CN107825805B - 一种超混杂层状复合结构及其制备方法 - Google Patents

一种超混杂层状复合结构及其制备方法 Download PDF

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CN107825805B
CN107825805B CN201710894021.6A CN201710894021A CN107825805B CN 107825805 B CN107825805 B CN 107825805B CN 201710894021 A CN201710894021 A CN 201710894021A CN 107825805 B CN107825805 B CN 107825805B
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layer
fiber
honeycomb
needled felt
composite structure
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CN107825805A (zh
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李华冠
陆一
孙邓辉
费炜杰
陶杰
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Liyang Shanhu New Material Technology Co.,Ltd.
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Nanjing Institute of Technology
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Abstract

本发明公开了一种超混杂层状复合结构制备方法，包括以下步骤：S01：裁剪与清洗；S02：阳极化处理；S03：贴胶膜；S04：纤维层‑金属层‑蜂窝层‑非织造复合针刺毡层按结构设计铺贴，S05：加热‑加压固化；S06：切割；S07：无损检测。本发明还公开了一种超混杂层状复合结构，由上述制备方法得到。本发明的一种超混杂层状复合结构及其制备方法，能够保证纤维金属层板原有优良性能的同时，并且获得较高的刚度，且无需在车辆门成型后加装内饰层，生产效率提高，舒适度要求进一步提升。

Description

一种超混杂层状复合结构及其制备方法
技术领域
本发明涉具体涉及一种超混杂层状复合结构及其制备方法，属于先进复合材料的制备及成形领域。
背景技术
轨道交通相对于公共汽车、私人汽车、自行车等大众交通工具而言，具有运置大、低污染、低噪音、低能耗、高速度、低成本、占地少、舒适、全天候等得天独厚的优势.是其他交通方式无法替代的。尤其随着高速铁路的发展，我国的轨道交通取得更大的进步，而随着一带一路的建设，“高铁外交”成为了我国对外发展的新名片，建设运营速度更快，更加安全舒适的高速铁路是现阶段我国轨道交通的新目标。轨道交通车辆门及其壳体是其重要的零件，目前大部分轨道交通车辆门及其壳体依旧采用铝合金制造。而针对运营速度更快的目标，若依然运用铝合金制造，显然无法减重，进而达到提速且不增加能耗的目标。而对于安全舒适的目标而言，现有的车辆门材料需要在车辆门及其壳体成型后加装内饰材料，效率低，且舒适度要求不理想。
