CN105965983A - 碳纤维复合板的制作方法及碳纤维复合板 - Google Patents
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Abstract
本发明公开了一种碳纤维复合板的制作方法及碳纤维复合板，该复合板的制作步骤包括：1）涂抹离型剂及间苯新戊二醇胶衣；2）铺设浸润有环氧树脂的碳纤维材料；3）铺设浸润有环氧树脂的玄武岩纤维材料；4）设置骨架；5）设置基板；6）抽真空脱模。该制备方法简单，易于操作，采用该制作方法所制得的碳纤维复合板，有效地排除了各材料层间产生气泡的可能性，提高了复合板的致密性及严实性，无需在制作完成后再涂油漆也能具有一个高光亮的外表，且耐候性、耐黄变性好，而采用该制作方法制得的复合板，质量轻、强度高、模量好、保温性能好，其导热系数可达0.3W/M.K，生产成本低，对环境友好，适于工业化生产。
Description
技术领域
本发明涉及复合板的加工技术领域，具体涉及一种碳纤维复合板的制作方法及碳纤维复合板。
背景技术
传统的冷藏车箱板、豪华房车面板、物流车面板等为实现保温，所使用的板材通常是采用钢结构加聚氨酯泡沫复合形成，而因钢结构导热系数大，使得其保温效果欠佳，同时钢材密度大，给车子本身增加了能耗，时间长了宜发生腐蚀。
碳纤维因其质量比金属铝轻，但其强度要高于钢铁，且其具有耐腐蚀、高模量的特性，常被用于制作成板材，如申请号2015101250530中提到的碳纤维板材，其采用碳纤维布浸渍环氧树脂胶制成，其具有抗拉强度高的特点，同时还提高了抗压、抗弯、抗扭、抗剪切强度，但是，因该板材几乎完全采用了碳纤维，导致其碳纤维材料的使用量大大增加，增加了生产成本。
而现有的碳纤维板材的制作方法，通常是采用的模压成型，如申请号为201210493779.6中提到的碳纤维板的制作工艺，采用模压成型的方法在制作碳纤维板材时存在以下缺点：不能有效避免复合板中各材料层间存在气泡，导致复合板的致密性得不到保证，同时一般在制作过程完成后使用时，为了防腐，还需在复合板的表面涂抹一层油漆，在长期露天使用过程中，油漆易发生开裂。
发明内容
本发明的目的是提供一种碳纤维复合板的制作方法，该方法操作方便，在制作过程中，先涂抹一层间苯新戊二醇胶衣，不仅保证了复合板高光亮的外表，同时还避免后期上漆，同时，采用该方法制作而成的复合板各层间无气泡，严实、致密。
为达到上述目的，本发明采用的一种技术方案是：
一种碳纤维复合板的制作方法，具体制作步骤如下：
1
）在模具腔室内的钢化玻璃平台上表面上涂抹一层离型剂，并在所述离型剂的上表面上涂抹一层间苯新戊二醇胶衣；
2
）待胶衣固化后，在所述胶衣的上表面上均匀地涂抹第一层环氧树脂，而后在所述第一层环氧树脂的上表面上平铺一层碳纤维材料；
3
）在所述碳纤维材料的上表面均匀地涂抹第二层环氧树脂，并确保所述第二层环氧树脂浸润所述碳纤维材料，而后在所述第二层环氧树脂的上表面上平铺一层玄武岩纤维材料；
4
）在所述玄武岩纤维材料的上表面上均匀地涂抹第三层环氧树脂，并确保所述第三层环氧树脂浸润所述玄武岩纤维材料，而后在所述第三层环氧树脂的上表面上放置骨架，所述骨架内填充有聚氨酯泡沫；
5
）在所述聚氨酯泡沫的上表面上开设若干凹槽，之后在所述骨架及聚氨酯泡沫的上表面上涂抹强力胶，而后在所述强力胶的上表面上铺设一基板；
6
）在所述基板的上表面覆一块压板，之后将所述模具密封并锁紧，对所述模具抽真空至结构胶固化即可脱模。
优选地，所述的基板为碳纤维板或木板。
优选地，所述胶衣层的厚度在0.5~1mm间。
优选地，步骤6）中，采用油布或硅胶袋对模具进行密封，并在所述模具的外边沿上加设压框。
