CN106313643A - 结构功能一体化复合材料头盔及其制造方法 - Google Patents
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Abstract
本发明提供一种结构功能一体化的复合材料头盔及其制造方法，属于人体防护用品技术领域。头盔采用三维经编间隔织物、热塑性/热固性树脂预浸料以及树脂胶膜复合而成。其特征在于织物无需裁剪，而且头盔的壳体、缓冲层和织物层三部分一体化成型。本发明相对于现有头盔的制备方法的优点：充分利用针织经编间隔织物优异的延展性和挠曲变形性，无裁剪大大减少了对原材料的浪费；头盔的壳体、缓冲层和织物层三部分一体化成型，可设计性强，节约成型时间，降低制件成本，产品美观，整体性好，提高了头盔的抗冲击性能。
Description
技术领域
本发明涉及一种结构功能一体化复合材料头盔及其制造方法，属于人体防护用品技术领域。
背景技术
众所周知，防护头盔是作为保护头部免受或减轻机械性碰撞伤害的头具，广泛地应用于建筑、军事、消防、交通、运动等领域。目前，头盔多呈半圆形，由外、中、内三层构成。其中外层壳体由强度较高的材料制成，比如特种钢、玻璃钢、芳纶、超高分子量聚乙烯、增强塑料等，以抵御外力对头部的伤害；中层为泡沫材料制造的缓冲层，像泡沫塑料或泡沫橡胶等，通过它的变形来吸收大部分冲击力；内层采用高分子纤维布制造的织物层，具有吸汗、保暖等的功能。在生产过程中，头盔的外壳体通常采用模压、注塑等成型方式，与制造的泡沫材料的缓冲层以及人体可接触的织物层，分布在产品的外、中、内三层，通过胶粘剂粘结在一起。在每部分单独成型过程中，裁剪产生大量边角废料，使得材料利用率低，这样不仅生产起来非常耗费劳动力，而且影响产品质量均一性以及性能稳定性。
三维经编间隔织物是一种整体编织成型，通过纱线连接上下两个面层，呈中空的纺织结构。针织间隔织物是由线圈相互穿套形成的，线圈结构使织物具有良好的延展性和形状可设计性，可以适用于复杂形状复合材料制品的制造。利用三维经编间隔织物制作头盔，充分利用其优异的延展性和挠曲变形性，无裁剪大大减少了对原材料的浪费，而且头盔的壳体、缓冲层和织物层三部分为一体化成型，可设计性强，节约成型时间，降低制件成本，产品美观，整体性好，提高了头盔的抗冲击性能。
发明内容
本发明的目的在于针对现有技术存在不足，提供一种结构功能一体化的复合材料头盔及其制造方法，使得材料的利用率高，成型快速，产品质量均一，性能稳定。
本发明结构功能一体化复合材料头盔是通过以下技术方案实现的：
结构功能一体化复合材料头盔及其制造方法，其特征在于三维间隔织物无需裁剪，头盔的壳体、缓冲层和织物层三部分一体化成型，由三维间隔织物、热塑性/热固性树脂预浸料以及树脂胶膜复合制造而成。
所述的结构功能一体化复合材料头盔及其制造方法，其特征在于三维间隔织物为一种针织的经编间隔织物，由上下面层以及中间的间隔丝层组成。
所述的结构功能一体化复合材料头盔及其制造方法，其特征在于预浸料材料是玻璃纤维、碳纤维、芳纶纤维增强热固性/热塑性树脂中的一种。
所述的结构功能一体化复合材料头盔及其制造方法，其特征在于胶膜材料是环氧树脂、酚醛树脂、热塑性树脂中的一种。
所述的结构功能一体化复合材料头盔及其制造方法，其特征在于三维经编间隔织物的面密度是0.3kg/m2～2.0kg/m2，总厚度为3～60mm，间隔丝层的密度为10～180根/cm2。
所述的结构功能一体化复合材料头盔及其制造方法，其特征在于树脂胶膜的厚度在0.2～2mm，树脂胶膜正好只完全浸渍三维间隔织物的上面层纤维。
结构功能一体化复合材料头盔及其制造方法，其特征在于三维间隔织物的上面层纤维是玻璃纤维、碳纤维、聚乙烯纤维、芳纶等，起到增强防护的作用，厚度在0.2～2mm；三维间隔织物的下面层纤维是涤纶、丙纶、锦纶等，起到吸汗、保温的作用，厚度在1～3mm；间隔丝层是涤纶单丝、丙纶单丝、锦纶单丝、乙纶单丝中的一种，起到支撑缓冲作用。
结构功能一体化复合材料头盔及其制造方法，其特征在于制备方法包括以下步骤：
第一步：在头盔模具上擦脱模剂或者脱模蜡；
第二步：先将预浸料裁剪，并铺贴在头盔模具中；
第三步：然后铺放一定厚度的树脂胶膜，再将三维经编间隔织物放在胶膜上，并在模具中固定形状；
第四步：采用RFI或热压罐成型工艺，通过控制三维间经编隔织物上面层纤维与树脂胶膜的比例，使得树脂胶膜恰好只完全浸渍三维间隔织物的上面层纤维，并固化成型。
附图说明
图1为本发明专利所述的结构功能一体化复合材料头盔的示意图
标号说明：1-壳体；2-缓冲层；3-织物层。
具体实施方式
下面给出本发明的一些具体实施例，但所述的具体实施例不限制本发明权利要求。
实施例1
(1)选用三维经编间隔织物的上面层作为头盔外表面增强材料。三维经编间隔织物由芳纶纤维和涤纶纤维共同织造而成，总厚度为15mm；上面层为芳纶纤维，厚度为0.5mm；间隔丝为涤纶纤维，间隔丝密度为90根/cm2下面层为丙纶纤维，厚度为1mm。选用酚醛树脂胶膜，按照三维间隔织物上面层纤维和树脂质量2∶3的比例，胶膜厚度为0.5mm。