由于轨道交通车辆门及其壳体面对的环境较为多变，需要其具有一定的抗腐蚀性能，能抵抗风、沙、雪、沙尘暴、盐雾、酸雨等，且必须具有较强的隔声消音性能、耐冲击性能、耐疲劳性能以及防火性能。纤维金属层板(Fiber Metal Laminates，FMLs)是一种由金属薄板和纤维复合材料交替铺层后，在一定的温度和压力下固化而成的层间混杂复合材料，也称为超混杂层板(Super Hybrid Laminates)。FMLs综合了传统纤维复合材料和金属材料的特点，具有高的比强度和比刚度，优良的疲劳性能以及高的损伤容限，这些优势使得FMLs在航空航天工业中获得了广泛的应用。作为第二代FMLs，Glare层板是由铝合金薄板与玻璃纤维增强环氧树脂预浸料交替层压而成，密度低且具有突出的抗拉-压疲劳性能及较高的缺口断裂性能，抗疲劳寿命得到极大提升，同时Glare层板具有优异的耐腐蚀、耐冲击以及防火性能。但是Glare层板的模量较低，刚度达不到轨道交通车辆门及其壳体的要求。铝蜂窝由于刚度大、重量轻、便于安装运输、不易变形等优点，在建筑、车辆领域应用广泛，如高铁、地铁的大部分构件都是采用铝蜂窝板制造而成。中国专利CN 201620872666公开了一种名称为“一种轨道交通用铝蜂窝板间壁门”专利，该实用新型专利主要是将铝蜂窝运用于轨道交通的间壁门，主要目的是用于减少噪音与防止火灾，其作用有限，且单纯地利用铝蜂窝进行轨道交通车辆门及其壳体的制造，其耐冲击性能、抗疲劳性能、耐腐蚀性能劳以及损伤容限较为一般，服役寿命较短，无法满足轨道交通的多变环境。
目前的轨道交通车辆门及其壳体仍然较大程度的使用铝合金材料，这对于轨道交通的进一步减重无疑是不利的；而使用铝蜂窝进行轨道交通车辆门及其壳体制造，其耐冲击性能、抗疲劳性能、耐腐蚀性能劳以及损伤容限较为一般，服役寿命短等问题无法避免。若单纯的使用纤维金属层板，它的刚度达不到轨道交通及其壳体的性能要求。而目前大部分车辆门内饰材料均在车辆门成型后加装内饰材料，其效率较低，因此寻求一种质量轻、强度大、刚度大、耐腐蚀、耐冲击、防火隔音、抗疲劳与损伤容限优异，同时又满足舒适性能要求的新型材料，成为轨道交通车辆门及其壳体进一步发展的新挑战。
发明内容
本发明要解决的技术问题是，解决现有技术的不足，提供一种能够保证纤维金属层板原有优良性能的同时，并且获得较高的刚度，且无需在车辆门成型后加装内饰层，生产效率提高，舒适度要求进一步提升的超混杂层状复合结构及其制备方法。
为解决上述技术问题，本发明采用的技术方案为：
一种超混杂层状复合结构制备方法，包括以下步骤：
S01：裁剪与清洗，首先将金属层、纤维层、蜂窝层、非织造复合针刺毡层以及面料层裁剪至合适的尺寸，然后将金属层表面用酒精或者丙酮清洗干净；
S02：阳极化处理，将金属层先碱洗，然后用自来水冲洗，再进行酸洗，并用自来水冲洗，再将金属层进行磷酸阳极氧化20～30min,再冲洗5～10min并晾干；
S03：贴胶膜，选择与纤维层以及非织造复合针刺毡层中所含树脂相同的胶膜，贴在所设计的复合结构层间界面处；
S04：纤维层-金属层-蜂窝层-非织造复合针刺毡层按结构设计铺贴，将金属层、纤维层、蜂窝层、非织造复合针刺毡层按照一定结构进行铺层，同时在非织造复合针刺毡的表层铺贴面料层，中间利用上述相同胶膜；
S05：加热-加压固化，将铺贴好的复合结构进行抽真空处理，加热加压，温度控制在160～180℃之间，压力控制在1.1～2.1MPa，保温保压0～6min，使纤维层中的树脂完全固化，固化结束后自然降温到室温；
S06：切割：取出固化完全的复合层板，将构件的溢料切割掉；
S07：无损检测：采用透射法对所得的复合层板进行超声波C扫，判断其内部有无缺陷。
所述金属层包括2系铝合金、6系铝合金或者铝锂合金。
所述非织造复合针刺毡层由增强纤维与基体纤维组成，其中增强纤维为麻纤维或者竹纤维，基体纤维为聚丙烯。
所述胶膜与纤维层以及非织造复合针刺毡中所含的树脂成分一致，均为聚丙烯。
所述纤维层中的纤维种类包括玻璃纤维、碳纤维、玄武岩纤维或者芳纶纤维，所述蜂窝层中的蜂窝材料包括芳纶纸蜂窝、铝蜂窝或者玻璃纤维三维立体织物，蜂窝的孔径为6mm、8mm或者10mm，
S04中，所述纤维层的铺层方向为单向或正交。
S05中，加热-加压固化方法采用非热压罐成型技术，模压技术或者真空袋冷压技术。
S06中，切割的方式为铣切加工，采用球头直径R2以上的硬质合金球头刀具，转速在8000r/min以上。
一种超混杂层状复合结构，采用上述任意一种超混杂层状复合结构制备方法制备得到。
