CN107487034B - 一种雷电防护金属网复合膜及其制备方法 - Google Patents
一种雷电防护金属网复合膜及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种雷电防护金属网复合膜及其制备方法,通过制备膜胶、模具预处理、真空吸注方式得到金属网复合膜;金属网复合膜包括依次连接的离型纸a、防雷层、粘结层和离型纸b;其中防雷层为经膜胶填充和浸透的延性金属网;粘结层为经膜胶填充和浸透的碳毡或者无纺布。本发明一种雷电防护金属网复合膜的制备方法采用真空吸注的方法制备雷电防护金属网复合膜,从而得到表面平整、均匀、防雷效果优异的雷电防护金属网复合膜,并且由于制备过程中有大气压力的存在,无纺布或碳毡、膜胶、延性金属网的粘接强度高,雷电防护纤维复合膜的综合性能更好,相比现有复合膜粘度更小,性能更优异,方法简单,有很好的实用价值。
Description
技术领域
本发明属于航空航天雷电防护复合材料技术领域,具体涉及一种雷电防护金属网复合膜,本发明还涉及一种雷电防护金属网复合膜的制备方法。
背景技术
现代先进飞机,为了提高飞行性能,大量采用了先进复合材料。复合材料能提供良好的强度和刚度特性,降低了重量,但其导电性能不如金属材料,不能像金属材料那样能将雷击的电流和热量迅速地分散开,因此复合材料遭受雷击的损失是巨大的。
为了给飞机和其它航空航天结构复合材料提供雷击防护,可以将金属导体附加物或者将不同结构的延性雷电防护金属网系统附加于复合材料外表面,以提供优良的导电性能,将电流从附着位置分散和转移出去,以此减小雷击事件的物理损害。
目前的飞机复合材料雷电防护中,常采用一体成型延性金属网和金属网集成材料。专利《用于制造集成雷击防护材料的系统和方法》(申请号: 200980113022.6,申请日:2009.03.05,公开号:102006995,公开日:2011.04.06) 中公开了一种雷电防护表面膜,但没有提供制备该表面膜的具体方法。专利《一种雷电防护表面膜及其制备方法》(申请号:201510289455.4,申请日: 2015.05.29,公开号:104943271,公开日:2015.09.30)中公开了一种雷电防护表面膜及其制备方法,但该方法制备的表面胶膜质量较差,不适合工业生产,且金属网和表面胶膜粘接强度不够,金属网和表面胶膜容易脱落。专利《一种高伸长率的韧性复合材料表面膜及其制备方法》(申请号: 201510677398.7,申请日:2015.10.16,公开号:105131533,公开日:2015. 12.09)中提到了一种表面膜胶料的制备方法,但该表面膜胶料粘度比较大,需要在开炼机上混炼和压膜机上进行压制,但该表面胶膜只是普通表面膜,不具有防雷功能。
发明内容
本发明的目的是提供一种雷电防护金属网复合膜,解决了现有雷电防护复合膜粘接强度不够,粘度较大、金属网和表面胶膜容易脱落的问题。
本发明的另一个目的是提供一种雷电防护金属网复合膜的制备方法。
本发明所采用的技术方案是,一种雷电防护金属网复合膜,依次连接的离型纸a、防雷层、粘结层和离型纸b;
防雷层为经膜胶填充和浸透的延性金属网;
粘结层为经膜胶填充和浸透的碳毡或者无纺布。
本发明的特征在于,
膜胶按质量份数由以下组份组成:固态树脂50~60份、半固态树脂30~40 份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100 份。
固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种;半固态树脂为F-51、F-44或JF-46环氧树脂中任意一种。
液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种。
固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;固化剂促进剂为EH-3293S。
本发明所采用的另一个技术方案是,一种雷电防护金属网复合膜的制备方法,包括以下步骤:
步骤1,制备膜胶
步骤1.1,按质量份数称取固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100 份;
步骤1.2,取步骤1.1中固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份,依次加入50~100份的酒精中溶解24~48h,待完全溶解后向溶液中依次加入固化剂10~12份、固化剂促进剂5~8份,搅拌溶解10-12h,待溶解完全后,即得膜胶,备用;
