CN108248124B - 一种pp蜂窝夹芯复合板材及其制备方法 - Google Patents

一种pp蜂窝夹芯复合板材及其制备方法 Download PDF

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CN108248124B
CN108248124B CN201810089309.0A CN201810089309A CN108248124B CN 108248124 B CN108248124 B CN 108248124B CN 201810089309 A CN201810089309 A CN 201810089309A CN 108248124 B CN108248124 B CN 108248124B
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epoxy resin
nano
die
honeycomb
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康红伟
王磊
康红亮
冒杰斌
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Shenzhen Langbowan Advanced Materials Co ltd
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Abstract

本发明公开了一种pp蜂窝夹芯复合板材，包括pp蜂窝板、环氧树脂泡沫以及碳纤维增强环氧树脂复合材料蒙皮；碳纤维增强环氧树脂复合材料蒙皮与pp蜂窝板之间通过环氧树脂胶膜粘接固定。pp蜂窝夹芯复合板材的制备方法包括：S1、制备发泡环氧树脂；S2、制备固化剂；S3、将发泡环氧树脂和固化剂混合注入PP蜂窝板的孔中，升温，发泡；S4、切边修整；S5、上蒙皮预浸料叠层，依次设置环氧树脂胶膜和PP蜂窝板，依次设置环氧树脂胶膜和下蒙皮预浸料叠层，放入模具内；S6、液压机合模，加压，升温，保温，降温，得到初产品。本发明的复合板材具有轻质高强、隔热、隔音、耐冲击及减振等优点，应用于飞机、箱式货车、高铁、轮船等外部承力结构及内饰次承力结构。

Description

一种pp蜂窝夹芯复合板材及其制备方法
技术领域
本发明涉及蜂窝复合板材技术，特别涉及一种轻质高强、隔热、隔音、耐腐蚀、耐冲击蜂窝夹层结构复合材料的制备方法。
背景技术
交通工具在给人们的出行带来方便的同时，也产生了油耗、安全和环保三大问题。不管是汽车、轨道交通，还是轮船、飞机，在国家节能减排的大背景下，结构、材料轻量化是最有效的手段和方法。
PP蜂窝板具有轻质高强、耐水、隔热、隔音、热塑再变型和耐冲击等特点，特别适合制作各种复合夹芯。目前，市面上的PP蜂窝夹芯板材多为PP蜂窝与玻璃纤维毡增强热塑性PP复合板蒙皮的复合，虽然韧性很好，但是强度不足，且易发生翘曲和变形。还有一部分夹芯板是PP蜂窝板与玻璃钢蒙皮复合，但是加工工艺较繁琐，无法一体成型。而且以上两种夹层结构均以纯PP蜂窝为夹芯层，存在耐温性差，层间剪切强度不足。
由于PP材质化学结构惰性，高结晶度，决定了此类塑料蜂窝板的低表面能、非极性和弱界面层特性，很难按常规的方法实现与碳纤维复合材料蒙皮的粘接。即使经过特殊的表面处理，不仅增加成本，而且由于PP材料的热变形温度在90℃左右，低于碳纤维增强环氧树脂基预浸料常规的成型温度120～150℃，无法满足碳纤维增强/环氧泡沫填充PP蜂窝夹芯板材一体成型的工艺要求，使得这种结构的应用受到限制。
