，轻量化产品的应用越来越广，轻量化产品在满足使用性能的同时，可以显著地降低能耗，节约资源，减少成本，还可以起到减振降噪，延长使用寿命等作用。传统的夹芯结构材料多为金属基板材，在轻量化实施方面多设计为铝蜂窝结构，高孔隙率多孔金属板材是一种集物理功能与结构一体化的新型工程材料，它具有独特的微结构特征，可承受较大的塑性变形，但这种铝蜂窝结构金属板材保温效果差，金属比重大，在轻量化实施方面略显不足。
中国专利CN201120294908.X以碳纤维复合材料作为上、下面板，以闭孔刚性泡沫塑料板为夹芯层，构建一种轻质多层结构板材，可以满足航空产品需求。但碳纤维价格昂贵，刚性泡沫塑料板制备工艺复杂，不适合一般的普及推广使用。中国专利CN200920109035.3报道了一种利用特殊的凹凸槽、加强龙骨、L型连接角等结构设计一种凹凸承接式复合板，虽然省去了焊接、铆接过程，但实质仍为物理连接，且该结构繁琐，锁紧力也有待提高。中国专利CN201110220912.6报道了三种不同制备工艺条件获得的金字塔点阵夹芯结构，制作金字塔芯子所用模具设计复杂，工艺操作繁锁，且金字塔芯子与面板采用点接触形式，接触面积较小，强度较低，制造成本高，不适合大量生产及产品化应用。
发明内容
本发明的目的是：提供一种工字型夹芯复合板的制备工艺，用该制备工艺制得的工字型夹芯复合板，不仅强度高、质量轻，同时能够避免物理连接缺陷，在面板与工字加强筋结构为面接触，与点接触及物理连接相比，大大增加粘接强度，同时又避免了焊接、铆接过程中产生的焊缝、连接缝问题。
为了实现上述目的，本发明所采用的技术方案为：一种工字型夹芯复合板材的制备工艺，其特征在于：包括如下步骤：
（1）、制得工字加强筋：将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成一定规格；
（2）、制得夹芯复合板架构：配制树脂浸胶液，浸渍纤维布，将浸渍好的纤维布铺在模具中，挤胶并赶走气泡，获得面板架构；同时将工字加筋结构浸渍在面板架构上，合上模具，进行保温温度为120-180℃，保压压力为0.1-0.3MPa，固化时间为90-150min的保温保压固化，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构；
（3）、添加阻燃剂和发泡：在配置好的聚氨酯白料中，加入阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得工字型夹芯复合树脂板材。
在本发明中：所述步骤（2）中的配制树脂浸胶液为不饱和聚酯树脂、环氧树脂、丙烯酸树脂、酚醛树脂或三聚氰胺甲醛树脂，其中树脂浸胶液的配方为基体树脂100份，固化剂0.1-2份，引发剂0.1-1.5份和脱模剂0.1-2份。
在本发明中：所述步骤（2）中的纤维布为玻璃纤维、碳纤维、芳纶纤维或凯夫拉纤维，其中纤维布的铺敷层数为2-10层，浸胶时间为50-100min。
在本发明中：所述步骤（2）中的工字加强筋结构浸渍在面板架构上的密度分布为3-10个/dm2。
在本发明中：所述步骤（3）中的阻燃剂为磷系阻燃剂，加入量为白料的10%-35%。
采用上述技术方案后，本发明的有益效果为：通过本发明的制备工艺制备出的工字型夹芯复合板材，不仅成本低、强度高、质量轻，符合轻量化特点，同时避免物理连接时的缺陷，适宜用于列车内门和绿色家居用门。
附图说明
图1为本发明中裁剪过的工字加强筋结构；
图2为本发明的夹芯复合板材组合示意图；
图3为本发明的夹芯复合板架构示意图。
具体实施方式
下面将结合附图对本发明作进一步的说明。
实施例1
（1）、将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成5mm×15mm×25mm规格，如图1所示；
（2）、按不饱和聚酯100份，TBPB（过氧化甲酸叔丁脂）1份，BPO（过氧化苯甲酰）0.5份，脱模剂1份配制不饱和聚酯树脂浸胶液，浸渍5层玻璃纤维布，90min后取出铺在模具中，挤胶并赶走气泡，获得面板架构；将上述规格的工字加筋结构浸渍在面板架构上，保证9个/dm2，合上模具，在150℃、0.15MPa下保持100min，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构，如图2所示；
（3）、在配置好的聚氨酯白料中，加入10%的磷系阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得一种工字型夹芯复合树脂板材，如图3所示。
实施例2
（1）、将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成5mm×15mm×30mm规格，如图1所示；
