CN106273902B - 一种泡沫铝夹层结构复合材料及其制备方法 - Google Patents
一种泡沫铝夹层结构复合材料及其制备方法 Download PDFInfo
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- CN106273902B CN106273902B CN201610642875.0A CN201610642875A CN106273902B CN 106273902 B CN106273902 B CN 106273902B CN 201610642875 A CN201610642875 A CN 201610642875A CN 106273902 B CN106273902 B CN 106273902B
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- composite material
- aluminium
- toughening
- foam sandwich
- covering
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- 239000002131 composite material Substances 0.000 title claims abstract description 68
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 62
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 62
- 239000006260 foam Substances 0.000 title claims abstract description 59
- 239000004411 aluminium Substances 0.000 title claims abstract description 53
- 238000002360 preparation method Methods 0.000 title claims abstract description 15
- 239000011162 core material Substances 0.000 claims abstract description 64
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 51
- 239000003822 epoxy resin Substances 0.000 claims abstract description 27
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- 239000000463 material Substances 0.000 claims abstract description 15
- 239000004005 microsphere Substances 0.000 claims abstract description 12
- 239000004593 Epoxy Substances 0.000 claims abstract description 9
- 239000003085 diluting agent Substances 0.000 claims abstract description 8
- 239000012745 toughening agent Substances 0.000 claims abstract description 8
- 239000000835 fiber Substances 0.000 claims description 43
- 229920005989 resin Polymers 0.000 claims description 41
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- 238000000465 moulding Methods 0.000 claims description 15
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- 238000000034 method Methods 0.000 claims description 8