环氧树脂泡沫同时具备泡沫材料的优点和环氧树脂固化物的特性，因而具有粘接性好、低密度、强度和损伤容限高、耐温好、收缩率小等优点。环氧树脂泡沫也可以直接作为碳纤维增强复合材料蒙皮的夹芯，但是环氧树脂泡沫属于开孔结构，容易吸水，不仅密度变大，而且耐温、耐蠕变等性能下降明显。
因此，在PP蜂窝板内填充大发泡倍率环氧树脂泡沫，然后与碳纤维增强环氧树脂预浸料叠层固化的碳纤维增强/环氧泡沫填充PP蜂窝夹芯复合板材不但是最佳的组合结构，而且是性能最佳的组合材料。
发明内容
本发明的一个目的是解决至少上述问题和/或缺陷，并提供至少后面将说明的优点。
本发明还有一个目的是解决PP蜂窝板与碳纤维复合材料蒙皮的粘接困难的技术问题，同时解决PP蜂窝板在较高温度下容易软化变形的技术问题。
本发明还有一个目的是提供一种工艺简单，快速成型的pp蜂窝夹芯复合板材制备方法。
为了实现本发明这些目的和其它优点，本发明提供了一种pp蜂窝夹芯复合板材，其包括：pp蜂窝板、填充在pp蜂窝板孔内的环氧树脂泡沫以及分别铺设于pp蜂窝板上、下表面的碳纤维增强环氧树脂复合材料蒙皮；所述碳纤维增强环氧树脂复合材料蒙皮与pp蜂窝板之间通过环氧树脂胶膜粘接固定。
优选的是，所述环氧树脂泡沫由环氧树脂与化学发泡剂和纳米增韧剂反应制成，其中，环氧树脂为双酚A环氧树脂或双酚F环氧树脂或两者的混合物，所述纳米增韧剂为纳米无机粒子或纳米聚合物，所述化学发泡剂为甲苯磺酰肼TSH、氧化双(苯磺酷)肋OBSH、偶氮二碳酸胺AZO或含氢硅油其中的一种。
优选的是，所述环氧树脂胶膜为无纺布增强的环氧树脂胶膜。所述pp蜂窝板的长、宽、高分别为600mm、500mm、10mm。
制备上述的pp蜂窝夹芯复合板材的方法，包括如下步骤：
S1、发泡环氧树脂的制备：将原料组分环氧树脂、纳米增韧剂、发泡剂按比例混合，升温至50～80℃，搅拌均匀，得到混合料液A；
S2、固化剂的制备：将脂环胺、脂肪胺、促进剂和触变剂按比例混合均匀，得到混合料液B；
S3、将PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按比例混合均匀后，匀速注入PP蜂窝板的孔中，然后闭合上模，模具升温至40～60℃，发泡5～30min，得到环氧树脂泡沫填充的PP蜂窝板；
S4、取出环氧树脂泡沫填充的PP蜂窝板，进行切边修整；
S5、上蒙皮预浸料叠层，然后依次设置环氧树脂胶膜和环氧树脂泡沫填充PP蜂窝板，再依次设置环氧树脂胶膜和下蒙皮预浸料叠层，层叠完后，放入涂有脱模剂的模具内；
S6、液压机闭合模具，加压，将模具先升温，然后保温，再降温，得到初产品；
S7、对初产品进行后处理，得到碳纤维增强/环氧树脂泡沫填充的pp蜂窝夹芯复合板材。
优选的是，所述步骤S1中，环氧树脂、纳米增韧剂和发泡剂的混合重量比为200：10～40：2～10，其中，所述纳米增韧剂为纳米无机粒子或纳米聚合物，所述发泡剂为甲苯磺酰肼TSH、氧化双(苯磺酷)肋OBSH、偶氮二碳酸胺AZO或含氢硅油其中任意一种。
进一步优选的是，所述纳米无机粒子为纳米二氧化硅、纳米碳酸钙或纳米氧化铝其中任意一种，所述纳米聚合物为纳米核壳橡胶、纳米丁腈橡胶、纳米丁苯橡胶或纳米热塑性树脂粉末其中任意一种。
优选的是，所述步骤S2中，脂环胺、脂肪胺、促进剂和触变剂的混合重量比16～30：6～20：1～4：4～16，其中，所述脂环胺为异佛尔酮二胺或N-氨基乙基哌嗪，所述脂肪胺为乙二胺、二乙烯三胺、三乙烯四胺或四乙烯五胺其中任意一种，所述促进剂为2,4,6-三(二甲氨基甲基)苯酚(俗称DMP-30)、苄基二甲胺(简称BDMA)、三乙醇胺或1,8-二氮杂双环[5.4.0]十一烯(简称DBU)其中任意一种，所述触变剂为气相二氧化硅、有机膨润土或氢化蓖麻油其中任意一种。
