CN106313790A - 一种防火玻璃纤维‑铝合金混杂层板的制备方法 - Google Patents
一种防火玻璃纤维‑铝合金混杂层板的制备方法 Download PDFInfo
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Abstract
本发明涉及一种防火玻璃纤维‑铝合金混杂层板的制备方法，它包含防火胶膜、玻璃纤维预浸料层和铝合金板，制备包括下列步骤：涂覆防火胶膜、铺贴和固化成型。本发明将防火涂料本体树脂涂覆为连续的防火胶膜，并将防火胶膜引入到玻璃纤维预浸料和表面铝合金板之间，防火层厚度为0.2mm～0.3mm，具有耐火特性，可有效隔绝失火后的火焰及热量冲击，可用于航空飞行器座舱隔板、汽车油箱盖件等易发生火灾部位。
Description
技术领域
本发明属于复合材料技术领域，涉及一种防火玻璃纤维-铝合金混杂层板的制备方法。
背景技术
复合材料在航空航天与民用汽车中的应用越来越广泛，大量的金属材料正在逐步的被复合材料所代替，但单一的树脂基复合材料因各向异性及较差的抗冲击性也阻扰的其在某些领域的应用。复合材料与金属叠层结构综合两者的优势，具备了树脂基复合材料的耐疲劳、低密度、高比强度以及金属的良好韧性等特点，这种材料可广泛替代传统的金属材料。
同时，材料在应用过程中，其安全性能是工程师考虑的重点，火灾是造成复合材料失效及人员伤亡的一个重要因素，传统的纤维-金属混杂层板仅含有金属层及纤维预浸料层，无防火特性，当其在遇到火焰冲击时，铝合金板迅速熔化使预浸料层裸露到火焰中，高温使树脂分解并放出大量的有毒气体，对人的生命造成威胁。为使纤维-金属混杂层板能够防御火焰冲击，传统的做法是在零件外表面刷涂防火涂料，这种刷涂工艺效率低、均匀性较差，且刷涂后零件表面防火涂料层增厚不易控制，使用过程中可能因碰撞脱落而减弱防火效果。本发明为解决这一问题，将防火涂料本体树脂制备成连续的、具有稳定厚度的防火胶膜，并将该防火胶膜铺贴到玻璃纤维-铝合金混杂层板中，使制备的玻璃纤维-铝合金混杂层板零件具有防火特性，该方法无外表面刷涂防火涂料工序，简化了零件制造工序，同时，因外表面无涂料层，可避免在运输、使用过程中的涂料脱落等问题。
发明内容
本发明的目的是提供一种能够抵抗高温火焰冲击及抗热传导的玻璃纤维-铝合金层板制备方法，以解决传统材料在应用过程面临的火灾风险，该方法可用于飞行器或汽车油箱与其他关键部位的玻璃纤维-铝合金层板隔板制造，以抵抗油箱意外起火造成的火焰冲击，保护人员安全。
本发明解决上述技术问题所采用的技术方案如下，
防火玻璃纤维-铝合金混杂层板由铝合金板、玻璃纤维预浸料层、防火胶膜组成，在模具上铺贴后给予压力及温度固化成型，铺叠顺序依次为：铝合金板-防火胶膜-玻璃纤维预浸料层-铝合金板-玻璃纤维预浸料层-防火胶膜-铝合金板，铝合金板厚度为0.2～0.5mm，该方法包括以下步骤：
a)将防火涂料本体树脂放置于涂膜设备的胶槽中，在离型纸上涂成连续的防火胶膜，防火涂料本体树脂的性能参数应满足：发泡温度为180℃～300℃；
b)在模具上依次铺贴铝合金板、防火胶膜、玻璃纤维预浸料层、铝合金板、玻璃纤维预浸料层、防火胶膜、铝合金板，形成零件预成型坯体，玻璃纤维预浸料的性能参数应满足：固化温度范围为115℃～125℃；
c)给予坯体压力及温度，使坯体在模具上固化成型，压力范围：0.3MPa～0.4MPa，温度范围：115℃～125℃。
玻璃纤维预浸料层由多层玻璃纤维预浸料铺贴而成，玻璃纤维预浸料中的玻璃纤维体积分数为60％～70％，玻璃纤维预浸料单层名义厚度为0.125mm～0.200mm。
