CN108215385A - 一种高吸收性能的电磁屏蔽薄膜及其制备方法 - Google Patents

一种高吸收性能的电磁屏蔽薄膜及其制备方法 Download PDF

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CN108215385A
CN108215385A CN201810098379.2A CN201810098379A CN108215385A CN 108215385 A CN108215385 A CN 108215385A CN 201810098379 A CN201810098379 A CN 201810098379A CN 108215385 A CN108215385 A CN 108215385A
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carbon fiber
layer
chopped carbon
fiber felt
wave
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陆龙生
汤伟津
邢迪
汤勇
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South China University of Technology SCUT
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Abstract

本发明公开了一种高吸收性能的电磁屏蔽薄膜及其制备方法。本发明提供的电磁屏蔽薄膜具有多层结构，包括绝缘粘合层和短切碳纤维毡吸波层，其中任意两层相邻的短切碳纤维毡吸波层之间通过绝缘粘合层粘合为一体，最外层的短切碳纤维毡吸波层采用绝缘粘合层作为保护膜。短切碳纤维毡吸波层拥有较低的屏蔽性能和优良的吸波性能。将多层短切碳纤维毡吸波层和绝缘粘合层叠加后进行热压成型，从而改善材料的屏蔽性能。本发明提供的电磁屏蔽薄膜兼具了机械强度高、柔性好、密度小以及高电磁屏蔽性和高吸波性等优点，在电磁辐射防护、反雷达系统等重要领域有着广泛的应用前景。

Description

一种高吸收性能的电磁屏蔽薄膜及其制备方法
技术领域
本发明涉及军用航空、精密电子设备等需要吸波技术的领域,具体涉及一种高吸收性能的电磁屏蔽薄膜及其制备方法。
背景技术
日益增长的电子设备为人类带来了巨大的便利，与此同时这些设备所产生的电磁波也在威胁着人类的生活。电子设备辐射的电磁波会干扰其他电子设备的正常运行，导致电磁干扰问题。而且电磁波对人类的健康有极大的危害，长期受到电磁波的辐射会导致头疼、睡眠障碍甚至癌症等严重的健康问题。
目前，金属材料是常用的电磁屏蔽材料。由于金属材料具有优异的导电性，导致了其吸波性能极差，基本是靠反射作用来屏蔽电磁波的。当电磁波入射到材料表面，大量的电磁波被发射出去，造成了电磁辐射的二次污染问题，电磁干扰问题未得到解决。此外，密度大、耐候性差等缺点严重地限制金属材料在航天航空等重要领域的应用。由于碳纤维有着密度低、机械强度好等优点，人们逐渐将碳纤维复合材料应用到电磁屏蔽领域中。在碳纤维含量低的时候，复合材料的整体屏蔽性能较低。为了达到较好的屏蔽性能，往往会提高复合材料中的碳纤维含量，这样导致了复合材料的吸波性能极差。良好的吸波性能在军工领域例如“隐身飞机”有着重要的意义。雷达通过接收军用飞行器所反射的电磁波，可以探测飞行器的位置，雷达隐身技术成为了现代战争取胜的决定性因素之一。所以说，目前迫切需要一种耐腐蚀，密度小，机械强度好，具有高屏蔽性能的吸波材料。