(2)在头盔模具中擦脱模剂，将树脂胶膜铺在模具中，再将三维经编间隔织物按头盔的形状和大小裁剪，放在头盔模具中并固定好形状；把铺好的头盔模具上放入真空袋，然后封袋；采用RFI成型工艺，成型温度130～160℃，成型压力-0.1MPa，成型时间40～50min，自然冷却至室温。
(3)将制造的头盔进行脱模，然后对盔体进行修边、表面处理后即是本发明提供的结构功能一体化复合材料头盔。
实施例2
(1)选取碳纤维预浸料作为外头盔表面的增强材料，面密度为300g/m2。选取三维经编间隔织物由玻璃纤维和涤纶纤维共同织造而成，总厚度为20mm；上面层为玻璃纤维，厚度为1mm；间隔丝和下面层为丙纶，间隔丝密度为120根/cm2，下面层厚度2mm。选取环氧树脂胶膜，按照三维间隔织物上面层纤维和树脂质量2∶3的比例，胶膜厚度为1mm。
(2)在头盔模具中擦脱模剂，将碳纤维预浸料和环氧树脂胶膜先后铺在头盔模具中，再将三维经编间隔织物按头盔的形状和大小裁剪，放入模具并固定好形状；把铺好的头盔模具上放入真空袋中，然后封袋；采用热压罐成型工艺，升温速率5℃/min，开始加压温度50～80℃，成型温度120～140℃，成型压力0.4MPa，成型时间30～40min，自然冷却至室温。
(3)将制造的头盔进行脱模，然后对盔体进行修边、表面处理后即是本发明提供的结构功能一体化复合材料头盔。
实施例3
(1)选取玻璃纤维增强聚乙烯预浸料作为外表面的增强材料，面密度为400g/m2；选取三维经编间隔织物由聚乙烯纤维和涤纶纤维共同织造而成，总厚度为25mm，上面层为聚乙烯纤维，厚度为1.5mm，间隔丝和下面层为涤纶纤维，间隔丝密度为60根/cm2，下面层厚度2.5mm；选取聚乙烯薄膜作为胶膜，每层厚度0.1mm，按照控制三维间隔织物上面层纤维和树脂质量1∶1的比例，共需要15层。
(2)在头盔模具中擦脱模剂，将预浸料和树脂胶膜先后铺在头盔模具中，再将三维经编间隔织物按头盔的形状和大小裁剪，放在头盔模具中并固定好形状；将铺好头盔模具上放入真空袋中，然后封袋；采用热压罐成型工艺，升温速率2℃/min，开始加压温度60～80℃，成型温度130～150℃，成型压力0.6MPa，成型时间40～50min，自然冷却至室温。
(3)将制造的头盔进行脱模，然后对盔体进行修边、表面处理后即是本发明提供的结构功能一体化复合材料头盔。
Claims (8)
1.结构功能一体化复合材料头盔及其制造方法，其特征在于三维间隔织物无需裁剪，头盔的壳体、缓冲层和织物层三部分一体化成型，由三维间隔织物、热塑性/热固性树脂预浸料以及树脂胶膜复合制造而成。
2.按照权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于三维间隔织物为一种针织的经编间隔织物，由上下面层以及中间的间隔丝层组成。
3.按照权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于所述的预浸料材料是玻璃纤维、碳纤维、芳纶纤维增强热固性/热塑性树脂中的一种。
4.按照权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于所述的胶膜材料是环氧树脂、酚醛树脂、热塑性树脂中的一种。
5.按照权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于三维经编间隔织物的面密度是0.3kg/m2～2.0kg/m2，总厚度为3～60mm，间隔丝层的密度为10～180根/cm2。
6.按照权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于树脂胶膜的厚度在0.2～2mm，树脂胶膜恰好只完全浸渍三维间隔织物的上面层纤维。
7.按照权利要求2所述的结构功能一体化复合材料头盔及其制造方法，其特征在于，三维间隔织物的上面层纤维是玻璃纤维、碳纤维、聚乙烯纤维、芳纶等，起到增强防护的作用，厚度在0.2～2mm；三维间隔织物的下面层纤维是涤纶、丙纶、锦纶等，起到吸汗、保温的作用，厚度在1～3mm；间隔丝层是涤纶单丝、丙纶单丝、锦纶单丝、乙纶单丝中的一种，起到支撑缓冲作用。
8.一种如权利要求1所述的结构功能一体化复合材料头盔及其制造方法，其特征在于制备方法包括以下步骤：
第一步：在头盔模具上擦脱模剂或者脱模蜡；
第二步：先将预浸料裁剪，并铺贴在头盔模具中；
第三步：然后铺放一定厚度的树脂胶膜，再将三维经编间隔织物放在胶膜上，并在模具中固定形状；
第四步：采用RFI或热压罐成型工艺，通过控制三维经编间隔织物上面层纤维与树脂胶膜的比例，使得树脂胶膜恰好只完全浸渍三维间隔织物的上面层纤维，并固化成型。
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