CN105459288A - 制造纤维增强树脂模制品的制造方法 - Google Patents
制造纤维增强树脂模制品的制造方法 Download PDFInfo
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Abstract
一种制造纤维增强树脂模制品的制造方法包括:在捏合机中将熔融热塑性树脂与通过将增强纤维束(FB)开松获得的开松增强纤维(F1)捏合以制造捏合的混合物(M);并将捏合的混合物(M)放入或装入模塑装置(30)中以制造纤维增强树脂模制品。
Description
技术领域
本发明涉及一种通过将树脂与增强纤维捏合,然后将捏合的混合物放入或装入模塑装置中而制造纤维增强树脂模制品的方法。
背景技术
由于轻质和高强度,由混有增强纤维的树脂制造的纤维增强树脂模制品(纤维增强塑料(FRP))用于各种工业领域中,例如汽车工业、建筑工业和航空工业。
例如,在汽车工业中,纤维增强树脂模制品用于车辆框架结构元件如支柱、摇臂和下部地板,以及需要提供精细外观的车辆非结构元件如发动机罩面板。这可降低车辆重量,同时确保车辆具有足够的强度,由此有助于制造节约燃料且环境友好车辆的尝试。
存在多种多样的制造上述纤维增强树脂模制品的制造方法。在一种制造方法中,使用捏合机,例如双螺杆挤出机。根据该方法,首先将树脂粒料供入捏合机的树脂熔融区中,在其中树脂粒料熔融,然后将熔融的树脂从树脂熔融区中挤出。然后,将增强纤维束供入捏合机的捏合区域中,在其中将熔融的树脂与增强纤维捏合,从而制得捏合的混合物。然后,将捏合的混合物放入或装入模塑装置中。以此方式制得了纤维增强的树脂模制品。
供入捏合机中的增强纤维的实例包括碳纤维和玻璃纤维。就易于处理和生产效率的角度而言,将作为用粘合剂结合在一起的例如12K(12000)、24K(24000)或50K(50000)纤维(单丝)束的粗纱原样供入捏合机中,在捏合机中切断,然后与熔融的树脂捏合,从而制得捏合的混合物。
美国专利6,776,596描述了一种纤维增强树脂的制造装置,在其中将树脂(热塑性树脂)和增强纤维的粗纱供入双螺杆挤出机中,将增强纤维的粗纱与热塑性树脂捏合,同时增强纤维由于双螺杆挤出机的螺杆旋转而切断,由此制得捏合的混合物。
如上所述,通过将增强纤维束供入捏合机中而制造用于纤维增强树脂模制品的捏合混合物。以此方式,无需对该易于处理的增强纤维进行任何加工。其结果是提高了生产效率。然而,增强纤维结合在一起,从而形成束,因此在各束的内部和外部之间由捏合机施加至纤维束上的外部力显著变化。其结果是在捏合机中破碎后,增强纤维的纤维长度显示出宽分布(宽范围波动)。纤维长度分布很宽(在宽范围内变化),例如从1mm或更短的长度至25mm或更长的长度。由包含具有宽长度分布的增强纤维的捏合混合物制得的纤维增强树脂模制品具有物理性质波动,因此成为具有强度波动的质量较次的模制品。
发明内容
本发明提供了一种通过将树脂与增强纤维捏合,然后将捏合的混合物放入或装入模塑装置中而制造纤维增强树脂模制品的制造方法,所述制造方法能制造具有较窄物理性质波动的纤维增强树脂模制品。
本发明的一个方面涉及一种制造纤维增强树脂模制品的制造方法。所述制造方法包括:在捏合机中将熔融热塑性树脂与通过将增强纤维束开松获得的开松增强纤维捏合以制造捏合的混合物;和将捏合的混合物放入或装入模塑装置中以制造纤维增强树脂模制品。