步骤2,模具的预处理
用酒精将模具擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜、脱模布和双面胶;
步骤3,双面胶一侧粘接脱模布,双面胶带有离型纸b的一侧上依次铺设厚度为0.1~0.2mm的碳毡或者无纺布、延性金属网、离型纸a、电加热装置和真空袋,延性金属网的两端分别设置有螺旋注胶管和抽真空管,抽真空管连接真空泵;
离型纸b和碳毡或者无纺布通过压敏胶条粘接固定;
延性金属网和离型纸a通过压敏胶条粘接固定;
离型纸b一周设置有密封胶条,密封胶条与真空袋粘接形成密封工作区;
步骤4,启动真空泵、夹紧螺旋注胶管,待密封工作区的真空度至-0.1Mpa 保持10~20min,然后放开螺旋注胶管,步骤1中的膜胶通过螺旋注胶管进行密封工作区的浇注;
步骤5,结束步骤4浇注后,继续抽真空2h、关闭真空泵,此时打开密封胶条与真空袋,去掉电加热装置,即得到通过膜胶填充和浸透后,由离型纸a、延性金属网、碳毡或者无纺布和离型纸b依次连接组成的雷电防护金属网复合膜。
本发明的特征还在于,
步骤2和步骤3中的双面胶的长度和宽度均不小于延性金属网对应的长度和宽度。
步骤4浇注的具体为:
膜胶通过螺旋注胶管流入密封工作区,此时启动电加热装置升温至50 ±3℃并保持温度,当膜胶完全填充和浸透延性金属网及碳毡或者无纺布后,夹紧螺旋注胶管停止注入膜胶,继续保持温度30~60min后关闭电加热装置,浇注完成。
步骤1中固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种;
半固态树脂为F-51、F-44或JF-46环氧树脂中任意一种;
液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种。
固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;固化剂促进剂为EH-3293S。
本发明的有益效果是:本发明一种雷电防护金属网复合膜的制备方法采用真空吸注的方法制备雷电防护金属网复合膜,从而得到表面平整、均匀、防雷效果优异的雷电防护金属网复合膜,并且由于制备过程中有大气压力的存在,无纺布或碳毡、膜胶、延性金属网的粘接强度高,雷电防护纤维复合膜的综合性能更好,相比现有复合膜粘度更小,性能更优异,方法简单,有很好的实用价值。
附图说明
图1是本发明一种雷电防护金属网复合膜的结构示意图;
图2是本发明金属网复合膜预制品的铺设顺序图;
图3是本发明金属网复合膜的工艺流程图;
图4是本发明金属网复合膜在制造飞机结构件的应用示意图。
图中,1.离型纸a,2.防雷层,3.粘结层,4.离型纸b,5.延性金属网,6. 膜胶,7.模具,8.隔离膜,9.脱模布,10.双面胶,11.碳毡或者无纺布,12. 电加热装置,13.真空袋,14.螺旋注胶管,15.抽真空管,16.密封胶条,17. 真空泵,18.抽真空装置,19.加热装置,20.压缩空气,21.热压罐,22.结构件模具,23.纤维预浸料,24.真空袋b。
具体实施方式
下面结合附图和具体实施方式对本发明进行详细说明。
本发明一种雷电防护金属网复合膜,如图1所示,包括依次连接的离型纸a1、防雷层2、粘结层3和离型纸b4;防雷层2为经膜胶6填充和浸透的延性金属网5;粘结层3为经膜胶6填充和浸透的碳毡或者无纺布11。
膜胶6按质量份数由以下组份组成:固态树脂50~60份、半固态树脂 30~40份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100份。其中固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种,固态树脂加热到90℃以上会变成液体,在膜胶6 中主要调节溶剂挥发后是否粘手;半固态树脂为F-51、F-44或JF-46环氧树脂中任意一种,在膜胶6中主要用来调节胶层的软硬度,同时用来调节膜胶 6固化后的胶层硬度及剥离强度;液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种,液态树脂加热到70℃以上会变成很稀的液体,主要用来调节溶剂挥发后复合膜是否粘手,另外液态树脂为耐高温树脂,用于提高膜胶6固化后的耐温范围;固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;固化剂促进剂为 EH-3293S,用来降低固化体系的固化温度。