发明内容
本发明的目的在于解决目前电磁屏蔽材料吸波性能差、不耐酸碱、密度大的问题，提供一种成型简单、成本低廉、高吸收性能的电磁屏蔽薄膜及其制备方法，能够使得薄膜具备较好的屏蔽性能的同时拥有良好的吸波性能。
本发明通过下述技术方案实现。
一种高吸收性能的电磁屏蔽薄膜，该电磁屏蔽薄膜具有多层结构，包括绝缘粘合层和短切碳纤维毡吸波层，其中任意两层相邻的短切碳纤维毡吸波层之间通过绝缘粘合层粘合为一体，最外层的短切碳纤维毡吸波层采用绝缘粘合层作为保护膜。
优选的，所述电磁屏蔽薄膜的层数为11~15层，对应于短切碳纤维毡吸波层的层数为5~7层，绝缘粘合层的层数为6~8层。
优选的，所述绝缘粘合层的材料为绝缘的热塑性树脂薄膜；所述短切碳纤维毡吸波层是由短切碳纤维和ES纤维通过湿法造纸技术制备得到。
优选的，所述短切碳纤维毡吸波层为碳纤维含量较低（4~6%wt）的短切碳纤维毡，拥有较好的吸波性能（吸波率大于50%）。
以上所述的一种高吸收性能的电磁屏蔽薄膜的制备方法，包括以下步骤：
（1）将连续的碳纤维束和ES纤维束分别切割成长度为2~8mm的碳纤维与ES纤维，根据实际的碳纤维含量以及面密度称取所需的碳纤维与ES纤维，再将所得碳纤维与ES纤维放置到浓度为0.6~1.4wt%的羧乙基纤维素水分散液中，进行均匀分散、混合后静置；
（2）将步骤（1）所得含有碳纤维和ES纤维的分散液通过滤网，抄造成短切碳纤维毡吸波层，再将短切碳纤维毡吸波层烘干；
（3）将烘干后的短切碳纤维毡吸波层和绝缘粘合层交叉叠放，其中最外层均用绝缘粘合层作为保护膜，形成多层结构，再将叠放后的多层材料放置到平板硫化机中进行层压得到高吸收性能的电磁屏蔽薄膜。
优选的，步骤（1）所述切割是采用径向短切技术。
优选的，步骤（1）所述均匀分散、混合的方式为机械搅拌或者气动匀浆；所述机械搅拌的速率为600~700rpm，时间为4~6min。
优选的，步骤（1）所述静置的时间为5~8分钟。
优选的，步骤（2）所述滤网的目数为70~90目；所述烘干的温度为40~60℃，时间为1~2小时。
优选的，步骤（2）、步骤（3）所述短切碳纤维毡吸波层具有多孔结构，孔隙率为65~70%；所述短切碳纤维毡吸波层的厚度小于250 μm。
优选的，步骤（3）中所述层压之前使用压辊来回挤压多层材料，以排走层与层之间的气体；所述层压的温度为165~180 ℃，层压的压力为0~6 MPa。
优选的，步骤（3）中所述电磁屏蔽薄膜的屏蔽性能可以通过改变短切碳纤维毡吸波层的数量来调节。
与现有技术相比，本发明具有如下有益效果：
1）本发明通过叠加多层碳纤维含量较低的短切碳纤维毡吸波层，使得材料在拥有较好的吸波性能的同时具有良好的屏蔽性能。克服了单层碳纤维复合材料在碳纤维含量低的时候屏蔽性能差，而在碳纤维含量高的时候吸波性能差的缺点。
2）材料的最外层采用绝缘的热塑性树脂膜作为保护层，有效地防止了短切碳纤维毡的导电网络被破坏。并且最外层为绝缘层，材料可以用于铁路、电气化等对电绝缘要求高的领域。
3）采用短切碳纤维毡吸波层和绝缘粘合层制备的电磁屏蔽薄膜，同时兼具了良好的机械强度、机械柔性、密度小以及较好的电磁屏蔽性能和吸波性能等优点，是传统的金属材料难以达到的。
4）本发明采用的成型工艺简单，使用的设备价格低廉，有较好的经济性，便于大规模推广应用。
附图说明
图1为本发明实施例1的电磁屏蔽薄膜的结构示意图。
图2为本发明实施例1的短切碳纤维毡吸波层的结构示意图。