在本发明的制造方法中,捏合的混合物通过将通过增强纤维束开松获得的开松增强纤维供入捏合机中而制造,而不是将增强纤维束,即增强纤维的粗纱供入捏合机中。由于将开松的增强纤维供入捏合机中,由捏合机施加至开松增强纤维上的外部力(切断力)变得尽可能均匀,从而使得增强纤维的纤维长度在切断后变得尽可能均匀。其结果是,获得了包含具有较窄纤维长度分布的增强纤维的捏合混合物。因此,可制得具有较窄物理性质波动的纤维增强树脂模制品。值得注意的是,“纤维开松”意指使增强纤维束变为连续且宽薄形式的步骤。由于存在于厚度方向上的纤维数量通过纤维开松而减少,因此纤维束容易且均匀地被树脂浸渍。
在这种情况下,可使用例如其中引入螺杆的双螺杆捏合机(捏合型挤出机)作为捏合机。
存在各种用于开松增强纤维束的方法。开松方法的实例包括用圆棒挤压纤维束的方法、通过将纤维暴露于水流或高压气流中而分开纤维的方法,和通过用超声振动法振动纤维而分开纤维的方法。然而,就生产效率以及开松宽度和开松厚度的高精度控制而言,优选使用装备有开松辊的开松装置。
所用热塑性树脂的实例包括结晶塑料如聚烯烃树脂,包括聚丙烯(PP),和尼龙(PA),以及无定形塑料如聚碳酸酯(PC)和热塑性环氧树脂。
所用增强纤维的实例包括由任一种下述纤维类型中构成的单一材料纤维和由两种或更多种下述纤维类型构成的混合材料纤维:无机纤维如玻璃纤维和碳纤维;陶瓷纤维;金属纤维;和有机纤维。
可使用包括压缩模塑、注射模塑、注射挤出模塑的各种模塑方法作为模塑捏合混合物的模塑方法。因此,就“将捏合的混合物放入或装入模塑装置中”而言,当对捏合的混合物进行压缩模塑时,将该捏合的混合物放入模塑装置中;而当对捏合的混合物进行注射模塑等时,将该捏合的混合物装入模塑装置中。
在根据本发明上述方面的制造方法中,可通过将开松的增强纤维切断而获得切段增强纤维,且可将切段增强纤维供入捏合机中以制造捏合的混合物。
通过将开松的增强纤维切断而获得切段增强纤维,并将切段增强纤维供入捏合机中。因此,可使得纤维长度分布变窄,由此制得包含具有较窄纤维长度分布的增强纤维的捏合混合物。
在根据本发明上述方面的制造方法中,捏合机可具有位于上游侧且热塑性树脂通过其供入捏合机的树脂进料口、位于树脂进料口的下游且增强纤维通过其供入捏合机的纤维进料口,和捏合的混合物通过其从捏合机挤出的挤出口。此外,捏合机可至少在树脂进料口和纤维进料口之间的位置具有放气口,其中由熔融热塑性树脂产生的挥发性气体通过放气口从捏合机中排出。
开松且切段的增强纤维(例如碳纤维)可为具有约6-7μm直径的显著细的纤维。因此,切段增强纤维供入纤维进料口可能受到由热塑性树脂产生的挥发性气流的阻碍。
为了防止该问题,在树脂进料口和纤维进料口之间的位置具有放气口,其中由熔融热塑性树脂产生的挥发性气体通过放气口从捏合机中排出。其结果是,切段增强纤维被高效供应至位于放气口下游的纤维进料口。
值得注意的是,“捏合机至少在树脂进料口和纤维进料口之间的位置具有放气口,其中由熔融热塑性树脂产生的挥发性气体通过放气口从捏合机中排出”不仅包括在树脂进料口和纤维进料口之间具有放气口的构造,而且包括其他设置,例如其中除上述放气口之外,在纤维进料口下游具有另一放气口的构造。
在根据本发明上述方面的制造方法中,捏合机可具有进料辅助机构,其将切段增强纤维辅助进料至纤维进料口,增强纤维通过纤维进料口供入捏合机中。所述进料辅助机构可为抽吸单元或产生朝向纤维进料口的气流的气流发生器,所述气流发生器位于纤维进料口附近。