超混杂层状复合结构包括以下三种铺贴方式：a、从上往下，依次为金属层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层；b、从上往下，依次为金属层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层；c、金属层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层，其中相邻的两层之间使用胶膜贴合。本发明的有益效果：与现有材料相比，本发明的改进之处在于，
(1)本发明针对于现有轨道交通车辆门及其壳体所用材料的问题，提出了一种优化的新型材料体系，在纤维金属层板的基础上引入蜂窝结构，改善了纤维金属层板的刚度不足的问题，同时有拥有良好的防腐性能，防火隔音性能，比强度高等优点。与铝合金材料相比，质量大大减轻。它也克服了铝蜂窝结构耐冲击性能、抗疲劳能力较差的缺点，抗疲劳能力与损伤容限得到很大提升。同时它直接考虑了车辆门后期需要加装内饰层以及轨道交通车辆门的舒适度要求，直接引入非制造针刺毡，提高生产效率，并提高轨道交通车辆门的舒适度。
(2)本发明将蜂窝引入纤维金属层板的体系中，较好地为纤维金属层板在航空航天的运用提供了新的思路。
(3)本发明采用的固化工艺成本较低，生产效率高，且在固化后进行无损检测，进一步保证了该材料的质量，为其实际的工程运用提供保障，此外由于本发明基于纤维金属层板中已经商业化运用的Glare层板，因此具有很高的实际工程运用可能与价值。
附图说明
图1为本发明的一种超混杂层状复合结构制备方法的工艺流程图；
图2是实施例1中一种超混杂层状复合结构的结构示意图；
图3是实施例2中一种超混杂层状复合结构的结构示意图；
图4是实施例3中一种超混杂层状复合结构的结构示意图。
图中附图标记，1-金属层、2-蜂窝层、3-胶膜、4-0°纤维层、5-90°纤维层、6-非织造复合针织毡层、7-面料层。
具体实施方式
下面结合附图对本发明作进一步描述，以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
具体实施例1
第一步：针对2024铝合金-玻璃纤维-芳纶纸蜂窝-非织造复合针织毡超混杂层状复合结构，首先选取0.3mm厚2024铝合金，玻璃纤维，其中含有PP树脂，以及孔径大小为6mm的芳纶纸蜂窝与2mm厚的非织造复合针刺毡，纤维层为麻纤维。将2024铝合金层、纤维层、芳纶纸蜂窝层、非织造复合针刺毡层以及面料层裁剪成300×300mm，然后用酒精将2024铝合金层表面清洗干净。
第二步：将2024铝合金层先碱洗1min，碱洗溶液的溶质为NaOH、Na2CO3，其中密度分别为30g/L，然后自来水冲洗5min，然后进行酸洗，酸洗的溶质为HNO3，其中密度为400g/L，然后自来水冲洗5min。最后将2024铝合金层进行磷酸阳极氧化，磷酸的密度为140g/L，时间为20min,再用自来水冲洗8min并晾干。
第三步：选择与纤维层以及非织造复合针刺毡层6中所含树脂相同的胶膜3，贴在所设计的复合结构层间界面处；且纤维层中含有PP(聚丙烯)树脂，选择PP(聚丙烯)胶膜，并根据结构在金属层1、纤维层、蜂窝层2以及非织造复合针刺毡层6的界面处贴胶膜3。
第四步：该复合结构如图2所示，该结构含有非纤维层有三层，其中有一层为蜂窝层2，有两层纤维层，且蜂窝层2只与纤维层接触,其中纤维层包括直接粘合在一起的0°纤维层4和90°纤维层5，图2中长度方向为铝板的轧制方向，纤维按此方向铺层定义为0°，纤维铺层方向为0°/90°的正交铺层。从上往下，依次为金属层1、90°纤维层5、0°纤维层4、蜂窝层2、0°纤维层4、90°纤维层5、非织造复合针刺毡层6和面料层7，相邻的两层之间使用胶膜3贴合。
第五步：将铺好的超混杂层状复合结构采用非热压罐成型技术(OOA技术)，先进行抽真空处理，再加热加压，温度峰值控制为160℃，压力控制在1.5MPa，保温保压3min，使纤维层中的树脂完全固化，固化结束后自然降温到室温。