其中，1-绝缘粘合层；2-短切碳纤维毡吸波层；3-电磁屏蔽薄膜；4-短切碳纤维；5-短切ES纤维；6-孔。
具体实施方式
下面结合具体实施例对本发明的实施例作进一步具体详细描述。
实施例1
一种高吸收性能的电磁屏蔽薄膜，如图1所示，该电磁屏蔽薄膜3具有多层结构，包括六层的绝缘粘合层1和五层的短切碳纤维毡吸波层2，其中任意两层相邻的短切碳纤维毡吸波层2之间通过绝缘粘合层1粘合为一体，最外层的短切碳纤维毡吸波层2采用绝缘粘合层1作为保护膜。
所述绝缘粘合层1的材料为聚碳酸酯薄膜。
所述短切碳纤维毡吸波层2的结构示意图如图2所示，为碳纤维含量为6wt%的短切碳纤维毡，是由短切碳纤维4和ES纤维5通过湿法造纸技术制备得到。
本发明高吸收性能的电磁屏蔽薄膜的制备方法，具体可通过如下步骤实现：
（1）通过径向短切技术（刀具材料为SK2模具钢）将连续的碳纤维束和ES纤维束均切割成6 mm的长度，根据最后所得短切碳纤维毡吸波层的碳纤维含量为6 wt%以及面密度为40g/㎡称取所需的碳纤维与ES纤维。将0.07536g的碳纤维与1.18064g的ES纤维放置到浓度为1.0 wt%、5000ml的羧乙基纤维素水分散液中，通过机械搅拌的方式进行均匀分散、混合后静置5分钟。机械搅拌速率为600rpm，时间为5min。
（2）将步骤（1）所得含有碳纤维和ES纤维的分散液通过一个80目的滤网，抄造成短切碳纤维毡吸波层，并将短切碳纤维毡吸波层置于40 ℃下烘干1小时，所得短切碳纤维毡吸波层具有多孔结构（见图2），孔隙率为70%，并且其厚度小于250 μm。
（3）将五层短切碳纤维毡吸波层和六层绝缘粘合层交叉叠放，其中材料最外层均用绝缘粘合层作为保护膜，形成五层短切碳纤维毡吸波层结构。使用压辊来回挤压多层材料，以排走层与层之间的气体。然后将叠放后的多层材料放置到平板硫化机中进行层压得到高吸收性能的电磁屏蔽薄膜。层压温度为180 ℃，层压压力为6 MPa。
在本实施例中，对高吸收性能的电磁屏蔽薄膜进行了厚度，拉伸性能，电磁屏蔽性能，吸波性能测试。测试结果得出电磁屏蔽薄膜的厚度为810 μm，拉伸强度为72.2 MPa，在频率为30-1500MHz的范围内其屏蔽效能达到30.1 dB，即能阻挡99.9%的入射电磁波，并且吸波率达到了53%，吸收电磁波起着主导作用。表明了该种方法制备的电磁屏蔽薄膜同时兼具良好的电磁屏蔽性能和较好的吸波性能，是一种超薄、高强度、高屏蔽性能的吸波材料。
实施例2
一种高吸收性能的电磁屏蔽薄膜，如图1所示，该电磁屏蔽薄膜3具有多层结构，包括六层的绝缘粘合层1和五层的短切碳纤维毡吸波层2，其中任意两层相邻的短切碳纤维毡吸波层2之间通过绝缘粘合层1粘合为一体，最外层的短切碳纤维毡吸波层2采用绝缘粘合层1作为保护膜。
所述绝缘粘合层1的材料为聚碳酸酯薄膜。
所述短切碳纤维毡吸波层2的结构示意图如图2所示，为碳纤维含量为5wt%的短切碳纤维毡，是由短切碳纤维4和ES纤维5通过湿法造纸技术制备得到。
本发明高吸收性能的电磁屏蔽薄膜的制备方法，具体可通过如下步骤实现：
（1）通过径向短切技术（刀具材料为SK2模具钢）将连续的碳纤维束和ES纤维束均切割成8 mm的长度，根据最后所得短切碳纤维毡吸波层的碳纤维含量为5 wt%以及面密度为40g/㎡称取所需的碳纤维与ES纤维。将0.0628g的碳纤维与1.1932g的ES纤维放置到浓度为1.4 wt%、5000ml的羧乙基纤维素水分散液中，通过机械搅拌的方式进行均匀分散、混合后静置6分钟。机械搅拌速率为600rpm，时间为6min。