至少在纤维进料口的上游位置处具有放气口防止了如下问题:切段增强纤维进料至纤维进料口会受到由热塑性树脂产生的挥发性气流的阻碍。在上述构造中,进料辅助机构位于捏合机处或其附近,从而辅助切段增强纤维进料至纤维进料口中。
进料辅助机构可为位于捏合机纤维进料口附近的抽吸单元。在这种情况下,切段增强纤维被抽吸单元抽吸,从而引入纤维进料口中。或者,进料辅助机构可为气流发生器,例如鼓风机,其位于纤维进料口附近。在这种情况下,切段增强纤维被气流发生器产生的气流引入纤维进料口中。
正如可从上文描述得知的那样,根据本发明的制造纤维增强树脂模制品的制造方法,通过将开松增强纤维供入捏合机中而制造捏合的混合物,且通过将捏合的混合物放入或装入模塑装置中而制造纤维增强树脂模制品。因此,由捏合机施加至供入捏合机中的开松增强纤维的外部力(切断力)在开松增强纤维的整个区域上变得尽可能均匀,从而使得增强纤维的纤维长度在切断后变得尽可能均匀。其结果是,获得包含具有较窄纤维长度分布的增强纤维的捏合混合物。因此,可制造具有较窄物理性质波动的纤维增强树脂模制品。
附图说明
下文将参照附图描述本发明示例性实施方案的特征、优点以及技术和工业意义,在附图中,相同的数字表示相同的零件,且其中:
图1是示意图,其显示了将增强纤维束开松以获得开松增强纤维的方法;
图2A和图2B是示意图,其显示了根据本发明第一实施方案的制造纤维增强树脂模制品的制造方法,其中使用开松增强纤维;
图3A和图3B是示意图,其显示了根据本发明第二实施方案的制造纤维增强树脂模制品的制造方法,其中使用切段增强纤维;
图3C是示意图,其显示了本发明第二实施方案的改进实例;
图4是照片图,其显示了从通过常规制造方法制造的纤维增强树脂模制品中取样的增强纤维;
图5是照片图,其显示了从通过本发明制造方法制造的纤维增强树脂模制品取样的增强纤维;
图6A是照片图,其显示了切出弯曲测试件的纤维增强树脂模制品的位置;
图6B是曲线图,其显示了在本发明实施例和对比实施例各自中在弯曲测试中测得的各测试件的弯曲强度以及测试件的弯曲强度标准偏差;和
图6C是曲线图,其显示了在各实施例和对比实施例中在弯曲测试中测得的各测试件的弯曲弹性模量以及测试件的弯曲弹性模量标准偏差。
具体实施方式
下文将参照附图描述根据本发明第一和第二实施方案的制造纤维增强树脂模制品的制造方法。在附图所示的制造方法中,使用压缩模塑装置作为模塑装置。然而,也可使用除压缩模塑之外的模塑方法,例如注射模塑和注射压缩模塑来模塑捏合的混合物。当使用除压缩模塑之外的模塑方法时,使用适于这些模塑方法的模塑机(模塑装置)。在附图所示的制造方法中,借助机器手将由捏合机挤出的捏合混合物输送至模塑装置。然而,不言而喻,可例如借助从捏合机延伸至模塑装置的辊式输送机将捏合的混合物输送至模塑装置,或者可手动输送至模塑装置。
下文将描述根据本发明第一实施方案的制造纤维增强树脂模制品的制造方法。图1为示意图,其显示了将增强纤维束开松以获得开松增强纤维的方法。图2A和图2B为示意图,其显示了根据本发明第一实施方案的制造纤维增强树脂模制品的制造方法,其中使用开松的增强纤维。
首先,如图1所示,借助开松装置(未示出)将增强纤维束FB开松以获得具有指定开松宽度和指定开松厚度的开松增强纤维F1。
该情况下所用的增强纤维的实例包括由任一种下述纤维类型构成的单一材料纤维和由两种或更多种下述纤维类型构成的混合材料纤维:由硼、氧化铝、碳化硅、氮化硅或二氧化锆制成的陶瓷纤维;玻璃纤维;碳纤维(聚丙烯腈(PAN)基碳纤维和沥青基碳纤维二者均可使用);由铜、钢、铝或不锈钢制成的金属纤维;和由聚酰胺或聚酯制成的有机纤维。