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- RIOQSEWOXXDEQQ-UHFFFAOYSA-N triphenylphosphine Chemical compound C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 RIOQSEWOXXDEQQ-UHFFFAOYSA-N 0.000 claims description 6
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- 238000007711 solidification Methods 0.000 claims description 5
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- WZCQRUWWHSTZEM-UHFFFAOYSA-N 1,3-phenylenediamine Chemical compound NC1=CC=CC(N)=C1 WZCQRUWWHSTZEM-UHFFFAOYSA-N 0.000 claims description 4
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- 239000004698 Polyethylene Substances 0.000 claims description 4
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 claims description 4
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- FQYUMYWMJTYZTK-UHFFFAOYSA-N Phenyl glycidyl ether Chemical compound C1OC1COC1=CC=CC=C1 FQYUMYWMJTYZTK-UHFFFAOYSA-N 0.000 claims description 3
- 239000004642 Polyimide Substances 0.000 claims description 3
- JDVIRCVIXCMTPU-UHFFFAOYSA-N ethanamine;trifluoroborane Chemical compound CCN.FB(F)F JDVIRCVIXCMTPU-UHFFFAOYSA-N 0.000 claims description 3
- QOHMWDJIBGVPIF-UHFFFAOYSA-N n',n'-diethylpropane-1,3-diamine Chemical compound CCN(CC)CCCN QOHMWDJIBGVPIF-UHFFFAOYSA-N 0.000 claims description 3
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- RPQRDASANLAFCM-UHFFFAOYSA-N oxiran-2-ylmethyl prop-2-enoate Chemical compound C=CC(=O)OCC1CO1 RPQRDASANLAFCM-UHFFFAOYSA-N 0.000 claims description 3
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- CUFXMPWHOWYNSO-UHFFFAOYSA-N 2-[(4-methylphenoxy)methyl]oxirane Chemical compound C1=CC(C)=CC=C1OCC1OC1 CUFXMPWHOWYNSO-UHFFFAOYSA-N 0.000 claims description 2
- AOBIOSPNXBMOAT-UHFFFAOYSA-N 2-[2-(oxiran-2-ylmethoxy)ethoxymethyl]oxirane Chemical compound C1OC1COCCOCC1CO1 AOBIOSPNXBMOAT-UHFFFAOYSA-N 0.000 claims description 2