（2）将步骤（1）所得含有碳纤维和ES纤维的分散液通过一个80目的滤网，抄造成短切碳纤维毡吸波层，并将短切碳纤维毡吸波层置于50 ℃下烘干1小时，所得短切碳纤维毡吸波层具有多孔结构（见图2），孔隙率为68%，并且其厚度小于250 μm。
（3）将五层短切碳纤维毡吸波层和六层绝缘粘合层交叉叠放，其中材料最外层均用绝缘粘合层作为保护膜，形成五层短切碳纤维毡吸波层结构。使用压辊来回挤压多层材料，以排走层与层之间的气体。然后将叠放后的多层材料放置到平板硫化机中进行层压得到高吸收性能的电磁屏蔽薄膜。层压温度为170 ℃，层压压力为0 MPa。
在本实施例中，对高吸收性能的电磁屏蔽薄膜进行了厚度，拉伸性能，电磁屏蔽性能，吸波性能测试。测试结果得出电磁屏蔽薄膜的厚度为806 μm，拉伸强度为71.5 MPa，在频率为30-1500MHz的范围内其屏蔽效能达到29.9 dB，即能阻挡99.89%的入射电磁波，并且吸波率达到了56%，吸收电磁波起着主导作用。
实施例3
一种高吸收性能的电磁屏蔽薄膜，具有多层结构，包括八层的绝缘粘合层1和七层的短切碳纤维毡吸波层2，其中任意两层相邻的短切碳纤维毡吸波层2之间通过绝缘粘合层1粘合为一体，最外层的短切碳纤维毡吸波层2采用绝缘粘合层1作为保护膜。
所述绝缘粘合层1的材料为聚碳酸酯薄膜。
所述短切碳纤维毡吸波层2为碳纤维含量为4wt%的短切碳纤维毡，是由短切碳纤维4和ES纤维5通过湿法造纸技术制备得到。
本发明高吸收性能的电磁屏蔽薄膜的制备方法，具体可通过如下步骤实现：
（1）通过径向短切技术（刀具材料为SK2模具钢）将连续的碳纤维束和ES纤维束均切割成2 mm的长度，根据最后所得短切碳纤维毡吸波层的碳纤维含量为4 wt%以及面密度为40g/㎡称取所需的碳纤维与ES纤维。即将0.05024g的碳纤维与1.20576g的ES纤维放置到浓度为0.6 wt%、5000ml的羧乙基纤维素水分散液中，通过机械搅拌的方式进行均匀分散、混合后静置8分钟。机械搅拌速率为700rpm，时间为4min。
（2）将步骤（1）所得含有碳纤维和ES纤维的分散液通过一个90目的滤网，抄造成短切碳纤维毡吸波层，并将短切碳纤维毡吸波层置于60 ℃下烘干2小时，所得短切碳纤维毡吸波层具有多孔结构，孔隙率为65%，并且其厚度小于250 μm。
（3）将七层短切碳纤维毡吸波层和八层绝缘粘合层交叉叠放，其中材料最外层均用绝缘粘合层作为保护膜，形成七层短切碳纤维毡吸波层结构。使用压辊来回挤压多层材料，以排走层与层之间的气体。然后将叠放后的多层材料放置到平板硫化机中进行层压得到高吸收性能的电磁屏蔽薄膜。层压温度为165 ℃，层压压力为3 MPa。
在本实施例中，对高吸收性能的电磁屏蔽薄膜进行了厚度，拉伸性能，电磁屏蔽性能，吸波性能测试。测试结果得出电磁屏蔽薄膜的厚度为1.06mm，拉伸强度为80.3 MPa，在频率为30-1500MHz的范围内其屏蔽效能达到29.5 dB，即能阻挡99.88%的入射电磁波，并且吸波率达到了58%，吸收电磁波起着主导作用。
对比例1
将实施例1中的五层短切碳纤维毡吸波层结构替换成单层短切碳纤维毡吸波层结构，其中单层的短切碳纤维毡吸波层的上下表面采用绝缘粘合层作为保护膜，其余不变。
在对比例1中，所得材料在频率为30-1500MHz的范围内其屏蔽效能为13.5 dB，即仅能阻挡95.5%的入射电磁波。对比例1制备的材料的电磁屏蔽性能远小于实施例1。证明了碳纤维含量低的单层复合材料电磁屏蔽性能较差，本发明的替换，屏蔽性能得到了极大的提升。
