CN105500782A - 高强度泡沫夹芯碳纤维复合材料外压容器及其制备方法 - Google Patents
高强度泡沫夹芯碳纤维复合材料外压容器及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种高强度泡沫夹芯碳纤维复合材料外压容器,该外压容器由内蒙皮层、外蒙皮层、高强度吸声泡沫夹芯层、碳纤维复合材料实心段、上部法兰以及下部法兰组成;内蒙皮层与外蒙皮层之间设置高强度吸声泡沫夹芯层;内蒙皮层、外蒙皮层以及高强度吸声泡沫夹芯层通过缠绕工艺一体成型为该外压容器的圆柱体筒身;筒身顶端和底端的碳纤维复合材料实心段也是通过缠绕工艺制备而成;并且通过螺钉的紧固连接分别可以实现筒身顶端与上部法兰以及筒身底端与下部法兰的连接;本发明外压容器具有较好的强度、刚度以及较好的吸声效果。
Description
技术领域
本发明涉及一种高强度泡沫夹芯碳纤维复合材料外压容器及其制备方法。
背景技术
海洋的勘测开发、科学研究以及水下武器装备都离不开潜水外压容器。尤其是一些大深度的潜水装备,不仅要求提高其外压容器的抗外压性能,同时还要实现减重要求,此外,有时还要求具有透波吸声的功能,因此深潜外压容器的材料选择和结构设计成为近年来的研究热点。
相对于传统金属材料,碳纤维复合材料具有较高的比强度、比刚度,用它制成的深潜外压容器,其重量/排水量之比(W/D)可以降到0.4-0.6,几乎比金属材料(W/D=1.0左右)降低了一半。由此可见,用碳纤维复合材料制造耐外压壳体其重量优势是极为明显的。
承受外压的容器,不仅必须有足够的强度,而且还必须有足以防止屈曲的刚度。采用高强度泡沫夹芯碳纤维复合材料不仅可以满足上述力学性能要求,而且可以进一步减轻重量。另一方面,碳纤维复合材料壳体可以透过声波,而作为泡沫夹芯的吸声材料可以吸收声波,从而实现外压容器的透波吸声功能。
发明内容
针对上述存在的问题,本发明旨在提供一种高强度泡沫夹芯碳纤维复合材料外压容器及其制备方法,提供具有较好的强度、刚度以及较好的吸声效果的外压容器,该外压容器结构简单、制备方法简便,节省成本,节约资源。
为了实现上述目的,本发明所采用的技术方案如下:
一种高强度泡沫夹芯碳纤维复合材料外压容器,该外压容器由内蒙皮层、外蒙皮层、高强度吸声泡沫夹芯层、碳纤维复合材料实心段、上部法兰以及下部法兰组成;所述内蒙皮层与所述外蒙皮层之间设置所述高强度吸声泡沫夹芯层;所述内蒙皮层、外蒙皮层以及高强度吸声泡沫夹芯层通过缠绕工艺一体成型为该外压容器的圆柱体筒身;筒身顶端和底端也通过缠绕工艺一体成型为所述碳纤维复合材料实心段;并且通过螺钉的紧固连接分别可以将筒身顶端与所述上部法兰之间、筒身底端与所述下部法兰之间相互对应进行连接。
进一步的,所述内蒙皮层、外蒙皮层的缠绕角度为50-60°,所述碳纤维复合材料实心段的缠绕角度为65-90°。
进一步的,所述碳纤维复合材料实心段是由螺旋层、内蒙皮层、环向层以及外蒙皮层组成。
进一步的,所述高强度吸声泡沫夹芯层两端部均设有倒角。
制备高强度泡沫夹芯碳纤维复合材料外压容器的方法,其特征在于,包括以下步骤:
通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型内蒙皮层,内蒙皮层按照50-60°的角度范围缠绕;内蒙皮层制备完成后,将高强度吸声泡沫夹芯层置于制备好的内蒙皮层上;通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段环向层;通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;通过碳纤维干法缠绕成型工艺或碳纤维湿法缠绕成型工艺制备外蒙皮层,外蒙皮层按照50-60°的角度范围缠绕;通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段环向层,使实心段厚度和筒身厚度相同;按照一定的固化制度,放入烘箱旋转固化;固化脱膜以后对碳纤维复合材料实心段进行切割打磨,并且将碳纤维复合材料实心段分别与上部法兰、下部法兰进行无胶装配预打孔,并对孔口以及连接面进行打磨、除杂和清洗;清理完成后,先将下部法兰凹槽内和碳纤维复合材料实心段一端涂抹结构胶膜进行胶接,然后再在螺钉上涂抹结构胶膜逐个进行固定,两者连接完成以后,在室温下固化24h;