随后,将借助图2A所示的捏合机10制造热塑性树脂和增强纤维的捏合混合物M。图2A中所示的捏合机10包括引入捏合机10主体11中的螺杆12。此外,捏合机10具有位于最上游侧的树脂进料口(进料斗)13,和位于最下游侧的挤出口14。
在树脂进料口13的下游位置处具有两个放气口16,17。由熔融热塑性树脂产生的挥发性气体通过放气口16,17分别沿气体排出方向Y1,Y2从主体11中排出。此外,在放气口16,17之间具有纤维进料口15。将由热塑性树脂制成的树脂粒料J沿方向X1供入树脂进料口13中。
在这种情况下,可使用结晶塑料或无定形塑料作为所述热塑性塑料。结晶塑料的实例包括聚乙烯(PE)、聚丙烯(PP)、尼龙(PA:尼龙6、尼龙66等)、聚甲醛(POM)和聚对苯二甲酸乙二醇酯(PET)。无定形塑料的实例包括聚苯乙烯(PS)、聚碳酸酯(PC)、聚甲基丙烯酸甲酯(PMMA)、ABS树脂和热塑性环氧树脂。
将由树脂进料口13供入的树脂粒料J在主体11中加热和熔融,且沿方向Z向下游输送,同时借助螺杆12捏合。
如上文所述,由熔融热塑性树脂产生挥发性气体。然而,挥发性气体通过放气口16,17沿方向Y1和方向Y2排出。这防止了开松增强纤维F1供应至纤维进料口15受到向上的挥发性气流的阻碍的问题。
借助螺杆12将通过纤维进料口15沿方向X2供入的开松增强纤维F1切断,与熔融热塑性树脂捏合,并挤出至挤出口14。然后,通过挤出口14获得捏合的混合物M。
随后,如图2B所示,通过位于捏合机10挤出口14附近的机器手20保持通过挤出口14挤出的捏合混合物M。然后,将捏合的混合物M沿方向W1输送至位于机器手20附近的模塑装置30。
模塑装置30为压缩模塑装置。在模塑装置30中,将捏合的混合物M放在下模32(其是模塑装置30的一个部件)上,并使冲头31沿方向W2运动至捏合的混合物M上以压缩捏合的混合物M。以此方式,制得了具有所需形状的纤维增强树脂模制品。
根据图2A和图2B所示的第一实施方案中的制造方法,通过将开松增强纤维F1供入捏合机10中而制造捏合的混合物M,并将捏合的混合物M放入模塑装置30中而制造纤维增强树脂模制品。因此,由捏合机10施加至供入捏合机10中的开松增强纤维F1的外部力(切断力)在开松增强纤维F1的整个区域上变得尽可能均匀,从而使得增强纤维的纤维长度在切断后变得尽可能均匀。其结果是,获得了包含具有较窄纤维长度分布的增强纤维的捏合混合物M。因此,可制得具有较窄物理性质波动的高质量纤维增强树脂模制品。
下文将描述根据本发明第二实施方案的制造纤维增强树脂模制品的制造方法。图3A和图3B为示意图,其显示了根据本发明第二实施方案的制造纤维增强树脂模制品的制造方法,其中使用切断的开松增强纤维。
在根据第二实施方案的制造方法中,气流发生器50位于捏合机10的纤维进料口15上方。气流发生器50为风扇,且用作将增强纤维辅助引入纤维进料口15的进料辅助机构。此外,切断机40位于气流发生器50上方。切断机40将开松增强纤维F1切断。
当开松增强纤维F1沿方向X4通过沿方向X3旋转的切断机40时,获得了具有尽可能均匀的纤维长度的切段增强纤维F2。然后,由此获得的切段增强纤维F2朝纤维进料口15落下。