- SHKUUQIDMUMQQK-UHFFFAOYSA-N 2-[4-(oxiran-2-ylmethoxy)butoxymethyl]oxirane Chemical class C1OC1COCCCCOCC1CO1 SHKUUQIDMUMQQK-UHFFFAOYSA-N 0.000 claims description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 2
- RPNUMPOLZDHAAY-UHFFFAOYSA-N Diethylenetriamine Chemical group NCCNCCN RPNUMPOLZDHAAY-UHFFFAOYSA-N 0.000 claims description 2
- LGRFSURHDFAFJT-UHFFFAOYSA-N Phthalic anhydride Natural products C1=CC=C2C(=O)OC(=O)C2=C1 LGRFSURHDFAFJT-UHFFFAOYSA-N 0.000 claims description 2
- AWMVMTVKBNGEAK-UHFFFAOYSA-N Styrene oxide Chemical compound C1OC1C1=CC=CC=C1 AWMVMTVKBNGEAK-UHFFFAOYSA-N 0.000 claims description 2
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- JIVZKJJQOZQXQB-UHFFFAOYSA-N tolazoline Chemical class C=1C=CC=CC=1CC1=NCCN1 JIVZKJJQOZQXQB-UHFFFAOYSA-N 0.000 claims description 2
- 229910052905 tridymite Inorganic materials 0.000 claims description 2
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- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims 2
- VLDPXPPHXDGHEW-UHFFFAOYSA-N 1-chloro-2-dichlorophosphoryloxybenzene Chemical compound ClC1=CC=CC=C1OP(Cl)(Cl)=O VLDPXPPHXDGHEW-UHFFFAOYSA-N 0.000 claims 1
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- HSRJKNPTNIJEKV-UHFFFAOYSA-N Guaifenesin Chemical compound COC1=CC=CC=C1OCC(O)CO HSRJKNPTNIJEKV-UHFFFAOYSA-N 0.000 claims 1
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- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 claims 1
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- YBEFXFBAXWUBNQ-UHFFFAOYSA-N n-methylmethanamine;propan-1-amine Chemical compound CNC.CCCN YBEFXFBAXWUBNQ-UHFFFAOYSA-N 0.000 claims 1
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- CZZYITDELCSZES-UHFFFAOYSA-N diphenylmethane Chemical compound C=1C=CC=CC=1CC1=CC=CC=C1 CZZYITDELCSZES-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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- C—CHEMISTRY; METALLURGY