一种雷电防护金属网复合膜的制备方法,包括以下步骤:
步骤1,制备膜胶6
步骤1.1,按质量份数称取固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100 份;
步骤1.2,取步骤1.1中固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份,依次加入50~100份的酒精中溶解24~48h,待完全溶解后向溶液中依次加入固化剂10~12份、固化剂促进剂5~8份,搅拌溶解10-12h,待溶解完全后,即得膜胶6,备用,其中固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种;半固态树脂为F-51、F-44或 JF-46环氧树脂中任意一种;液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种;固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;固化剂促进剂为EH-3293S。
步骤2,模具的预处理
用酒精将模具7擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜8、脱模布9和双面胶10;
步骤3,双面胶10一侧粘接脱模布9,双面胶10带有离型纸b4的一侧上依次铺设厚度为0.1~0.2mm的碳毡或者无纺布11、延性金属网5、离型纸 a1、电加热装置12和真空袋13,延性金属网5的两端分别设置有螺旋注胶管14和抽真空管15,抽真空管15连接真空泵17,铺设顺序如图2所示;
离型纸b4和碳毡或者无纺布11通过压敏胶条粘接固定,延性金属网5 和离型纸a1通过压敏胶条粘接固定;
双面胶10的长度和宽度均不小于延性金属网5对应的长度和宽度;双面胶10的离型纸b4一周设置有密封胶条16,密封胶条16与真空袋13粘接形成密封工作区;
电加热装置12为电加热丝;
步骤4,如图3所示,启动真空泵17、用大力钳夹紧螺旋注胶管14,待密封工作区的真空度至-0.1Mpa保持10~20min,然后撤去大力钳、放开螺旋注胶管14,步骤1中的膜胶6通过螺旋注胶管14进行密封工作区的浇注,具体为:
由于密封工作区的压力较小,膜胶6通过螺旋注胶管14流入密封工作区,缓慢填充和浸透延性金属网5的孔和碳毡或者无纺布11,此时启动电加热装置12升温至50±3℃并保持温度,促进膜胶6流动,使制备的雷电防护金属网复合膜表面均匀,当膜胶6完全填充和浸透延性金属网5及碳毡或者无纺布11后,用大力钳夹紧螺旋注胶管14停止注入膜胶6,继续保持温度 30~60min后关闭电加热装置12,浇注完成。
步骤5,结束步骤4浇注后,继续抽真空2h、关闭真空泵17,此时打开密封胶条16与真空袋13,去掉电加热装置12,即得到通过膜胶6填充和浸透后,由离型纸a1、延性金属网5、碳毡或者无纺布11 和离型纸b4依次连接组成的雷电防护金属网复合膜,裁剪成固定尺寸,得到雷电防护金属网复合膜成品,并在-18℃条件下进行保存。
实施例1
(1)制备膜胶6
按质量份数称取X4502双马来酰亚胺树脂50份、F-51环氧树脂30份、端羧基液体丁腈橡胶增韧环氧树脂20份、三氟化硼-乙二胺络合物10份、 EH-3293S固化剂促进剂5份、酒精60份;将X4502双马来酰亚胺树脂、F-51 环氧树脂和端羧基液体丁腈橡胶增韧环氧树脂全部加入酒精中溶解24h,待所有树脂完全溶解后再加入三氟化硼-乙二胺络合物10份、固化剂促进剂5 份,搅拌溶解10h,待溶解完全后,即得膜胶6,备用;
(2)真空浇注
用酒精将模具7擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜8、脱模布9和双面胶10;双面胶10一侧粘接脱模布9,双面胶10带有离型纸 b4的一侧上依次铺设厚度为0.1mm的碳毡或者无纺布11、延性金属网5、离型纸a1、电加热装置1和真空袋13,真空袋13通过离型纸b4一周的密封胶带16粘接呈密封工作区,延性金属网5的两端分别设置有螺旋注胶管 14和抽真空管15,抽真空管15连接旋片式真空泵17;