本发明的另一个目的是提供一种由上述制作方法制作而成的碳纤维复合板，具体的：所述的复合板包括胶衣层、碳纤维层、玄武岩纤维层、骨架、基板，所述的胶衣层采用了间苯新戊二醇胶衣制成，所述基板的一侧表面沿自身厚度方向依次覆盖有所述的骨架、玄武岩纤维层、碳纤维层、胶衣层，所述骨架内填充有聚氨酯泡沫，所述的胶衣层、碳纤维层、玄武岩纤维层、骨架中每相邻两层间均涂抹有环氧树脂，所述骨架与基板间涂抹有结构胶。
优选地，所述骨架中的聚氨酯泡沫上涂抹有结构胶的一侧面上开设有若干凹槽，用于收集多余的结构胶。
优选地，根据客户对所述复合板的厚度要求，所述骨架与所述碳纤维层间设有一层或多层玄武岩纤维层。
优选地，所述的骨架为铝型材骨架。
优选地，所述的胶衣层、碳纤维层、玄武岩纤维层、骨架、基板的边沿相齐平设置。
由于上述技术方案的运用，本发明与现有技术相比具有下列优点：本发明的碳纤维复合板的制作方法简单，消除了复合板各材料层间产生气泡的可能性，同时在制作时，复合了一层间苯新戊二醇胶衣，不仅使制作完成后的复合板具有一个高光亮的外表，无需后期上漆，避免了现有技术中使用油漆所导致的表面开裂的现象发生，同时采用间苯新戊二醇作为胶衣，其耐候性及耐黄变性均高于油漆。而采用本发明的制作方法制成的复合板，因其采用了碳纤维材玄武岩纤维材料，不仅质量轻且强度高、模量高，保温性能好，其导热系数可达0.3W/M.K，对环境友好，而在该复合板内采用了少量的碳纤维材料，有效地降低了生产成本。
附图说明
附图1为本发明所述的碳纤维复合板的结构示意图；
其中：1、胶衣；2、第一层环氧树脂；3、碳纤维层；4、第二层环氧树脂；5、玄武岩纤维层；6、第三层环氧树脂；7、骨架；71、聚氨酯泡沫；711、凹槽；8、结构胶； 9、基板。
具体实施方式
下面结合附图及具体实施例来对本发明的技术方案作进一步的阐述。
一种碳纤维复合板的制作方法，具体制作步骤如下：
1
）在模具腔室内的钢化玻璃平台上表面上涂抹一层离型剂，并在离型剂的上表面上涂抹一层0.5mm的间苯新戊二醇胶衣1；
2
）待胶衣1固化后，在胶衣1的上表面上均匀地涂抹第一层环氧树脂2，而后在第一层环氧树脂2的上表面上平铺一层碳纤维材料；
3
）在碳纤维材料的上表面均匀地涂抹第二层环氧树脂4，并确保第二层环氧树脂4浸润碳纤维材料，并用滚筒排除碳纤维材料与第一层环氧树脂2及第二层环氧树脂4间的气泡，而后在第二层环氧树脂4的上表面上平铺一层玄武岩纤维材料；
4
）在玄武岩纤维材料的上表面上均匀地涂抹第三层环氧树脂6，并确保第三层环氧树脂6浸润玄武岩纤维材料，并用滚筒排除玄武岩纤维材料与第二层环氧树脂4及第三层环氧树脂6间的气泡，而后在第三层环氧树脂6的上表面上放置骨架7，骨架7内填充有聚氨酯泡沫71；
5
）在聚氨酯泡沫71的上表面上开设若干凹槽711，之后在骨架7及聚氨酯泡沫71的上表面上涂抹强力胶，而后在强力胶的上表面上铺设一基板9，这里的基板9可以是碳纤维板或木板；
6
）最后在基板9的上表面覆一块压板以确保基板9与骨架7间的平整性，之后采用油布或硅胶袋将模具密封并采用压框对模具的外边沿进行密封，而后用快速夹具将模具锁紧，之后连接真空泵管路，启动真空泵对模具进行抽真空，至结构胶8固化后停止，之后可脱模得到我们所需的碳纤维复合板。
这里，通过涂抹离型剂，可使在复合板制作完成后能快速脱模。而因间苯新戊二醇胶衣1的耐水性、耐候性及耐腐性非常好且表面光洁度高，使得制作完成的复合板表面光滑、有光泽、硬度高、耐用，且耐黄变性好。
因玄武岩纤维不仅具有高强度、高模量等特点，还具有耐高温性佳、抗氧化性好、抗辐射性好、绝热隔音、过滤性能好、抗压缩强度和剪切强度高，适应于各种环境下使用，且其废弃后可直接转入生态环境中，无任何危害，对环境友好，因此，本实施例的复合板中添加了玄武岩纤维材料以增强复合板的强度，同时符合环保要求。
这里，根据客户对复合板的厚度要求，可以在碳纤维材料与骨架7间铺设一层或多层玄武岩纤维材料，如铺设多层玄武岩纤维材料时，每铺设一层玄武岩纤维材料，均需在其上表面涂抹一层环氧树脂，并使环氧树脂浸润该层玄武岩纤维材料，同时需排除每层玄武岩纤维材料与环氧树脂间的气泡。