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- B32B2260/02—Composition of the impregnated, bonded or embedded layer
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- B32B2262/02—Synthetic macromolecular fibres
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Abstract
本发明提供了一种泡沫铝夹层结构复合材料及其制备方法,所述泡沫铝夹层结构复合材料包括泡沫铝芯材、增韧界面层和蒙皮,所述增韧界面层位于泡沫铝芯材和蒙皮之间;所述增韧界面层的材质为环氧树脂复合材料,所述环氧树脂复合材料的组分包括环氧树脂基体、增韧剂、稀释剂、中空微球、短切纤维、固化剂和促进剂,所述环氧树脂复合材料填充于泡沫铝芯材表面的孔隙形成增韧界面层。本发明的技术方案,采用多组分低密度的环氧填充胶在复合材料蒙皮和泡沫铝芯材之间形成界面增韧层,可有效提高界面粘接强度,通过功能梯度设计的蒙皮,提高了泡沫铝夹层结构湿热环境下的界面粘接性能,同时可提高了泡沫铝夹层结构的抗冲击性能。
Description
技术领域
本发明属于材料技术领域,尤其涉及一种泡沫铝夹层结构复合材料及其制备方法。
背景技术
夹层结构复合材料是厚度薄、强度高的蒙皮和密度较低的芯材组成。由于其比刚度大、重量轻等突出优点已在航空航天、汽车、轨道交通、建筑及其它工程领域中得到广泛应用。传统夹层结构所用的泡沫芯材包括PU、PS、PVC和PET等聚合物泡沫,但由于其耐高温、阻燃性能差使其应用领域受到限制。泡沫铝是在纯铝或铝合金中加入添加剂后,经过发泡而成,具有密度小、耐高温、热导率小、隔音阻燃等优异的综合性能。以泡沫铝为芯材的夹层结构复合材料的应用领域有望越来越广泛。
传统泡沫夹层结构复合材料是采用蒙皮和芯材进行二次粘接制备,成型周期较长,制备效率低,造成制备成本和能耗较高。蒙皮和芯材之间没有增强,造成面板和芯材容易发生界面脱粘破坏。在冲击载荷作用下,面板和芯材易发生面板和芯材的界面失效,造成冲击性能较差。同时,由于蒙皮和芯材的热膨胀系数差异较大,在湿热环境下夹层结构的蒙皮易出现鼓包和界面失效现象。针对以上问题,国内外研究机构采用三维编织缝纫和Z-Pin等方法增强夹层结构厚度方向和界面性能。如中国专利CN102390129A通过设置在泡沫芯材内的一组拉挤杆的一端与上蒙皮连接,另一端与下蒙皮连接并构成米字型结构,不仅提高了蒙皮和芯材的结合力,也提高了抗剪强度。但由于泡沫铝硬度较大,复合材料拉挤杆的植入较困难。而且,泡沫铝芯材表面孔隙较大,按照传统方法制备夹层结构复合材料界面缺陷相对更大。因此,改善泡沫铝芯材与蒙皮材料的界面性能、提高夹层结构复合材料制备效率,降低成型周期和制备成本是泡沫铝夹层结构复合材料在各领域应用前急需解决的问题。
发明内容
针对以上技术问题,本发明公开了一种泡沫铝夹层结构复合材料及其制备方法,解决了传统夹层结构复合材料在冲击作用或湿热环境下易发生界面脱粘破坏问题。
对此,本发明采用的技术方案为:
一种泡沫铝夹层结构复合材料,所述泡沫铝夹层结构复合材料包括泡沫铝芯材、增韧界面层和蒙皮,所述蒙皮位于夹层结构的最外侧,所述蒙皮包括已浸渍树脂的金属纤维层和无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层和无机和或有机纤维预浸料层泡沫铝芯材、增韧界面层共固化成型;所述增韧界面层位于泡沫铝芯材和蒙皮之间;所述增韧界面层的材质为环氧树脂复合材料,所述环氧树脂复合材料的组分包括环氧树脂基体、增韧剂、稀释剂、中空微球、短切纤维、固化剂和促进剂,所述环氧树脂复合材料填充于泡沫铝芯材表面的孔隙形成增韧界面层。
优选的,所述环氧树脂复合材料包括的组分及其重量份数为:环氧树脂基体100份、增韧剂1~30份、稀释剂5~20份、中空微球10~90份、短切纤维0.5~10份、固化剂3~50份和促进剂0.5~5份。
采用此技术方案,采用蒙皮和芯材之间设有增韧界面层,蒙皮和芯材的界面性能好,不易发生界面脱粘破坏的现象,而且在冲击载荷作用下,蒙皮和芯材不易界面失效,具有更好的冲击性能。
另外,此技术方案中,已浸渍树脂的金属纤维层、无机和或有机纤维预浸料层的各层预浸料、与增韧界面层、泡沫铝芯材表面共固化之后,使得各层间界面具有更好的粘接,而且形成的蒙皮材料热膨胀系数是沿厚度方向呈现变化趋势,,由内层靠近芯材处至蒙皮外表面逐渐减小,从而形成了结构内部的性能过渡,提高了匹配性能,在湿热环境下夹层结构的蒙皮不易出现鼓包和界面失效现象。