启动真空泵17、夹紧螺旋注胶管14,待密封工作区的真空度至-0.1Mpa 保持10min,然后放开螺旋注胶管14,膜胶6通过螺旋注胶管14流入密封工作区,此时启动电加热装置12升温至47℃并保持温度,当膜胶6完全填充和浸透延性金属网5及碳毡或者无纺布11后,夹紧螺旋注胶管14停止注入膜胶6,继续保持温度30min后关闭电加热装置12,浇注完成。浇注完成后继续抽真空2h、关闭真空泵17,此时打开密封胶条16与真空袋13,去掉电加热装置12,即得到雷电防护金属网复合膜。
实施例2
(1)制备膜胶6
按质量份数称取QY8911双马来酰亚胺树脂60份、JF-46环氧树脂40 份、端羟基聚丁二烯环氧树脂25份、苄基二甲胺12份、EH-3293S固化剂促进剂5份、酒精100份;将QY8911双马来酰亚胺树脂、JF-46环氧树脂和端羟基聚丁二烯环氧树脂全部加入酒精中溶解30h,待所有树脂完全溶解后再加入苄基二甲胺12份、固化剂促进剂5份,搅拌溶解12h,待溶解完全后,即得膜胶6,备用;
(2)真空浇注
用酒精将模具7擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜8、脱模布9和双面胶10;双面胶10一侧粘接脱模布9,双面胶10带有离型纸 b4的一侧上依次铺设厚度为0.2mm的碳毡或者无纺布11、延性金属网5、离型纸a1、电加热装置1和真空袋13,真空袋13通过离型纸b4一周的密封胶带16粘接呈密封工作区,延性金属网5的两端分别设置有螺旋注胶管 14和抽真空管15,抽真空管15连接旋片式真空泵17;
启动真空泵17、夹紧螺旋注胶管14,待密封工作区的真空度至-0.1Mpa 保持15min,然后放开螺旋注胶管14,膜胶6通过螺旋注胶管14流入密封工作区,此时启动电加热装置12升温至50℃并保持温度,当膜胶6完全填充和浸透延性金属网5及碳毡或者无纺布11后,夹紧螺旋注胶管14停止注入膜胶6,继续保持温度50min后关闭电加热装置12,浇注完成。浇注完成后继续抽真空2h、关闭真空泵17,此时打开密封胶条16与真空袋13,去掉电加热装置12,即得到雷电防护金属网复合膜。
实施例3
(1)制备膜胶6
按质量份数称取QY8911双马来酰亚胺树脂55份、F-44环氧树脂35份、端羟基聚丁二烯环氧树脂23份、邻羟基苄基二甲胺11份、EH-3293S固化剂促进剂5份、酒精8-份;将QY8911双马来酰亚胺树脂、F-44环氧树脂和端羟基聚丁二烯环氧树脂全部加入酒精中溶解48h,待所有树脂完全溶解后再加入邻羟基苄基二甲胺11份、固化剂促进剂5份,搅拌溶解11h,待溶解完全后,即得膜胶6,备用;
(2)真空浇注
用酒精将模具7擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜8、脱模布9和双面胶10;双面胶10一侧粘接脱模布9,双面胶10带有离型纸 b4的一侧上依次铺设厚度为0.15mm的碳毡或者无纺布11、延性金属网5、离型纸a1、电加热装置1和真空袋13,真空袋13通过离型纸b4一周的密封胶带16粘接呈密封工作区,延性金属网5的两端分别设置有螺旋注胶管 14和抽真空管15,抽真空管15连接旋片式真空泵17;
启动真空泵17、夹紧螺旋注胶管14,待密封工作区的真空度至-0.1Mpa 保持20min,然后放开螺旋注胶管14,膜胶6通过螺旋注胶管14流入密封工作区,此时启动电加热装置12升温至53℃并保持温度,当膜胶6完全填充和浸透延性金属网5及碳毡或者无纺布11后,夹紧螺旋注胶管14停止注入膜胶6,继续保持温度60min后关闭电加热装置12,浇注完成。浇注完成后继续抽真空2h、关闭真空泵17,此时打开密封胶条16与真空袋13,去掉电加热装置12,即得到雷电防护金属网复合膜。
如实施例1-3得到的雷电防护金属网复合膜,包括依次连接的离型纸a1、延性金属网5、碳毡或者无纺布11 和离型纸b4,裁剪成固定尺寸,并在-18℃条件下进行保存。
图4为实施例1-3得到的雷电防护金属网复合膜在飞机上的应用示意图。在制备飞机结构件时,首先铺上几层纤维预浸料23在结构件模具22上;然后将雷电防护金属网复合膜置于纤维预浸料23上,通过真空袋b24密封,启动抽真空装置18抽真空后,将纤维预浸料23和雷电防护金属网复合膜在热压罐21中进行通过加热装置19加压加热固化,固化温度为120℃~180℃,固化时间2~4h。雷电防护金属网复合膜通过热压罐21工艺做成具有防雷功能的结构件,延性金属网和纤维连接强度高,结构件的表面平整,雷电防护效果好,有很好的应用价值。
Claims (8)