优选的是，所述步骤S3具体为：将长、宽、高分别为600mm、500mm、10mm的PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按重量比100:15～30混合均匀后，采用灌胶机匀速注入PP蜂窝板的每个孔洞中，注入高度为1～3mm，然后闭合上模，模具升温至40～60℃，发泡5～30min，发泡倍率在5～10倍，冷却，得到环氧树脂泡沫填充的PP蜂窝板。
优选的是，所述步骤S5具体为：上蒙皮按照3K斜纹/0°/90°预浸料叠层，然后依次放置0.3mm厚度的环氧树脂胶膜和清理完晾干的环氧树脂泡沫填充PP蜂窝板，之后再依次放置0.3mm厚度的环氧树脂胶膜，下蒙皮按照90°/0°/3K斜纹预浸料叠层，层叠完后，放入涂有脱模剂的模具内；其中，预浸料为中温快速固化预浸料，环氧树脂胶膜的固化体系与预浸料的固化条件相同。
优选的是，所述步骤S6具体为：液压机闭合模具，加压到0.5～5Mpa，然后以5～10℃/min的升温速度将模具升温至120℃，保温15～20min，再降温至60℃，打开模具取出初产品。
与现有技术相比，本发明的有益之处在于：
其一、本发明采用PP蜂窝板内填充大发泡倍率的环氧树脂泡沫，然后与碳纤维增强环氧树脂预浸料叠层固化的成型方式，这样既解决了PP蜂窝板与碳纤维复合材料蒙皮的粘接问题，又能使PP蜂窝板在较高温度下不至软化变形，保持了PP蜂窝板原有的优良性能，从而得到性能优异的碳纤维增强/环氧泡沫填充PP蜂窝夹芯复合板材。
其二、环氧泡沫填充PP蜂窝板作为夹芯层，高强度、高刚性碳纤维增强环氧树脂复合材料作为结构蒙皮，具有质量轻、比强度高、比刚度高、耐老化、隔热、隔音、耐冲击、阻尼、减振、降噪等优异性能，且制造成本低、成型快速，广泛应用于飞机、箱式货车、高铁、轮船等的外部承力结构及内饰次承力结构中。
其三、PP蜂窝夹芯复合板材的制备方法工艺简单、成型快速，提高生产效率，降低生产成本，从而满足工业领域产业化应用，此种夹芯结构的不同预浸料叠层、不同夹芯层高度、不同环氧树脂发泡倍率，使其体现出不同的力学性能、减重及稳定性，给设计提供了多种选择方案。
附图说明
图1是PP蜂窝夹芯复合板材的等轴测视图。
图2是PP蜂窝夹芯复合板材的结构示意图。
图中标号：
PP蜂窝板1、环氧树脂泡沫2、环氧树脂胶膜3、碳纤维增强环氧树脂复合材料蒙皮4。
具体实施方式
以下结合附图对本发明的优选实施例进行说明，应当理解，此处所描述的优选实施例仅用于说明和解释本发明，并不用于限定本发明。
如图1和图2所示，本发明提供了一种pp蜂窝夹芯复合板材，其包括：pp蜂窝板1、填充在pp蜂窝板孔内的环氧树脂泡沫2以及分别铺设于pp蜂窝板上、下表面的碳纤维增强环氧树脂复合材料蒙皮4。所述碳纤维增强环氧树脂复合材料蒙皮4与pp蜂窝板1之间通过环氧树脂胶膜3粘接固定。优选的pp蜂窝板1的长、宽、高分别为600mm、500mm、10mm。所述环氧树脂泡沫由环氧树脂与化学发泡剂和纳米增韧剂反应制成，环氧树脂为双酚A环氧树脂或双酚F环氧树脂或两者的混合物。所述环氧树脂胶膜3为无纺布增强的环氧树脂胶膜。
本发明的pp蜂窝夹芯复合板材的制备方法实施例：
实施例1
制备方法步骤如下：
S1、发泡环氧树脂的制备：将200g双酚A环氧树脂、10g纳米二氧化硅和2g甲苯磺酰肼TSH混合，升温至50～80℃，在高速混合搅拌机里搅拌10～15min，得到混合料液A；