这里，为了防止多余的结构胶8在聚氨酯泡沫71表面没有地方流动，造成骨架7与基板9间产生气泡，因此在步骤5）中，在聚氨酯泡沫71开设凹槽711。
通过采用抽真空的方式来代替模压成型工艺来制作复合板，可有效排除复合板各材料层间残留的气泡，使得各层间的附着力更强。
采用上述制作方法得到的碳纤维复合板如下：该复合板包括胶衣1层、碳纤维层3、玄武岩纤维层5、骨架7、基板9。该基板9的一侧表面沿自身厚度方向依次覆有骨架7、玄武岩纤维层5、碳纤维层3、胶衣1层。这里，该胶衣1层、碳纤维层3、玄武岩纤维层5、骨架7、基板9的边沿相齐平设置。
该骨架7内填充有聚氨酯泡沫71用于保温，为了各层间粘结牢固，在胶衣1层、碳纤维层3、聚氨酯纤维层、骨架7中每相邻两层间均涂抹有环氧树脂，该骨架7与基板9间涂抹有强力结构胶8。该碳纤维复合板质量轻，有效地降低了汽车本身的能耗，且强度高、模量高。
这里，所采用的骨架7为铝型材骨架7。铝型材制成的骨架7其抗腐蚀性强、稳定性好、可成形性强且具有良好的回收性能。
上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰，都应涵盖在本发明的保护范围之内。
Claims (9)
1.一种碳纤维复合板的制作方法，其特征在于，具体制作步骤如下：
1）在模具腔室内的钢化玻璃平台上表面上涂抹一层离型剂，并在所述离型剂的上表面上涂抹一层间苯新戊二醇胶衣；
2）待胶衣固化后，在所述胶衣的上表面上均匀地涂抹第一层环氧树脂，而后在所述第一层环氧树脂的上表面上平铺一层碳纤维材料；
3）在所述碳纤维材料的上表面均匀地涂抹第二层环氧树脂，并确保所述第二层环氧树脂浸润所述碳纤维材料，而后在所述第二层环氧树脂的上表面上平铺一层玄武岩纤维材料；
4）在所述玄武岩纤维材料的上表面上均匀地涂抹第三层环氧树脂，并确保所述第三层环氧树脂浸润所述玄武岩纤维材料，而后在所述第三层环氧树脂的上表面上放置骨架，所述骨架内填充有聚氨酯泡沫；
5）在所述聚氨酯泡沫的上表面上开设若干凹槽，之后在所述骨架及聚氨酯泡沫的上表面上涂抹强力胶，而后在所述强力胶的上表面上铺设一基板；
6）在所述基板的上表面覆一块压板，之后将所述模具密封并锁紧，对所述模具抽真空至结构胶固化即可脱模。
2.根据权利要求1所述的碳纤维复合板的制作方法，其特征在于，所述的基板为碳纤维板或木板。
3.根据权利要求1所述的碳纤维复合板的制作方法，其特征在于，所述胶衣层的厚度在0.5~1mm间。
4.根据权利要求1所述的碳纤维复合板的制作方法，其特征在于，步骤6）中，采用油布或硅胶袋对模具进行密封，并在所述模具的外边沿上加设压框。
5.一种碳纤维复合板，由权利要求1至4任一项权利要求所述的制作方法制成，其特征在于，所述的复合板包括胶衣层、碳纤维层、玄武岩纤维层、骨架、基板，所述的胶衣层采用了间苯新戊二醇胶衣制成，所述基板的一侧表面沿自身厚度方向依次覆盖有所述的骨架、玄武岩纤维层、碳纤维层、胶衣层，所述骨架内填充有聚氨酯泡沫，所述的胶衣层、碳纤维层、玄武岩纤维层、骨架中每相邻两层间均涂抹有环氧树脂，所述骨架与基板间涂抹有结构胶。
6.根据权利要求5所述的碳纤维复合板，其特征在于，所述骨架中的聚氨酯泡沫上涂抹有结构胶的一侧面上开设有若干凹槽，用于收集多余的结构胶。
7.根据权利要求5所述的碳纤维复合板，其特征在于，根据客户对所述复合板的厚度要求，所述骨架与所述碳纤维层间设有一层或多层玄武岩纤维层。
8.根据权利要求5所述的碳纤维复合板，其特征在于，所述的骨架为铝型材骨架。
9.根据权利要求5至8任一项权利要求所述的碳纤维复合板，其特征在于，所述的胶衣层、碳纤维层、玄武岩纤维层、骨架、基板的边沿相齐平设置。
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