作为本发明的进一步改进,所述环氧树脂复合材料包括的组分及其重量份数为:环氧树脂基体100份、增韧剂5~25份、稀释剂10~15份、中空微球20~70份、短切纤维2~8份、固化剂5~30份和促进剂1~4份。
作为本发明的进一步改进,所述泡沫铝芯材为闭孔泡沫铝,密度为0.1~0.7g/cm3。优选的,所述泡沫铝芯材的密度为0.25~0.6g/cm3。
作为本发明的进一步改进,所述环氧树脂基体为低分子量双酚A环氧树脂E54、E51、E44、脂环族环氧树脂、AG80、TED-85中的至少一种。
作为本发明的进一步改进,所述增韧剂为羧基液体丁腈橡胶、聚硫橡胶、液体硅橡胶、聚醚、聚砜、聚酰亚胺、纳米碳酸钙、纳米二氧化钛中的至少一种。
作为本发明的进一步改进,所述中空微球为中空SiO2微球、中空玻璃微球、酚醛树脂微球和Expancle微球的至少一种。
作为本发明的进一步改进,所述稀释剂为丁基缩水甘油醚、丙烯酸缩水甘油酯、1,4-丁二醇二缩水甘油醚、聚丙二醇二缩水甘油醚、丙三醇三缩水甘油醚、苯乙烯氧化物、丁二烯单环氧化物、苯基缩水甘油醚、甲苯基缩水甘油醚中的至少一种。
作为本发明的进一步改进,所述短切纤维为芳纶纤维、尼龙纤维、玻璃纤维、玄武岩纤维、不锈钢纤维或铜纤维的至少一种。
作为本发明的进一步改进,所述固化剂为二亚乙基三胺、三亚乙基四胺、二甲胺基丙胺、二乙胺基丙胺、聚酰胺650、间苯二胺、4,4-二氨基二苯砜,4,4-二氨基二苯基甲烷,2-乙基-4-甲基咪唑,双氰胺、三氟化硼-乙胺络合物、邻苯二甲酸酐、马来酸酐和均苯四甲酸酐的至少一种。
作为本发明的进一步改进,所述促进剂苄基二甲胺、三苯基膦、有机酸盐-胺络合物、2-苯基咪唑啉、硫脲及衍生物、卤化季铵盐的至少一种。
作为本发明的进一步改进,所述蒙皮为采用增强材料为金属纤维、玻璃纤维、碳纤维、玄武岩纤维、芳纶纤维或超高分子量聚乙烯纤维中至少一种对蒙皮材料进行复合改性得到。采用此技术方案,采用增强材料为金属纤维、玻璃纤维、碳纤维、玄武岩纤维、芳纶纤维或超高分子量聚乙烯纤维对蒙皮材料进行改进,缩小了蒙皮与泡沫铝芯材之间的热膨胀系数,使得泡沫铝芯材、增韧界面层和蒙皮形成热膨胀系数梯度设计,提高了泡沫铝夹层结构复合材料在冲击作用或湿热环境下的机械性能,大大减小了界面脱粘破坏问题的发生。
作为本发明的进一步改进,所述蒙皮包括已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层位于靠近泡沫铝芯材及增韧界面的最内层,所述已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层与泡沫铝芯材及增韧界面层共固化成型。
此技术方案,在泡沫铝芯材、增韧界面层的外侧依次铺设已浸渍树脂的金属纤维层、以及至少一层无机和或有机纤维预浸料层,然后与增韧界面层、泡沫铝芯材进行共同固化而得到蒙皮。已浸渍树脂的金属纤维层、无机和或有机纤维预浸料层与增韧界面层、泡沫铝芯材共固化之后,增强了界面性能,而且金属纤维层位于靠近泡沫铝芯材的最内层,使得形成的蒙皮材料热膨胀系数沿厚度方向变化的,从内到外的热膨胀系数由大变小,从而形成了从泡沫夹芯层到面板外层的性能过渡,提高了匹配性能,不易出现鼓包现象。
作为本发明的进一步改进,所述无机和或有机纤维预浸料层中的无机和或有机纤维包括玻璃纤维、碳纤维、玄武岩纤维、芳纶纤维或超高分子量聚乙烯纤维中至少一种。
作为本发明的进一步改进,所述已浸渍树脂的金属纤维层为浸渍树脂的铝纤维网层、浸渍树脂的铜纤维网层或浸渍树脂的不锈钢纤维网。
作为本发明的进一步改进,所述无机和或有机纤维预浸料层包括碳纤维预浸料、玻璃纤维预浸料、芳纶纤维预浸料或高强玻璃纤维预浸料。
此技术方案采用多组分增韧的低密度环氧填充胶处理泡沫铝表面孔隙进行增韧界面层设计提高蒙皮和泡沫铝芯材的界面粘接强度,通过采用金属纤维和不同无机和或有机纤维织物预浸料对蒙皮进行功能梯度设计使得蒙皮和芯材的热膨胀系数更匹配,从而提高泡沫铝夹层结构耐湿热环境和抗冲击下的界面粘接性能。
本发明还提供了一种如上任意一项所述的泡沫铝夹层结构复合材料的制备方法,其特征在于,包括以下步骤:
步骤S1:将泡沫铝芯材进行前处理,并烘干;
步骤S2:将所述环氧树脂复合材料的各成分按配比混合搅拌均匀,得到配好的树脂体系;
步骤S3:将配好的树脂体系分别填充泡沫铝芯材的上、下表面的孔隙形成增韧界面层;
步骤S4:按蒙皮依次铺覆在泡沫铝芯材的上下表面;