最后按照步骤(13)的方法,完成上部法兰和碳纤维复合材料实心段另一端的连接,最后,将碳纤维复合材料实心段与上部法兰、下部法兰的连接外边缘以及螺钉边缘涂抹一圈防水密封胶,形成防水密封胶环,完成外压容器的制备。
优选的,所述碳纤维复合材料实心段的螺旋缠绕角度为65-90°,所述内蒙皮层、外蒙皮层的缠绕角度为50-60°。
进一步的,所述高强度吸声泡沫夹芯层为高强度无机物填充树脂。
进一步的,所述高强度吸声泡沫夹芯层的热变形温度为120℃。
进一步的,所述内蒙皮层、外蒙皮层和碳纤维复合材料实心段的树脂基体均为热固性树脂,并且所述树脂基体质量含量为28%-35%。
本发明的有益效果是:该种高强度泡沫夹芯碳纤维复合材料外压容器,不仅能够满足深潜外压容器在一定的静水外压作用下对材料强度和刚度的要求,而且能够同时实现减重的目标。此外,通过在碳纤维复合材料内外蒙皮之间设置高强度无机物填充树脂作为吸声材料,实现了该种外压容器透波吸声的功能,使其在某些深潜特殊装备上具有广泛的应用;此外,采用本发明的制备方法,简单、易行,可操作性强,而且节省成本,节约资源。
附图说明
图1为本发明高强度泡沫夹芯碳纤维复合材料外压容器结构示意图。
图2为本发明高强度泡沫夹芯碳纤维复合材料外压容器局部连接示意图。
图3为本发明高强度泡沫夹芯碳纤维复合材料外压容器筒身段结构示意图。
其中:1-内蒙皮层,2-外蒙皮层,3-高强度吸声泡沫夹芯层,4-碳纤维复合材料实心段,41~44-螺旋层,45~46-环向层,5-上部法兰,6-下部法兰,7-螺钉,8-结构胶膜,9-防水密封胶环,10-螺孔。
具体实施方式
为了使本领域的普通技术人员能更好的理解本发明的技术方案,下面结合附图和实施例对本发明的技术方案做进一步的描述。
参照附图1-3所示的一种高强度泡沫夹芯碳纤维复合材料外压容器,该外压容器由内蒙皮层1、外蒙皮层2、吸声泡沫夹芯层3、碳纤维复合材料实心段4、上部法兰5以及下部法兰6组成;所述内蒙皮层1与所述外蒙皮层2之间设置所述高强度吸声泡沫夹芯层3;所述内蒙皮层1、外蒙皮层2以及高强度吸声泡沫夹芯层3通过缠绕工艺一体成型为该外压容器的圆柱体筒身,所述高强度吸声泡沫夹芯层两端部均设有倒角,所述内蒙皮层、外蒙皮层的缠绕角度为50-60°;筒身顶端和底端也通过缠绕工艺一体成型为所述碳纤维复合材料实心段4,所述碳纤维复合材料实心段的缠绕角度为65-90°,所述碳纤维复合材料实心段是由螺旋层、内蒙皮层、环向层以及外蒙皮层组成;并且通过所述螺钉7的紧固连接分别可以将筒身顶端与所述上部法兰5之间、筒身底端与所述下部法兰6之间相互对应连接。
上述外压容器按照以下步骤制备:
通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层44和内蒙皮层1,螺旋层44按照65-90°的角度范围缠绕,而内蒙皮层1按照50-60°的角度范围缠绕;
内蒙皮层1制备完成后,将高强度吸声泡沫夹芯层3置于制备好的内蒙皮层1上,所述吸声泡沫夹芯层3为高强度无机物填充树脂,并且所述高强度吸声泡沫夹芯层3的热变形温度为120℃。再采用碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层43、环向层45和螺旋层42,螺旋层43、42按照65-90°的角度缠绕;然后采用碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型外蒙皮层2,外蒙皮层2按照50-60°的角度范围缠绕,并且保证内蒙皮层1、外蒙皮层2和高强度吸声泡沫夹芯层3之间的紧密贴合;最后,采用碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层41和环向层46,螺旋层41按照65-90°的角度缠绕,而环向层46是为了调整碳纤维复合材料实心段和筒身段高度保持一致;所述内蒙皮层1、外蒙皮层2和碳纤维复合材料实心段4的树脂基体均为热固性树脂,并且所述树脂基体质量含量为28%-35%,玻璃化转变温度高于120℃;
固化脱膜以后对碳纤维复合材料实心段4进行切割打磨,以达到装配要求,并且将碳纤维复合材料实心段4分别与上部法兰5、下部法兰6进行无胶装配打孔,在下部法兰6上还均匀分布若干螺孔10,用于与外部工装连接试验;
打孔完成后,对孔口以及连接面进行打磨、除杂和清洗,保证连接的强度;
清理完成后,先将下部法兰6凹槽内和碳纤维复合材料实心段4一端涂抹结构胶膜8进行胶接,然后再在螺钉7上涂抹结构胶膜8逐个进行固定,两者连接完成以后,在室温下固化24h;