1.一种雷电防护金属网复合膜,其特征在于,包括依次连接的离型纸a(1)、防雷层(2)、粘结层(3)和离型纸b(4);
所述防雷层(2)为经膜胶(6)填充和浸透的延性金属网(5);
所述粘结层(3)为经膜胶(6)填充和浸透的碳毡或者无纺布(11);
所述膜胶(6)按质量份数由以下组份组成:固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100份。
2.根据权利要求1所述的一种雷电防护金属网复合膜,其特征在于,所述固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种;所述半固态树脂为F-51、F-44或JF-46环氧树脂中任意一种。
3.根据权利要求1所述的一种雷电防护金属网复合膜,其特征在于,所述液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种。
4.根据权利要求1所述的一种雷电防护金属网复合膜,其特征在于,所述固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;所述固化剂促进剂为EH-3293S。
5.一种如权利要求1-4任一所述的雷电防护金属网复合膜的制备方法,其特征在于,包括以下步骤:
步骤1,制备膜胶(6)
步骤1.1,按质量份数称取固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份、固化剂10~12份、固化剂促进剂5~8份、酒精50~100份;
步骤1.2,取步骤1.1中固态树脂50~60份、半固态树脂30~40份、液态树脂20~25份,依次加入50~100份的酒精中溶解24~48h,待完全溶解后向溶液中依次加入固化剂10~12份、固化剂促进剂5~8份,搅拌溶解10-12h,待溶解完全后,即得膜胶(6),备用;
步骤2,模具的预处理
用酒精将模具(7)擦拭干净并涂上脱模蜡,然后依次铺设一层隔离膜(8)、脱模布(9)和双面胶(10);
步骤3,双面胶(10)一侧粘接脱模布(9),双面胶(10)带有离型纸b(4)的一侧上依次铺设厚度为0.1~0.2mm的碳毡或者无纺布(11)、延性金属网(5)、离型纸a(1)、电加热装置(12)和真空袋(13),延性金属网(5)的两端分别设置有螺旋注胶管(14)和抽真空管(15),抽真空管(15)连接真空泵(17);
所述离型纸b(4)和碳毡或者无纺布(11)通过压敏胶条粘接固定;
所述延性金属网(5)和离型纸a(1)通过压敏胶条粘接固定;
所述离型纸b(4)一周设置有密封胶条(16),密封胶条(16)与真空袋(13)粘接形成密封工作区;
步骤4,启动真空泵(17)、夹紧螺旋注胶管(14),待密封工作区的真空度至-0.1Mpa保持10~20min,然后放开螺旋注胶管(14),所述步骤1中的膜胶(6)通过螺旋注胶管(14)进行密封工作区的浇注;
步骤5,结束步骤4浇注后,继续抽真空2h、关闭真空泵(17),此时打开密封胶条(16)与真空袋(13),去掉电加热装置(12),即得到通过膜胶(6)填充和浸透后,由离型纸a(1)、延性金属网(5)、碳毡或者无纺布(11 )和离型纸b(4)依次连接组成的雷电防护金属网复合膜;
所述步骤2和步骤3中的双面胶(10)的长度和宽度均不小于延性金属网(5)对应的长度和宽度。
6.根据权利要求5所述的一种雷电防护金属网复合膜的制备方法,其特征在于,所述步骤4浇注的具体为:
膜胶(6)通过螺旋注胶管(14)流入密封工作区,此时启动电加热装置(12)升温至50±3℃并保持温度,当膜胶(6)完全填充和浸透延性金属网(5)及碳毡或者无纺布(11)后,夹紧螺旋注胶管(14)停止注入膜胶(6),继续保持温度30~60min后关闭电加热装置(12),浇注完成。
7.根据权利要求5所述的一种雷电防护金属网复合膜的制备方法,其特征在于,所述步骤1中固态树脂为X4502双马来酰亚胺树脂或QY8911双马来酰亚胺树脂中任意一种;
所述半固态树脂为F-51、F-44或JF-46环氧树脂中任意一种;
所述液态树脂为端羧基液体丁腈橡胶增韧环氧树脂或端羟基聚丁二烯环氧树脂中任意一种。
8.根据权利要求5所述的一种雷电防护金属网复合膜的制备方法,其特征在于,所述固化剂为三氟化硼-乙二胺络合物、苄基二甲胺或者邻羟基苄基二甲胺中任意一种;所述固化剂促进剂为EH-3293S。
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