步骤S5:采用模压或真空袋压共固化成型,得到所述泡沫铝夹层结构复合材料。
作为本发明的进一步改进,步骤S1中,所述前处理的步骤为:将泡沫铝芯材用重铬酸钾浸蚀液处理后,用自来水进行冲洗,然后采用去离子水彻底清洗,并烘干。
作为本发明的进一步改进,所述蒙皮包括已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层位于靠近泡沫铝芯材及增韧界面的最内层,所述已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层与泡沫铝芯材及增韧界面层共固化成型。实施时,在泡沫铝芯材、增韧界面层的外侧依次铺设已浸渍树脂的金属纤维层、以及至少一层无机和或有机纤维预浸料层,然后与增韧界面层、泡沫铝芯材进行共同固化而得到蒙皮,此过程中,泡沫铝芯材、增韧界面层、蒙皮形成功能梯度。此技术方案中,已浸渍树脂的金属纤维层与无机和或有机纤维预浸料层、与泡沫铝芯材、增韧界面层共固化之后,增强了界面性能;而且金属纤维层位于靠近泡沫铝芯材的最内层,使得形成的蒙皮材料热膨胀系数沿厚度方向变化的,从外到内的热膨胀系数由大变小,从而形成了从泡沫夹芯层到面板外层的性能过渡,提高了匹配性能,不易出现鼓包现象。
作为本发明的进一步改进,所述已浸渍树脂的金属纤维层为浸渍树脂的铝纤维网层、浸渍树脂的铜纤维网层或浸渍树脂的不锈钢纤维网。
作为本发明的进一步改进,所述无机和或有机纤维预浸料层包括碳纤维预浸料、玻璃纤维预浸料、芳纶纤维预浸料或高强玻璃纤维预浸料。
作为本发明的进一步改进,步骤S3中,采用浸渍、刮涂或灌注的方法将配好的树脂体系分别填充泡沫铝芯材的上、下表面的孔隙形成增韧界面层。
作为本发明的进一步改进,步骤S5中,所述模压共固化工艺为压力0.05~2MPa,固化时间10min~3h,固化温度为80~240℃;所述真空袋压共固化工艺为压力0.06~0.1MPa,固化时间为10min~3h,固化温度为80~180℃。
与现有技术相比,本发明的有益效果为:
第一,本发明的技术方案,采用多组分低密度的环氧填充胶在复合材料蒙皮和泡沫铝芯材之间形成界面增韧层,可有效提高界面粘接强度。
第二,通过功能梯度设计,复合材料蒙皮与泡沫铝芯材的热膨胀系数差异较小,提高了泡沫铝夹层结构湿热环境下的界面粘接性能,同时可提高泡沫铝夹层结构的抗冲击性能。
第三,采用共固化成型进行泡沫铝夹层结构复合材料制备,有利于提高制备效率,降低制备成本。本发明的技术方案制备的功能梯度泡沫铝夹层结构复合材料具有质轻、界面粘接性能优异、耐湿热环境和抗冲击性能好等优异的综合性能,可广泛应用于轨道交通、装甲防护和军用设备等领域。
附图说明
图1是本发明一种泡沫铝夹层结构复合材料截面示意图。
附图标记,1为功能梯度复合材料蒙皮,2为泡沫铝芯材,3为增韧界面层。
图2是本发明实施例1和对比实施例1制备的传统泡沫铝夹层结构的冲击曲线对比图。
具体实施方式
下面通过具体实施例并结合附图对本发明作进一步详细说明。以下实施例仅对本发明进行进一步说明,不应理解为对本发明的限制。
如图1所示,所述泡沫铝夹层结构复合材料包括功能梯度复合材料蒙皮1、泡沫铝芯材2和增韧界面层3,所述增韧界面层3位于泡沫铝芯材2和功能梯度复合材料蒙皮1之间;所述增韧界面层3的材质为环氧树脂复合材料,所述环氧树脂复合材料的组分包括环氧树脂基体、增韧剂、稀释剂、中空微球、短切纤维、固化剂和促进剂,所述环氧树脂复合材料填充于泡沫铝芯材表面的孔隙形成增韧界面层3。所述功能梯度复合材料蒙皮1为包括已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层位于最内层。
实施例 1
选用厚度为20mm,密度为0.30g/cm3的闭孔泡沫铝用重铬酸钾浸蚀液处理后,用自来水冲洗,然后采用去离子水彻底清洗干净,在60℃烘箱中进行干燥待用。
环氧树脂E51:环氧丁腈预聚物:丙烯酸缩水甘油酯:玻璃微球:短切芳纶纤维:间苯二胺:三氟化硼单乙胺按重量配比100:10:10:70:10:10:1,采用机械搅拌均匀,通过刮涂方式将配置好的树脂体系填充在泡沫铝表面孔隙。
在处理好的泡沫铝上下表面依次铺覆浸渍树脂的铝纤维网、2层碳纤维预浸料和2层玻璃纤维预浸料,放入平板模具进行热压固化成型。其固化工艺为热压机从室温以平均3℃/min的升温速度升温至80℃后保温30min,进一步升温至150℃,加压0.5MPa,保温30min后冷却至80℃,制备的泡沫铝表面光滑。