防火胶膜厚度为0.2mm～0.3mm。
防火胶膜为连续性薄膜卷材，表面衬塑料膜。
铝合金板、玻璃纤维预浸料层及防火胶膜组合为坯体后，在坯体上施加压力及温度固化的压力范围：0.3MPa～0.4MPa，温度范围：120℃～125℃。
本发明具有的优点和有益效果：本发明将连续防火胶膜引入到玻璃纤维-铝合金混杂层板中，使材料具有防火特性，在受到火焰冲击时，防火胶膜层的热分解发泡能够在一定时间内抵御高温冲击，达到防火目的。
本发明的防火玻璃纤维-铝合金混杂层板的制备方法，使材料在具有传统特性的前提下，增加防火性能，在实现防火性的同时可单独作为飞机或汽车等的零件使用；同时，在结构设计中，该防火玻璃纤维-铝合金混杂层板不仅能够作为单独的零件使用，而且该材料具备的隔热冲击性能，可使其单独作为防火材料使用，发挥防火玻璃纤维-铝合金混杂层板的防火、隔热等特性。本发明的防火玻璃纤维-铝合金层板的制备方法，无需再在零件表面涂覆其他防火材料，不仅降低了零件后期处理成本，并且在同一结构中实现了结构与防火的多功能特性。
本发明结合了防火涂料、预浸料和铝合金板的特点，将三种材料一体化成型为具有防火功能的玻璃纤维-铝合金混杂层板，该方法简化了制造工序，连续性防火胶膜使零件制造更加高效、稳定，同时避免了涂料在外表面可能引起的脱落问题，零件外表面无需再设置防火层，实现了承力、防火的一体化。
附图说明
图1是防火玻璃纤维-铝合金混杂层板结构示意图；
图2是防火胶膜的涂膜示意图；
图3是防火玻璃纤维-铝合金混杂层板半圆结构零件外形及铺贴示意图；
图4是防火玻璃纤维-铝合金混杂层板半圆结构零件成型示意图；
图5是防火玻璃纤维-铝合金混杂层板半圆结构零件受火焰冲击后的结构示意图。
具体实施方式
本发明方法包括以下步骤：
a)将防火涂料本体树脂放置于涂膜设备的胶槽中，在离型纸上涂成连续的防火胶膜；
b)在模具上铺贴材料，铺贴顺序为：铝合金板、防火胶膜、玻璃纤维预浸料层、铝合金板、玻璃纤维预浸料层、防火胶膜、铝合金板，形成零件预成型坯体；
c)给予坯体压力及温度，使坯体在模具上固化成型。
铝合金板厚度为0.2～0.5mm，玻璃纤维预浸料层由多层玻璃纤维预浸料单层组成，玻璃纤维预浸料单层名义厚度为0.125mm～0.200mm，玻璃纤维预浸料可在115℃～125℃固化，玻璃纤维体积分数为60％～70％。
防火胶膜厚度为0.2mm～0.3mm，铺贴在防火玻璃纤维-铝合金混杂层板表层铝合金板的内侧，发泡温度为180℃～300℃，发泡遇火炭化后厚度为原发泡层厚度的35倍～40倍。
铝合金板、玻璃纤维预浸料层及防火胶膜依次铺贴完成后，外加压力及温度固化，压力范围：0.3MPa～0.4MPa，温度范围：115℃～125℃。
当防火玻璃纤维-铝合金混杂层板受到火焰冲击时，防火胶膜升温到180℃时开始逐步发泡，并将外表面铝合金板向外顶出鼓包，强的火焰冲击在瞬时间内击穿铝合金板，使防火胶膜层发泡溢出，发泡厚度为原防火胶膜厚度的35倍～40倍，并在火焰灼烧下分解形成多孔炭化结构，防火胶膜的化学分解可吸收热量，且形成的多孔结构可有效隔绝高温，达到防火目的。
如图1所示，防火玻璃纤维-铝合金混杂层板由铝合金板1、玻璃纤维预浸料层2及防火胶膜3组成。
如图2所示，防火胶膜的涂膜过程是，调整上涂胶辊22和下涂胶辊19的辊间距至0.3mm，将离型纸17放置于离型纸退卷辊18上，PE膜26放置于PE膜退卷辊24上，使离型纸17通过上涂胶辊22和下涂胶辊19的之间的间隙，中间经过冷却台20降温，PE膜26从PE膜退卷辊24上退出，经过调整辊27调整张力，PE膜26与离型纸17经过上压辊25及下压辊28的间隙后，共同收入收卷辊21。