S2、固化剂的制备：将16g异佛尔酮二胺、20g乙二胺、1g DMP-30和4g有机膨润土，在搅拌机里搅拌10～15min，得到混合料液B；
S3、将长、宽、高分别为600mm、500mm、10mm的PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按重量比100:15混合均匀后，使用灌胶机匀速注入PP蜂窝板的孔中，注入高度为1～3mm，然后闭合上模，模具升温至40～60℃，发泡5～30min，发泡倍率在5～10倍，冷却，得到环氧树脂泡沫填充的PP蜂窝板；
S4、取出环氧树脂泡沫填充的PP蜂窝板，进行切边修整；
S5、上蒙皮按照3K斜纹/0°/90°预浸料叠层，然后依次放置0.3mm厚度的环氧树脂胶膜和清理完晾干的环氧树脂泡沫填充PP蜂窝板，之后再依次放置0.3mm厚度的环氧树脂胶膜，下蒙皮按照90°/0°/3K斜纹预浸料叠层，层叠完后，放入涂有脱模剂的模具内；
S6、液压机闭合模具，加压到0.5～5Mpa，然后以5～10℃/min的升温速度将模具升温至120℃，保温15～20min，再降温至60℃，打开模具取出初产品；
S7、对初产品进行后处理，得到碳纤维增强/环氧泡沫填充的pp蜂窝夹芯复合板材。
其中，步骤S5中，预浸料为中温快速固化预浸料，固化温度120℃，时间20min，环氧树脂胶膜的固化体系与预浸料的固化条件相似或相同。
实施例2
制备方法步骤如下：
S1、发泡环氧树脂的制备：将200g双酚F环氧树脂、40g纳米碳酸钙和10g氧化双(苯磺酷)肋混合，升温至50～80℃，在高速混合搅拌机里搅拌1～15min，得到混合料液A；
S2、固化剂的制备：将30g N-氨基乙基哌嗪、6g三乙烯四胺、4g苄基二甲胺和16g气相二氧化硅，在搅拌机里搅拌10～15min，得到混合料液B；
S3、将长、宽、高分别为600mm、500mm、10mm的PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按重量比100:30混合均匀后，使用灌胶机匀速注入PP蜂窝板的孔中，注入高度为1～3mm，然后闭合上模，模具升温至40～60℃，发泡5～30min，发泡倍率在5～10倍，冷却，得到环氧树脂泡沫填充的PP蜂窝板；
S4、取出环氧树脂泡沫填充的PP蜂窝板，进行切边修整；
S5、上蒙皮按照3K斜纹/0°/90°预浸料叠层，然后依次放置0.3mm厚度的环氧树脂胶膜和清理完晾干的环氧树脂泡沫填充PP蜂窝板，之后再依次放置0.3mm厚度的环氧树脂胶膜，下蒙皮按照90°/0°/3K斜纹预浸料叠层，层叠完后，放入涂有脱模剂的模具内；
S6、液压机闭合模具，加压到0.5～5Mpa，然后以5～10℃/min的升温速度将模具升温至120℃，保温15～20min，再降温至60℃，打开模具取出初产品；
S7、对初产品进行后处理，得到碳纤维增强/环氧泡沫填充的pp蜂窝夹芯复合板材。
其中，步骤S5中，预浸料为中温快速固化预浸料，固化温度120℃，时间20min。环氧树脂胶膜的固化体系与预浸料的固化条件相似或相同。
实施例3
制备方法步骤如下：
S1、发泡环氧树脂的制备：将200g双酚A环氧树脂与双酚F环氧树脂的混合物、25g纳米核壳橡胶和6g偶氮二碳酸胺AZO混合，升温至50～80℃，在高速混合搅拌机里搅拌1～15min，得到混合料液A；
S2、固化剂的制备：将20gN-氨基乙基哌嗪、15g四乙烯五胺、2g三乙醇胺和10g氢化蓖麻油，在搅拌机里搅拌10～15min，得到混合料液B；