气流发生器50(其为风扇)位于切断机40上方,其作为将切段增强纤维F2辅助引入纤维进料口15的进料辅助机构。因此,气流发生器50沿方向X5的旋转产生了朝向纤维进料口15的气流,所述气流有效地将切段增强纤维F2沿方向X6引入纤维进料口15中。代替借助由气流发生器50产生的气流引入纤维进料口15中,可以以如下方式将切段增强纤维F2引入纤维进料口15中。如图3C所示,抽吸单元60提供在纤维进料口15附近,且切段增强纤维F2被抽吸单元60抽吸,从而引入捏合机10中。
如上文所述,通过将开松增强纤维F1切断而获得切段增强纤维F2,且将切段增强纤维F2供入捏合机10中。因此,可使得纤维长度分布较窄,由此制得包含具有较窄纤维长度分布的增强纤维的捏合混合物M。
正如在根据第一实施方案的制造方法中那样,借助机器手20将由此制得的捏合混合物M输送至模塑装置30。在模塑装置30中,实施压缩模塑以制造纤维增强树脂模制品。
根据图3A和图3B所示第二实施方案中的制造方法,通过将开松增强纤维F1切成具有均匀纤维长度的切段增强纤维F2,并将切段增强纤维F2供入捏合机10中而制得捏合混合物M,并由捏合混合物M制造纤维增强树脂模制品。因此,可制得具有与通过根据第一实施方案的制造方法制得的纤维增强树脂模制品相比更窄物理性质波动范围的高质量纤维增强树脂模制品。
下文将描述关于在原型制造的纤维增强树脂模制品中所含的增强纤维的纤维长度分布实验以及关于原型中弯曲强度的实验和实验结果。本发明人等通过常规制造方法(对比实施例)制造了纤维增强树脂模制品,且还通过本发明的制造方法(实施例)制造了纤维增强树脂模制品。然后,本发明人等从通过这些制造方法制得的各纤维增强树脂模制品中抽出了增强纤维,测量了各纤维长度范围内的增强纤维的质量%以验证实施例纤维增强树脂模制品和对比实施例纤维增强树脂模制品之间的纤维长度分布差异。此外,本发明人等从实施例和对比实施例的纤维增强树脂模制品中切出多个测试件,实施弯曲测试以测量各测试件的弯曲强度和弯曲弹性模量,并获得标准偏差,由此验证实施例纤维增强树脂模制品和对比实施例纤维增强树脂模制品之间的强度波动差异。
在这种情况下,“常规制造方法”意指其中通过将增强纤维束在不开松纤维下供入捏合机中并将增强纤维与熔融热塑性树脂捏合而制造捏合的混合物,然后通过将由此制得的捏合混合物压缩模塑而制造纤维增强树脂模制品的方法。此外,“本发明的制造方法”意指其中通过将增强纤维束开松而获得开松增强纤维,通过将开松增强纤维供入捏合机中并将开松增强纤维与熔融热塑性树脂捏合而制得捏合的混合物,然后通过将制得的捏合混合物压缩模塑而制造纤维增强树脂模制品的方法。
图4是照片图,其显示了从由常规制造方法制得的纤维增强树脂模制品取样的增强纤维。图5是照片图,其显示了从由本发明制造方法制得的纤维增强树脂模制品取样的增强纤维。
正如可从图4看出的那样,由常规制造方法制得的纤维增强树脂模制品中的增强纤维具有宽纤维长度分布。特别地,由常规制造方法制得的纤维增强树脂模制品包含各种长度的增强纤维,例如短于5mm的增强纤维和长于25mm的增强纤维。
与此相反,正如可从图5看出的那样,由本发明制造方法制得的纤维增强树脂模制品中的增强纤维具有相当窄的纤维长度分布。特别地,由本发明制造方法制得的纤维增强树脂模制品既不包含短于5mm的增强纤维,也不包含长于25mm的增强纤维,且具有5-10mm纤维长度的增强纤维占全部增强纤维的95质量%或更高。
图6A是照片图,其显示了切出弯曲测试件的纤维增强树脂模制品的位置。图6B是曲线图,其显示了在各实施例和对比实施例中在弯曲测试中测得的各测试件的弯曲强度和各测试件弯曲强度的标准偏差。图6C是图表,其显示了在各实施例和对比实施例中在弯曲测试中测得的各测试件的弯曲弹性模量和测试件弯曲弹性模量的标准偏差。