第六步：取出固化完成的超混杂层状复合结构材料，利用铣切的方式去除溢料，采用球头直径R2的硬质合金球头刀具，具体工艺参数为：转速在8000r/min，进给速度2m/min，背吃刀量0.3mm，水冷。
第七步：采用透射法对所得的超混杂层状复合结构材料进行超声波C扫，判断其有无内部缺陷。
具体实施例2：
第一步：针对6061铝合金-碳纤维-玻璃纤维三维立体织物-非织造针刺毡层超混杂层状复合结构，首先选取0.3mm厚6061铝合金，碳纤维，其中含有PP聚丙烯树脂，以及孔径大小为8mm的玻璃纤维三维立体织物与2.5mm厚的非织造复合针刺毡，增强纤维为竹纤维。将6061铝合金层、碳纤维层、玻璃纤维三维立体织物层、非织造复合针刺毡层以及面料层裁剪成400×400mm,然后用丙酮将6061铝合金层表面清洗干净。
第二步：将6061铝合金层先碱洗1.5min，碱洗溶液的溶质为NaOH、Na2CO3，其中密度分别为30g/L，然后自来水冲洗8min,然后进行酸洗，酸洗的溶质为HNO3，其中密度为500g/L，然后自来水冲洗10min。最后将6061铝合金层进行磷酸阳极氧化，磷酸的密度为130g/L，时间为20min,再用自来水冲洗10min并晾干。
第三步：选择与纤维层以及非织造复合针刺毡层6中所含树脂相同的胶膜3，贴在所设计的复合结构层间界面处；且纤维层中含有PP(聚丙烯)树脂，选择PP(聚丙烯)胶膜，并根据结构在金属层1、纤维层、蜂窝层2以及非织造复合针刺毡层6的界面处贴胶膜3。
第四步：该复合结构如图3所示，该结构含有非纤维层有四层，其中有两层为蜂窝层2，有三层纤维层，且蜂窝层2只与纤维层接触,其中纤维层包括直接粘合在一起两层0°纤维层4，图3中长度方向为铝板的轧制方向，纤维按此方向铺层定义为0°，纤维铺层方向为0°/0°的铺层。从上往下，依次为金属层1、两层0°纤维层4、蜂窝层2、两层0°纤维层4、蜂窝层2、两层0°纤维层4、非织造复合针刺毡层6和面料层7，相邻的两层之间使用胶膜3贴合。
第五步：采用热压工艺，对铺好的超混杂层状复合结构先用真空袋包覆，再进行抽真空处理，将其放入模具中并将模具加热，峰值温度控制在170℃，模具闭合，压力控制在1.8MPa，保温保压5min，使纤维层中的树脂完全固化，固化结束后自然降温到室温。
第六步：取出固化完成的超混杂层状复合结构材料，利用铣切的方式去除溢料，采用球头直径R2.5的硬质合金球头刀具，具体工艺参数为：转速在10000r/min，进给速度2m/min，背吃刀量0.1mm，油冷。
第七步：采用透射法对所得的超混杂层状复合结构材料进行超声波C扫，判断其有无内部缺陷。
具体实施例3：
第一步：针对铝锂合金-芳纶纤维-铝蜂窝-非织造针刺毡层的超混杂层状复合结构，首先选取0.3mm厚铝锂合金，芳纶纤维，其中含有PP(聚丙烯)树脂，以及孔径大小为10mm的铝蜂窝与3mm厚的非织造复合针刺毡层，增强纤维为麻纤维。将铝锂合金层、芳纶纤维层、铝蜂窝层、非织造复合针刺毡层以及面料层裁剪成500×500mm，然后用酒精将铝锂合金层表面清洗干净。
第二步：将铝锂合金层先碱洗，然后用自来水冲洗，再进行酸洗，并用自来水冲洗。将铝锂合金层进行磷酸阳极氧化30min,再冲洗10min并晾干；
第三步：选择与纤维层以及非织造复合针刺毡层6中所含树脂相同的胶膜3，贴在所设计的复合结构层间界面处；且纤维层中含有PP(聚丙烯)树脂，选择PP(聚丙烯)胶膜，并根据结构在金属层1、纤维层、蜂窝层2以及非织造复合针刺毡层6的界面处贴胶膜3。
第四步：该复合结构如图4所示，该结构含有非纤维层有五层，其中有三层为蜂窝层2，有四层纤维层，且蜂窝层2只与纤维层接触,其中纤维层包括直接粘合在一起的0°纤维层4和90°纤维层5，图4中长度方向为铝板的轧制方向，纤维按此方向铺层定义为0°，纤维铺层方向为0°/90°的正交铺层。从上往下，依次为金属层1、90°纤维层5、0°纤维层4、蜂窝层2、0°纤维层4、90°纤维层5、蜂窝层2、90°纤维层5、0°纤维层4、蜂窝层2、0°纤维层4、90°纤维层5、非织造复合针刺毡层6和面料层7，相邻的两层之间使用胶膜3贴合。