对比例2
将实施例1中的五层短切碳纤维毡吸波层结构替换成单层短切碳纤维毡吸波层结构，其中单层的短切碳纤维毡吸波层的上下表面采用绝缘粘合层作为保护膜。短切碳纤维毡吸波层中的碳纤维含量为6 wt%替换成含量为50 wt%，其余不变。
在对比例2中，所得材料在频率为30-1500MHz的范围内其屏蔽效能为28.7 dB，即能阻挡99.8%的入射电磁波，而吸波率仅达到29%，反射电磁波起着主导作用。对比例2制备的材料的吸波性能远小于实施例1。证明了碳纤维含量高的单层复合材料吸波性能较差，本发明的替换，吸波性能得到了极大的提升。
需要强调的是：上述实施例仅为本发明较佳的实施方式，但本发明的实施方式并不受上述实施例的限制，其他任何未背离本发明的精神实质与原理下所作的改变、修饰、代替、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。

Claims (10)

1.一种高吸收性能的电磁屏蔽薄膜，其特征在于，该电磁屏蔽薄膜具有多层结构，包括绝缘粘合层和短切碳纤维毡吸波层，其中任意两层相邻的短切碳纤维毡吸波层之间通过绝缘粘合层粘合为一体，最外层的短切碳纤维毡吸波层采用绝缘粘合层作为保护膜。
2.根据权利要求1所述的一种高吸收性能的电磁屏蔽薄膜，其特征在于：所述电磁屏蔽薄膜的层数为11~15层，对应于短切碳纤维毡吸波层的层数为5~7层，绝缘粘合层的层数为6~8层。
3.根据权利要求1所述的一种高吸收性能的电磁屏蔽薄膜，其特征在于：所述绝缘粘合层的材料为绝缘的热塑性树脂薄膜；所述短切碳纤维毡吸波层是由短切碳纤维和ES纤维通过湿法造纸技术制备得到。
4.根据权利要求1所述的一种高吸收性能的电磁屏蔽薄膜，其特征在于：所述短切碳纤维毡吸波层为碳纤维含量4~6wt%的短切碳纤维毡，吸波率大于50%。
5.制备权利要求1-4任一项所述的一种高吸收性能的电磁屏蔽薄膜的方法，其特征在于，包括以下步骤：
（1）将连续的碳纤维束和ES纤维束分别切割成长度为2-8mm的碳纤维与ES纤维，再将所得碳纤维与ES纤维放置到浓度为0.6~1.4wt%的羧乙基纤维素水分散液中，进行均匀分散、混合后静置；
（2）将步骤（1）所得含有碳纤维和ES纤维的分散液通过滤网，抄造成短切碳纤维毡吸波层，再将短切碳纤维毡吸波层烘干；
（3）将烘干后的短切碳纤维毡吸波层和绝缘粘合层交叉叠放，其中最外层均用绝缘粘合层作为保护膜，形成多层结构，再将叠放后的多层材料放置到平板硫化机中进行层压得到高吸收性能的电磁屏蔽薄膜。
6.根据权利要求5所述的方法，其特征在于：步骤（1）所述均匀分散、混合的方式为机械搅拌或者气动匀浆；所述机械搅拌的速率为600~700rpm，时间为4~6min。
7.根据权利要求5所述的方法，其特征在于：步骤（1）所述静置的时间为5~8分钟。
8.根据权利要求5所述的方法，其特征在于：步骤（2）所述滤网的目数为70~90目；所述烘干的温度为40~60℃，时间为1~2小时。
9.根据权利要求5所述的方法，其特征在于：步骤（2）、步骤（3）所述短切碳纤维毡吸波层具有多孔结构，孔隙率为65~70%；所述短切碳纤维毡吸波层的厚度小于250 μm。
10.根据权利要求5所述的方法，其特征在于：步骤（3）中所述层压之前使用压辊来回挤压多层材料，以排走层与层之间的气体；所述层压的温度为165~180 ℃，层压的压力为0~6MPa。
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