在原型制造的纤维增强树脂模制品中,使用PA6作为热塑性树脂,且使用由碳纤维制成的增强纤维。在对比实施例的测试件中,使用未开松的增强纤维束(尺寸为50K(50000纤维/束))。在各对比实施例和实施例中,从呈平板(400mm×400mm×4mm厚)形式的纤维增强树脂模制品中切出7个80mm长×15mm宽的测试件,并评价弯曲强度。
正如可从图6B和图6C看出的那样,实施例中测试件的弯曲强度和弯曲弹性模量均高于对比实施例中测试件的那些。此外,实施例测试件的弯曲强度和弯曲弹性模量的标准偏差显著小于对比实施例测试件的那些(实施例测试件的弯曲强度和弯曲弹性模量的标准偏差分别为对比实施例测试件那些的约60%和约40%)。这意味着实施例的强度波动显著小于对比实施例的那些。
据认为,强度的提高和强度波动的降低归因于其中通过将热塑性树脂与通过将增强纤维束开松获得的开松增强纤维捏合而制造纤维增强树脂模制品的制造方法。
尽管已参照附图详细描述了本发明的实施方案,然而本发明的具体构造不限于前文实施方案中的那些,且本发明包括具有落入本发明范围内的改变设计的构造。
Claims (6)
1.纤维增强树脂模制品的制造方法,所述制造方法包括:
在捏合机中将熔融热塑性树脂与通过将增强纤维束开松获得的开松增强纤维(F1)捏合以制造捏合的混合物;和
将捏合的混合物放入或装入模塑装置(30)中以制造纤维增强树脂模制品。
2.根据权利要求1的制造方法,其中:
通过将开松增强纤维(F1)切断获得切段增强纤维(F2);和
将切段增强纤维(F2)供入捏合机中以制造捏合的混合物。
3.根据权利要求1或2的制造方法,其中:
捏合机具有位于上游侧且热塑性树脂通过其供入捏合机的树脂进料口(13)、位于树脂进料口(13)的下游且增强纤维通过其供入捏合机的纤维进料口(15),和捏合的混合物通过其从捏合机挤出的挤出口(14);和
捏合机至少在树脂进料口(13)和纤维进料口(15)之间的位置具有放气口(16,17),其中由熔融热塑性树脂产生的挥发性气体通过放气口从捏合机中排出。
4.根据权利要求2或3的制造方法,其中捏合机具有进料辅助机构,其将切段增强纤维辅助进料至纤维进料口,增强纤维通过所述纤维进料口供入捏合机中,其中进料辅助机构为抽吸单元(60)或产生朝向纤维进料口(15)气流的气流发生器(50),所述抽吸单元(60)位于纤维进料口(15)附近。
5.根据权利要求1或2的制造方法,其进一步包括在捏合机的树脂进料口(13)和捏合机的纤维进料口(15)之间的位置将熔融热塑性树脂产生的挥发性气体排出,其中热塑性树脂通过树脂进料口(13)供入捏合机中,和增强纤维通过纤维进料口(15)供入捏合机中。
6.根据权利要求2或3的制造方法,其中当切段增强纤维(F2)供入捏合机时,通过从捏合机侧抽吸切段增强纤维(F2)或通过使用朝向捏合机的气流将切段增强纤维(F2)供入捏合机中。
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CN111132805A (zh) * | 2017-09-26 | 2020-05-08 | 株式会社日本制钢所 | 纤维增强热塑性树脂的捏合方法、塑化装置和挤出机 |
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