（2）、按不饱和聚脂100份，TBPB（过氧化甲酸叔丁脂）1.5份，BPO（过氧化苯甲酰）0.5份，脱模剂1.5份配制不饱和聚酯树脂浸胶液，浸渍8层凯夫拉纤维布，120min后取出铺在模具中，挤胶并赶走气泡，获得面板架构；将上述规格的工字加强筋结构浸渍在面板架构上，保证4个/dm2，合上模具，在170℃、0.2MPa下保持80min，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构，如图2所示；
（3）、在配置好的聚氨酯白料中，加入25%的磷系阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得一种工字型夹芯复合树脂板材，如图3所示。
实施例3
（1）、将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成5mm×15mm×20mm规格，如图1所示；
（2）、按不饱和聚酯100份，TBPB（过氧化甲酸叔丁脂）1.5份，BPO（过氧化苯甲酰）1份，脱模剂1份配制不饱和聚酯树脂浸胶液，浸渍6层纤维布，100min后取出铺在模具中，挤胶并赶走气泡，获得面板架构；将上述规格的工字加强筋结构浸渍在面板架构上，保证9个/dm2，合上模具，在120℃、0.3MPa下保持150min，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构，如图2所示；
（3）、在配置好的聚氨酯白料中，加入15%的磷系阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得一种工字型夹芯复合树脂板材，如图3所示。
实施例4
（1）、将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成5mm×15mm×25mm规格，如图1所示；
（2）、按不饱和聚酯100份，TBPB（过氧化甲酸叔丁脂）2份，BPO（过氧化苯甲酰）0.5份，脱模剂2份配制不饱和聚酯树脂浸胶液，浸渍10层纤维布，150min后取出铺在模具中，挤胶并赶走气泡，获得面板架构；将上述规格的工字加强筋结构浸渍在面板架构上，保证6个/dm2，合上模具，在150℃、0.2MPa下保持90min，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构，如图2所示；
（3）、在配置好的聚氨酯白料中，加入20%的磷系阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得一种工字型夹芯复合树脂板材，如图3所示。
以上对本发明的具体实施方式进行了描述，但本发明并不限于以上描述。对于本领域的技术人员而言，任何对本技术方案的同等修改和替代都是在本发明的范围之中。因此，在不脱离本发明的精神和范围下所作的均等变换和修改，都应涵盖在本发明的范围内。
Claims (5)
1.一种工字型夹芯复合板材的制备工艺，其特征在于：包括如下步骤：
（1）、制得工字加强筋：将玻璃纤维增强树脂通过拉挤工艺获得工字加强筋结构，并将成型后的结构裁剪成一定规格；
（2）、制得夹芯复合板架构：配制树脂浸胶液，浸渍纤维布，将浸渍好的纤维布铺在模具中，挤胶并赶走气泡，获得面板架构；同时将工字加筋结构浸渍在面板架构上，合上模具，进行保温温度为120-180℃，保压压力为0.1-0.3MPa，固化时间为90-150min的保温保压固化，获得单面板加强筋结构，将单面板加强筋结构另一端面浸渍在另一面板架构上，固化后制得夹芯复合板架构；
（3）、添加阻燃剂和发泡：在配置好的聚氨酯白料中，加入阻燃剂和聚氨酯黑料，注入夹芯复合板架构内，发泡后即得工字型夹芯复合树脂板材。
2.根据权利要求1所述的一种工字型夹芯复合板材的制备工艺，其特征在于：所述步骤（2）中的配制树脂浸胶液为不饱和聚酯树脂、环氧树脂、丙烯酸树脂、酚醛树脂或三聚氰胺甲醛树脂，其中树脂浸胶液的配方为基体树脂100份，固化剂0.1-2份，引发剂0.1-1.5份和脱模剂0.1-2份。
3.根据权利要求1所述的一种工字型夹芯复合板材的制备工艺，其特征在于：所述步骤（2）中的纤维布为玻璃纤维、碳纤维、芳纶纤维或凯夫拉纤维，其中纤维布的铺敷层数为2-10层，浸胶时间为50-100min。
4.根据权利要求1所述的一种工字型夹芯复合板材的制备工艺，其特征在于：所述步骤（2）中的工字加强筋结构浸渍在面板架构上的密度分布为3-10个/dm2。
5.根据权利要求1所述的一种工字型夹芯复合板材的制备工艺，其特征在于：所述步骤（3）中的阻燃剂为磷系阻燃剂，加入量为白料的10%-35%。
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