按照上述步骤的方法,完成上部法兰5和碳纤维复合材料实心段4另一端的连接,最后,将碳纤维复合材料实心段4与上部法兰5、下部法兰6的连接外边缘以及螺钉7边缘涂抹一圈防水密封胶,形成防水密封胶环9,完成外压容器的制备;结构胶膜8和防水密封胶环9在静水压力作用下均具有较好的密封作用,并且耐水性能好,从而提高了该外压容器的水密性。
Claims (8)
1.高强度泡沫夹芯碳纤维复合材料外压容器,其特征在于:该外压容器由内蒙皮层(1)、外蒙皮层(2)、高强度吸声泡沫夹芯层(3)、碳纤维复合材料实心段(4)、上部法兰(5)以及下部法兰(6)组成;所述内蒙皮层(1)与所述外蒙皮层(2)之间设置所述高强度吸声泡沫夹芯层(3);所述内蒙皮层(1)、外蒙皮层(2)以及高强度吸声泡沫夹芯层(3)通过缠绕工艺一体成型为该外压容器的圆柱体筒身;筒身顶端和底端也通过缠绕工艺一体成型为所述碳纤维复合材料实心段(4);并且通过螺钉(7)的紧固连接分别可以将筒身顶端与所述上部法兰(5)之间、筒身底端与所述下部法兰(6)之间相互对应进行连接。
2.根据权利要求1所述的一种高强度泡沫夹芯碳纤维复合材料外压容器,其特征在于:所述内蒙皮层(1)、外蒙皮层(2)的缠绕角度为50-60°,所述碳纤维复合材料实心段(4)的缠绕角度为65-90°。
3.根据权利要求1所述的一种高强度泡沫夹芯碳纤维复合材料外压容器,其特征在于:所述碳纤维复合材料实心段(4)是由螺旋层、内蒙皮层、环向层以及外蒙皮层组成。
4.根据权利要求1所述的一种高强度泡沫夹芯碳纤维复合材料外压容器,其特征在于:所述高强度吸声泡沫夹芯层(3)两端部均设有倒角。
5.制备如权利要求1所述的高强度泡沫夹芯碳纤维复合材料外压容器的方法,其特征在于,包括以下步骤:
第一步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
第二步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型内蒙皮层,内蒙皮层按照50-60°的角度范围缠绕;
第三步:内蒙皮层制备完成后,将高强度吸声泡沫夹芯层置于制备好的内蒙皮层上;
第四步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
第五步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段环向层;
第六步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
第七步:通过碳纤维干法缠绕成型工艺或碳纤维湿法缠绕成型工艺制备外蒙皮层,外蒙皮层按照50-60°的角度范围缠绕;
第八步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段螺旋层,螺旋层按照65-90°的角度范围缠绕;
第九步:通过碳纤维干法缠绕工艺或碳纤维湿法缠绕工艺成型两端实心段环向层,使实心段厚度和筒身厚度相同;
第十步:按照一定的固化制度,放入烘箱旋转固化;
第十一步:固化脱膜以后对碳纤维复合材料实心段进行切割打磨,并且将碳纤维复合材料实心段分别与上部法兰、下部法兰进行无胶装配预打孔;
第十二步:打孔完成后,对孔口以及连接面进行打磨、除杂和清洗;
第十三步:清理完成后,先将下部法兰凹槽内和碳纤维复合材料实心段一端涂抹结构胶膜进行胶接,然后再在螺钉上涂抹结构胶膜逐个进行固定,两者连接完成以后,在室温下固化24h;
第十四步:按照步骤(十三)的方法,完成上部法兰和碳纤维复合材料实心段另一端的连接,最后,将碳纤维复合材料实心段与上部法兰、下部法兰的连接外边缘以及螺钉边缘涂抹一圈防水密封胶,形成防水密封胶环,完成外压容器的制备。
6.根据权利要求5所述的制备高强度泡沫夹芯碳纤维复合材料外压容器的方法,其特征在于:所述高强度吸声泡沫夹芯层为高强度无机物填充树脂。
7.根据权利要求5所述的制备高强度泡沫夹芯碳纤维复合材料外压容器的方法,其特征在于:所述高强度吸声泡沫夹芯层的热变形温度为120℃。
8.根据权利要求5所述的制备高强度泡沫夹芯碳纤维复合材料外压容器的方法,其特征在于:所述内蒙皮层、外蒙皮层和碳纤维复合材料实心段的树脂基体均为热固性树脂,并且所述树脂基体质量含量为28%-35%。
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