第五步：将铺好的超混杂层状复合结构放入真空袋中，先抽真空再加热至峰值温度180℃,保温1min，5s内转移至模具中，立即将模具闭合，压力控制在2MPa，保压2min，使纤维层中的树脂完全固化，固化结束后自然降温到室温。
第六步：取出固化完成的超混杂层状复合结构材料，利用铣切的方式去除溢料，采用球头直径R3的硬质合金球头刀具，具体工艺参数为：转速在12000r/min，进给速度1.5m/min，背吃刀量0.2mm，油冷。
第七步：采用透射法对所得的超混杂层状复合结构材料进行超声波C扫，判断其有无内部缺陷。
以上所述仅是本发明的优选实施方式，应当指出：对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (7)

1.一种超混杂层状复合结构制备方法，其特征在于：包括以下步骤：
S01：裁剪与清洗，首先将金属层、纤维层、蜂窝层、非织造复合针刺毡层以及面料层裁剪至合适的尺寸，然后将金属层表面用酒精或者丙酮清洗干净；
S02：阳极化处理，将金属层先碱洗，然后用自来水冲洗，再进行酸洗，并用自来水冲洗，再将金属层进行磷酸阳极氧化20~30min，再冲洗5~10min并晾干；
S03：贴胶膜，选择与纤维层以及非织造复合针刺毡层中所含树脂相同的胶膜，贴在所设计的复合结构层间界面处；
S04：纤维层-金属层-蜂窝层-非织造复合针刺毡层按结构设计铺贴，将金属层、纤维层、蜂窝层、非织造复合针刺毡层按照一定结构进行铺层，包括以下三种铺贴方式：a、从上往下，依次为金属层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层；b、从上往下，依次为金属层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层；c、金属层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、蜂窝层、纤维层、非织造复合针刺毡层和面料层，其中相邻的两层之间使用胶膜贴合；同时在非织造复合针刺毡的表层铺贴面料层，中间利用上述相同胶膜，蜂窝的孔径为6mm、8mm或者10mm，所述胶膜与纤维层以及非织造复合针刺毡中所含的树脂成分一致，均为聚丙烯；
S05：加热-加压固化，将铺贴好的复合结构进行抽真空处理，加热加压，温度控制在160~180℃之间，压力控制在1.1~2.1MPa，保温保压0~6min，使纤维层中的树脂完全固化，固化结束后自然降温到室温；
S06：切割：切割的方式为铣切加工，采用球头直径R2以上的硬质合金球头刀具，转速在8000r/min以上，取出固化完全的复合层板，将构件的溢料切割掉；
S07：无损检测：采用透射法对所得的复合层板进行超声波C扫，判断其内部有无缺陷。
2.根据权利要求1所述的一种超混杂层状复合结构制备方法，其特征在于：所述金属层包括2系铝合金、6系铝合金或者铝锂合金。
3.根据权利要求1所述的一种超混杂层状复合结构制备方法，其特征在于：所述非织造复合针刺毡层由增强纤维与基体纤维组成，其中增强纤维为麻纤维或者竹纤维，基体纤维为聚丙烯。
4.根据权利要求1所述的一种超混杂层状复合结构制备方法，其特征在于：所述纤维层中的纤维种类包括玻璃纤维、碳纤维、玄武岩纤维或者芳纶纤维，所述蜂窝层中的蜂窝材料包括芳纶纸蜂窝、铝蜂窝或者玻璃纤维三维立体织物。
5.根据权利要求1所述的一种超混杂层状复合结构制备方法，其特征在于：S04中，所述纤维层的铺层方向为单向或正交。
6.根据权利要求1所述的一种超混杂层状复合结构制备方法，其特征在于：S05中，加热-加压固化方法采用非热压罐成型技术，模压技术或者真空袋冷压技术。
7.一种超混杂层状复合结构，其特征在于：采用权利要求1到权利要求6任意所述的一种超混杂层状复合结构制备方法制备得到。
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