S3、将长、宽、高分别为600mm、500mm、10mm的PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按重量比100:22混合均匀后，使用灌胶机匀速注入PP蜂窝板的孔中，注入高度为1～3mm，然后闭合上模，模具升温至40～60℃，发泡5～30min，发泡倍率在5～10倍，冷却，得到环氧树脂泡沫填充的PP蜂窝板；
S4、取出环氧树脂泡沫填充的PP蜂窝板，进行切边修整；
S5、上蒙皮按照3K斜纹/0°/90°预浸料叠层，然后依次放置0.3mm厚度的环氧树脂胶膜和清理完晾干的环氧树脂泡沫填充PP蜂窝板，之后再依次放置0.3mm厚度的环氧树脂胶膜，下蒙皮按照90°/0°/3K斜纹预浸料叠层，层叠完后，放入涂有脱模剂的模具内；
S6、液压机闭合模具，加压到0.5～5Mpa，然后以5～10℃/min的升温速度将模具升温至120℃，保温15～20min，再降温至60℃，打开模具取出初产品；
S7、对初产品进行后处理，得到碳纤维增强/环氧泡沫填充的pp蜂窝夹芯复合板材。
其中，步骤S5中，预浸料为中温快速固化预浸料，固化温度120℃，时间20min。环氧树脂胶膜的固化体系与预浸料的固化条件相似或相同。
性能测试：
经检测，在常温下，上述实施例中制备的复合板材的性能指标如表1所示。
表1.实施例1-3制备的复合板材的性能测试数据
Figure BDA0001563250160000091
耐老化测试，将3个实施例制备的复合板材放入设定温度为110℃的烘箱内经过500h(相对于自然环境下5年时间)的热老化处理后，进行测试，老化前、后数据对比如表2所示。
表2.实施例1-3制备的复合板材的耐老化测试数据
Figure BDA0001563250160000092
Figure BDA0001563250160000101
由表1可知，本发明制备的碳纤维增强/环氧泡沫填充的pp蜂窝夹芯复合板材的拉伸弹性模量最高可达13.1Gpa，拉伸强度最大值305Mpa，弯曲弹性模量最佳值15Mpa，弯曲强度高达296Mpa，受冲击强度高达161KJ/m2，各项指标都优于现有的普通pp复合板材，强度和刚度显著提高。由表2可知，本发明的复合板材抗老化性能优良，板材的使用时间寿命比普通pp复合板材更长。
综上所述，本发明使用环氧泡沫填充PP蜂窝作为夹芯层，高强度、高刚性碳纤维增强环氧树脂复合材料作为结构蒙皮，制得碳纤维增强/环氧泡沫填充的pp蜂窝夹芯复合板材。该复合板材具有质量轻、比强度高、比刚度高、耐老化、隔热、隔音、耐冲击、阻尼、减振、降噪等优异性能，且制造成本低、成型速度快，广泛应用于飞机、箱式货车、高铁、轮船等的外部承力结构及内饰次承力结构中。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例，但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (8)

1.一种pp蜂窝夹芯复合板材，其特征在于，包括：pp蜂窝板、填充在pp蜂窝板孔内的环氧树脂泡沫以及分别铺设于pp蜂窝板上、下表面的碳纤维增强环氧树脂复合材料蒙皮；所述碳纤维增强环氧树脂复合材料蒙皮与pp蜂窝板之间通过环氧树脂胶膜粘接固定；
所述环氧树脂泡沫由发泡环氧树脂和固化剂按比例混合均匀反应制成；其中，所述发泡环氧树脂由环氧树脂、化学发泡剂和纳米增韧剂按比例混合制成，所述环氧树脂、纳米增韧剂和发泡剂的混合重量比为200：10～40：2～10；其中，所述环氧树脂为双酚A环氧树脂或双酚F环氧树脂或两者的混合物，所述纳米增韧剂为纳米无机粒子或纳米聚合物，所述化学发泡剂为甲苯磺酰肼TSH、氧化双(苯磺酷)肋OBSH、偶氮二碳酸胺AZO或含氢硅油其中的一种；