按GB/T 1457-2005选取60mm×300mm试样进行滚筒剥离强度测试,经测试滚筒剥离强度为60.2(N.mm)/mm。选择100mm×100mm试样进行冲击性能测试,冲击能量为20J,最大冲击载荷为8354N,吸收能量为14.42J。按GB/T2573-2008进行湿热老化性能测试后外观良好,未发生界面脱粘现象。
对比实施例1
选用厚度为20mm,密度为0.30g/cm3的闭孔泡沫铝用重铬酸钾浸蚀液处理后,用自来水冲洗,然后采用去离子水彻底清洗干净,在60℃烘箱中进行干燥待用。采用与实施例1相同的铺层结构制备复合材料蒙皮,采用传统二次粘接法将复合材料蒙皮和泡沫铝芯材进行粘接制备泡沫铝夹层结构复合材料。
按GB/T 1457-2005选取对比实施例1所制得60mm×300mm试样进行滚筒剥离强度测试,经测试滚筒剥离强度为38.5(N.mm)/mm。选择100mm×100mm试样进行冲击性能测试,冲击能量为20J,最大冲击载荷为4650N,吸收能量为9.58J。按GB/T2573-2008对对比实施例1进行湿热老化性能测试后蒙皮存在鼓包现象。
实施例1制备的泡沫铝夹层结构复合材料和对比实施例1制备的传统泡沫铝夹层结构的冲击曲线对比如图2所示。图2是实施例1与对比实例1完成相同条件下的冲击试验所测得冲击力-时间曲线,由图2可见,实施例1的功能梯度泡沫铝夹层结构具有较高的峰值与吸能(力对作用位移的积分),代表了实施例1对冲击载荷的阻抗性更优异。
实施例2
选用厚度为10mm,密度为0.47g/cm3的闭孔泡沫铝用重铬酸钾浸蚀液处理后,用自来水冲洗,然后采用去离子水彻底清洗干净,在60℃烘箱中进行干燥待用。
将10份Expancle微球、5份丁腈橡胶、2份短切玄武岩纤维、10份Al2O3微球加入到100份环氧树脂TED-85和10份丙三醇三缩水甘油醚中混合均匀,然后再加入30份4,4-二氨基二苯基甲烷和1份2-乙基-4-甲基咪唑采用机械搅拌充分搅拌均匀。在超声作用下,将泡沫铝浸泡在树脂体系中10min后提出,将表面多余的树脂刮掉。
在处理好的泡沫铝上下表面依次铺覆浸渍树脂的铜纤维网、碳纤维预浸料、芳纶纤维预浸料和高强玻璃纤维预浸料,放入模具内进行热压固化成型,升温至120℃,加压1MPa,保温30min后冷却至80℃。
制备的泡沫铝夹层结构复合材料上下表面光滑,经防弹性能测试可通过防弹四级测试,测试后未出现蒙皮和泡沫铝芯材的分离现象。
实施例3
选用厚度为20mm,密度为0.70g/cm3的闭孔泡沫铝用重铬酸钾浸蚀液处理后,用自来水冲洗,然后采用去离子水彻底清洗干净,在60℃烘箱中进行干燥待用。
将20份已发泡的Expancle微球、5份聚砜粒子、5份短切玄武岩纤维与100份脂环族环氧树脂和20份苯基缩水甘油醚混合体系中,加入30份4,4-二氨基二苯砜和2份2-苯基咪唑啉搅拌均匀,采用灌注法将树脂体系填充到泡沫铝表面孔隙,在处理好的泡沫铝上下表面依次铺覆浸渍树脂的不锈钢纤维网和玄武岩纤维预浸料,放入模具内进行真空袋压固化成型,固化温度为120℃,固化压力为0.1MPa,保温30min后冷却至80℃。与传统闭孔泡沫芯材常用的聚氨酯泡沫相比,本例制备的泡沫铝夹层复合材料表面光滑、具有较好的耐高温和阻燃性能,可广泛应用轨道交通地板等领域。
实施例4
在实施例1的基础上,环氧树脂复合材料包括的组分及其重量配比为:环氧树脂AG80:端羧基液体丁腈橡胶: 丁基缩水甘油醚:中空玻璃微球: 尼龙纤维: 二氨基二苯砜:三苯基膦按重量配比100:30:20:90:10:50:5。按GB/T 1457-2005选取60mm×300mm试样进行滚筒剥离强度测试,经测试滚筒剥离强度为58.6 (N.mm)/mm。选择100mm×100mm试样进行冲击性能测试,冲击能量为20J,最大冲击载荷为7849N,吸收能量为13.81 J。按GB/T2573-2008进行湿热老化性能测试后外观良好,未发生界面脱粘现象。
实施例5
在实施例1的基础上,环氧树脂复合材料包括的组分及其重量配比为:环氧树脂E54:聚酰亚胺: 丙三醇三缩水甘油醚: 酚醛树脂微球: 不锈钢纤维: 二乙胺基丙胺:2-苯基咪唑啉按重量配比100:15:5:40:5:6:2。按GB/T 1457-2005选取60mm×300mm试样进行滚筒剥离强度测试,经测试滚筒剥离强度为57.3 (N.mm)/mm。选择100mm×100mm试样进行冲击性能测试,冲击能量为20J,最大冲击载荷为7625N,吸收能量为12.98J。按GB/T2573-2008进行湿热老化性能测试后外观良好,未发生界面脱粘现象。