将满足参数为发泡温度为180℃～300℃的防火涂料本体树脂放置于胶槽16中，搅拌胶槽16中的树脂，使树脂混合均匀，通过上涂胶辊22的旋转和下涂胶辊19对合旋转，使树脂通过预定辊间隙的缝隙，并粘连在离型纸17上，在离型纸17上形成0.3mm厚度的防火胶膜，防火胶膜随离型纸17送至冷却台20降低温度及粘度，并经过上压辊25及下压辊28，使PE膜26覆盖在形成的防火胶膜上，最终送入收卷辊21收卷，形成连续的防火胶膜。
参见图3，防火玻璃纤维-铝合金混杂层板半圆结构零件外形及成型示意图，依次在下模12上铺贴铝合金板1、防火胶膜2、玻璃纤维预浸料层3、铝合金板1、玻璃纤维预浸料层3、防火胶膜2、铝合金板1，在压机上将上模13与下模12对合，并通过压机给予模具加0.35MPa压力，同时给模具升温，模具温度控制在115℃～125℃之间，下模12的限位块23可限制零件成型厚度，零件固化完成后，打开上模13，并从下模12取出零件。
参见图4，防火玻璃纤维-铝合金混杂层板半圆结构零件受火焰冲击后的结构示意图，火焰15从外部冲击到半圆结构零件顶部，零件顶部上表面的铝合金1板迅速升温到180℃以上，贴近上表面铝合金板1的防火胶膜2开始逐步发泡，上表面的铝合金板1随火焰冲击而迅速熔化，使贴近上表面铝合金板1的防火胶膜2裸漏于火焰中加速发泡，并随温度升高分解碳化为多孔防火层14，防火胶膜2发泡过程中能够依靠分解能吸收热量，并且多孔防火层14能够有效的隔绝火焰及高温向零件另外一侧扩展。
本发明不仅限于以上的实施例，对本领域普通专业技术人员，所做的各种变化和修改，都应在本发明的构思及保护范围之内。
Claims (5)
1.一种防火玻璃纤维-铝合金混杂层板的制备方法，其特征在于：防火玻璃纤维-铝合金混杂层板由铝合金板、玻璃纤维预浸料层、防火胶膜组成，在模具上铺贴后给予压力及温度固化成型，铺叠顺序依次为：铝合金板-防火胶膜-玻璃纤维预浸料层-铝合金板-玻璃纤维预浸料层-防火胶膜-铝合金板，铝合金板厚度为0.2～0.5mm，该方法包括以下步骤：
a)将防火涂料本体树脂放置于涂膜设备的胶槽中，在离型纸上涂成连续的防火胶膜，防火涂料本体树脂的性能参数应满足：发泡温度为180℃～300℃。
b)在模具上依次铺贴铝合金板、防火胶膜、玻璃纤维预浸料层、铝合金板、玻璃纤维预浸料层、防火胶膜、铝合金板，形成零件预成型坯体，玻璃纤维预浸料层的性能参数应满足：固化温度范围为115℃～125℃；
c)给予坯体压力及温度，使坯体在模具上固化成型，压力范围：0.3MPa～0.4MPa，温度范围：115℃～125℃。
2.根据权利1所述防火玻璃纤维-铝合金混杂层板的制备方法，其特征在于：玻璃纤维预浸料层由多层玻璃纤维预浸料铺贴而成，玻璃纤维预浸料中的玻璃纤维体积分数为60％～70％，玻璃纤维预浸料单层名义厚度为0.125mm～0.200mm。
3.根据权利1所述防火玻璃纤维-铝合金混杂层板的制备方法，其特征在于：防火胶膜厚度为0.2mm～0.3mm。
4.根据权利1所述防火玻璃纤维-铝合金混杂层板的制备方法，其特征在于：防火胶膜为连续性薄膜卷材，表面衬塑料膜。
5.根据权利1所述防火玻璃纤维-铝合金混杂层板的制备方法，其特征在于：铝合金板、玻璃纤维预浸料层及防火胶膜铺贴为坯体后，在坯体上施加压力及温度使零件固化，压力范围：0.3MPa～0.4MPa，温度范围：120℃～125℃。
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