所述固化剂由脂环胺、脂肪胺、促进剂和触变剂按比例混合均匀制成，所述脂环胺、脂肪胺、促进剂和触变剂的混合重量比为16～30：6～20：1～4：4～16。
2.如权利要求1所述的pp蜂窝夹芯复合板材，其特征在于，所述环氧树脂胶膜为无纺布增强的环氧树脂胶膜。
3.一种如权利要求1～2任意一项所述的pp蜂窝夹芯复合板材的制备方法，其特征在于，包括如下步骤：
S1、发泡环氧树脂的制备：将原料组分环氧树脂、纳米增韧剂、发泡剂按比例混合，升温至50～80℃，搅拌均匀，得到混合料液A；
S2、固化剂的制备：将脂环胺、脂肪胺、促进剂和触变剂按比例混合均匀，得到混合料液B；
S3、将PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按比例混合均匀后，匀速注入PP蜂窝板的每个孔洞中，然后闭合上模，模具升温至40～60℃，发泡5～30min，得到环氧树脂泡沫填充的PP蜂窝板；
S4、取出环氧树脂泡沫填充的PP蜂窝板，进行切边修整；
S5、上蒙皮预浸料叠层，然后依次设置环氧树脂胶膜和环氧树脂泡沫填充PP蜂窝板，再依次设置环氧树脂胶膜和下蒙皮预浸料叠层，层叠完后，放入涂有脱模剂的模具内；
S6、液压机闭合模具，加压，将模具先升温，然后保温，再降温，得到初产品；
S7、对初产品进行后处理，得到碳纤维增强/环氧树脂泡沫填充的pp蜂窝夹芯复合板材。
4.如权利要求3所述pp蜂窝夹芯复合板材的制备方法，其特征在于，所述纳米增韧剂为纳米无机粒子或纳米聚合物，所述纳米无机粒子为纳米二氧化硅、纳米碳酸钙或纳米氧化铝其中任意一种，所述纳米聚合物为纳米核壳橡胶、纳米丁腈橡胶、纳米丁苯橡胶或纳米热塑性树脂粉末其中任意一种。
5.如权利要求3所述pp蜂窝夹芯复合板材的制备方法，其特征在于，所述步骤S2中，脂环胺、脂肪胺、促进剂和触变剂的混合重量比16～30：6～20：1～4：4～16，其中，所述脂环胺为异佛尔酮二胺或N-氨基乙基哌嗪，所述脂肪胺为乙二胺、二乙烯三胺、三乙烯四胺或四乙烯五胺其中任意一种，所述促进剂为2,4,6-三(二甲氨基甲基)苯酚、苄基二甲胺、三乙醇胺或1,8-二氮杂双环[5.4.0]十一烯其中任意一种，所述触变剂为气相二氧化硅、有机膨润土或氢化蓖麻油其中任意一种。
6.如权利要求3所述pp蜂窝夹芯复合板材的制备方法，其特征在于，所述步骤S3具体为：将长、宽、高分别为600mm、500mm、10mm的PP蜂窝板放入模具的下模中，将混合料液A和混合料液B按重量比100:15～30混合均匀后，采用灌胶机匀速注入PP蜂窝板的每个孔洞中，注入高度为1～3mm，然后闭合上模，模具升温至40～60℃，发泡5～30min，发泡倍率在5～10倍，冷却，得到环氧树脂泡沫填充的PP蜂窝板。
7.如权利要求6所述pp蜂窝夹芯复合板材的制备方法，其特征在于，所述步骤S5具体为：上蒙皮按照3K斜纹/0°/90°预浸料叠层，然后依次放置0.3mm厚度的环氧树脂胶膜和清理完晾干的环氧树脂泡沫填充PP蜂窝板，之后再依次放置0.3mm厚度的环氧树脂胶膜，下蒙皮按照90°/0°/3K斜纹预浸料叠层，层叠完后，放入涂有脱模剂的模具内。
8.如权利要求7所述pp蜂窝夹芯复合板材的制备方法，其特征在于，所述步骤S6具体为：液压机闭合模具，加压到0.5～5Mpa，然后以5～10℃/min的升温速度将模具升温至120℃，保温15～20min，再降温至60℃，打开模具取出初产品。
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