通过上述实施例对比可知,通过本发明制备的功能梯度泡沫铝夹层结构复合材料成型周期短,具有优异的界面性能和抗冲击性能,可广泛应用于轨道交通、装甲防护和军用设备等领域。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明,不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干简单推演或替换,都应当视为属于本发明的保护范围。
Claims (10)
1.一种泡沫铝夹层结构复合材料,其特征在于:所述泡沫铝夹层结构复合材料包括泡沫铝芯材、增韧界面层和蒙皮,所述蒙皮位于夹层结构的最外侧,所述蒙皮包括已浸渍树脂的金属纤维层和无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层和无机和或有机纤维预浸料层与泡沫铝芯材、增韧界面层共固化成型;所述增韧界面层位于泡沫铝芯材和蒙皮之间;所述增韧界面层的材质为环氧树脂复合材料,所述环氧树脂复合材料包括的组分及其重量份数为:环氧树脂基体100份、增韧剂1~30份、稀释剂5~20份、中空微球10~90份、短切纤维0.5~10份、固化剂3~50份和促进剂0.5~5份,所述环氧树脂复合材料填充于泡沫铝芯材表面的孔隙形成增韧界面层。
2.根据权利要求1所述的泡沫铝夹层结构复合材料,其特征在于:所述泡沫铝芯材为闭孔泡沫铝,密度为0.1~0.7g/cm3。
3.根据权利要求1所述的泡沫铝夹层结构复合材料,其特征在于:所述环氧树脂基体为低分子量双酚A环氧树脂E54、E51、E44、脂环族环氧树脂、AG80、TED-85中的至少一种。
4.根据权利要求1所述的泡沫铝夹层结构复合材料,其特征在于:所述增韧剂为羧基液体丁腈橡胶、聚硫橡胶、液体硅橡胶、聚醚、聚砜、聚酰亚胺、纳米碳酸钙、纳米二氧化钛中的至少一种。
5.根据权利要求1所述的泡沫铝夹层结构复合材料,其特征在于:所述中空微球为中空SiO2微球、中空玻璃微球、酚醛树脂微球和Expancle微球的至少一种。
6.根据权利要求1所述的泡沫铝夹层结构复合材料,其特征在于:所述稀释剂为丁基缩水甘油醚、丙烯酸缩水甘油酯、1,4-丁二醇二缩水甘油醚、聚丙二醇二缩水甘油醚、丙三醇三缩水甘油醚、苯乙烯氧化物、丁二烯单环氧化物、苯基缩水甘油醚、甲苯基缩水甘油醚中的至少一种;
所述短切纤维为芳纶纤维、尼龙纤维、玻璃纤维、玄武岩纤维、不锈钢纤维或铜纤维的至少一种;
所述固化剂为二亚乙基三胺、三亚乙基四胺、二甲胺基丙胺、二乙胺基丙胺、聚酰胺650、间苯二胺、4,4-二氨基二苯砜,4,4-二氨基二苯基甲烷,2-乙基-4-甲基咪唑,双氰胺、三氟化硼-乙胺络合物、邻苯二甲酸酐、马来酸酐和均苯四甲酸酐的至少一种;
所述促进剂苄基二甲胺、三苯基膦、有机酸盐-胺络合物、2-苯基咪唑啉、硫脲及衍生物、卤化季铵盐的至少一种。
7.根据权利要求1~6任意一项所述的泡沫铝夹层结构复合材料,其特征在于:所述蒙皮包括已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层位于靠近泡沫铝芯材及增韧界面的最内层,所述已浸渍树脂的金属纤维层和至少一层无机和或有机纤维预浸料层与泡沫铝芯材及增韧界面层共固化成型。
8.根据权利要求7所述的泡沫铝夹层结构复合材料,其特征在于:所述无机和或有机纤维预浸料层中的无机和或有机纤维包括玻璃纤维、碳纤维、玄武岩纤维、芳纶纤维或超高分子量聚乙烯纤维中至少一种。
9.一种如权利要求1~8任意一项所述的泡沫铝夹层结构复合材料的制备方法,其特征在于,包括以下步骤:
步骤S1:将泡沫铝芯材进行前处理;
步骤S2:将所述环氧树脂复合材料的各成分按配比混合搅拌均匀,得到配好的树脂体系;
步骤S3:将配好的树脂体系分别填充泡沫铝芯材的上、下表面的孔隙形成增韧界面层;
步骤S4:按蒙皮依次铺覆在泡沫铝芯材的上下表面;所述蒙皮包括已浸渍树脂的金属纤维层和无机和或有机纤维预浸料层,所述已浸渍树脂的金属纤维层位于最内层;
步骤S5:采用模压或真空袋压共固化成型,得到所述泡沫铝夹层结构复合材料。
10.根据权利要求9所述的泡沫铝夹层结构复合材料的制备方法,其特征在于:步骤S5中,所述模压共固化工艺为压力0.05~2MPa,固化时间10min~3h,固化温度为80~240℃;所述真空袋压共固化工艺为压力0.06~0.1MPa,固化时间为10min~3h,固化温度为80~180℃。
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