CN108274830B - 一种具有宽频屏蔽功能的轻量化的方舱壁板及其制备方法 - Google Patents
一种具有宽频屏蔽功能的轻量化的方舱壁板及其制备方法 Download PDFInfo
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Abstract
本发明提供了一种具有宽频屏蔽功能的轻量化的方舱壁板及其制备方法,方舱壁板包括蜂窝芯材层和设置在蜂窝芯材层上下表面的第一面板层和第二面板层;所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。该壁板采用表面金属化的蜂窝芯材和多层表面金属化纤维织物的设置,均能提高壁板的屏蔽性能;金属化纤维织物表面的金属根据屏蔽波段需要设计导电或导磁金属或者二者复合,使其具有低频到高频的宽频屏蔽功能。表面金属化纤维织物取代传统的金属面板,使得方舱壁板质量轻。方舱壁板在100KHz~20MHz≥30dB,20MHz~40GHz≥60dB。
Description
技术领域
本发明涉及方舱壁板技术领域,尤其涉及一种具有宽频屏蔽功能的轻量化的方舱壁板及其制备方法。
背景技术
电磁屏蔽在信息化战争中具有很重要的意义,电磁干扰将使战场中通讯中断、雷达失盲、武器失灵、指挥瘫痪、信息泄露,对战争胜负起着重要作用。方舱以其较好的防护性能,密闭性能、运输灵活性广泛应用于武器系统、指挥中心、电子对抗、野战勤务以及医疗保障体系,而电磁屏蔽又为方舱顺利完成任务提供了保障。
蜂窝夹芯屏蔽材料作为一种特殊的复合材料结构,拥有比强度高、隔热保温、减震性能好等特点,其多孔结构可以使电磁波在蜂窝芯夹层内多次反射、散射,提高蜂窝结构材料的电磁屏蔽性能。
传统的电磁屏蔽方舱壁板一般由铝合金板作为内外面板和低密度聚氨酯硬质泡沫板复合而成,采用该结构制成的方舱壁板存在质量大、屏蔽性能差的问题。中国实用新型专利“一种电磁屏蔽方舱壁板”(申请号:201620442853.5)公开了一种轻量化方舱壁板的制备方法,采用碳纤维或芳纶纤维与金属屏蔽材料夹层制备面板取代传统的铝合金面板,该方法可以达到轻量化目的,但仍存在屏蔽性能低,屏蔽波段窄,难以满足高屏蔽方舱需求。
发明内容
有鉴于此,本发明的目的在于提供一种方舱壁板及其制备方法,该方舱壁板具有较高的屏蔽功能和宽频屏蔽功能。
本发明提供了一种具有宽频屏蔽功能的轻量化的方舱壁板,包括蜂窝芯材层和设置在所述蜂窝芯材层上下表面的第一面板层和第二面板层;
所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;
所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。
优选地,所述表面金属化原料纸蜂窝芯材中的金属选自铜、镍、银、铁、铁镍合金、锡镍合金、镍钴合金和金属氧化物中的一种或多种。
优选地,所述表面金属化聚氨酯硬质泡沫芯材中的金属选自铜、镍、银、铁、铁镍合金、锡镍合金、镍钴合金和金属氧化物中的一种或多种。
优选地,所述表面金属化纤维织物的组织结构为平纹或斜纹。
优选地,所述表面金属化纤维织物中的金属选自铜、镍、银、铁、铁镍合金、锡镍合金和镍钴合金中的一种或多种。
优选地,所述表面金属化原料纸蜂窝芯材表面的金属层的厚度1~15μm;
表面金属化聚氨酯硬质泡沫芯材表面的金属层的厚度为1~20μm;
每层所述表面金属化纤维织物表面的金属层的厚度为1~10μm。
优选地,所述第一面板层的厚度为0.5~3mm;第二面板层的厚度为0.5~3mm。
优选地,所述第一面板层中表面金属化纤维织物的基材选自碳纤维、玻璃纤维和芳纶纤维中的一种或多种。
本发明提供了一种上述技术方案所述方舱壁板的制备方法,包括以下步骤:
将蜂窝芯材层、第一面板层和第二面板层粘接,得到具有宽频屏蔽功能的轻量化的方舱壁板;
所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;
所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。
本发明提供了一种具有宽频屏蔽功能的轻量化的方舱壁板,包括蜂窝芯材层和设置在所述蜂窝芯材层上下表面的第一面板层和第二面板层;所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。该方舱壁板采用表面金属化的蜂窝芯材,利用蜂窝的多次反射;面板层中多层表面金属化纤维织物的设置对电磁波的多次反射损耗,均能提高壁板的屏蔽性能;金属化纤维织物表面的金属可以根据屏蔽波段需要设计导电或导磁金属或者二者复合,使得方舱壁板具有低频到高频的宽频屏蔽功能。另外,表面金属化纤维织物取代传统的金属面板,使得方舱壁板质量轻。实验结果表明:方舱壁板的屏蔽功能在100KHz~20MHz≥30dB,20MHz~40GHz≥60dB。
附图说明
图1为本发明提供的屏蔽方舱壁板的结构示意图。
具体实施方式
本发明提供了一种具有宽频屏蔽功能的轻量化的方舱壁板,包括蜂窝芯材层和设置在所述蜂窝芯材层上下表面的第一面板层和第二面板层;
所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;
所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。
该方舱壁板采用表面金属化的蜂窝芯材,利用蜂窝的多次反射;面板层中多层表面金属化纤维织物的设置对电磁波的多次反射损耗,均能提高壁板的屏蔽性能。另外,表面金属化纤维织物取代传统的金属面板,使得方舱壁板质量轻;金属化纤维织物表面的金属可以根据屏蔽波段需要设计导电或导磁金属或者二者复合,使得方舱壁板具有低频到高频的宽频屏蔽功能。
参见图1,图1为本发明提供的屏蔽方舱壁板的结构示意图。其中,1;其中,1为第一面板层,2为蜂窝芯材层,3为第二面板层。
本发明提供的方舱壁板包括蜂窝芯材层2;所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材。所述表面金属化原料纸蜂窝芯材中的金属优选选自铜、镍、银、铁、铁镍合金、锡镍合金、镍钴合金和金属氧化物中的一种或多种,更优选选自铁。所述表面金属化聚氨酯硬质泡沫芯材中的金属优选选自铜、镍、银、铁、铁镍合金、锡镍合金、镍钴合金和金属氧化物中的一种或多种,更优选选自银、铁镍合金和氧化铁中的一种或多种。
在本发明的具体实施例中,所述表面金属化聚氨酯硬质泡沫芯材按照以下方法制得:
将聚氨酯硬质泡沫板浸渍在导电银胶液中,取出干燥,将浸渍有导电银胶液的泡沫板放入烘箱中进行固化,得到表面金属化聚氨酯硬质泡沫芯材。
在本发明中,所述表面金属化原料纸蜂窝芯材表面的金属层的厚度优选为1~15μm。表面金属化聚氨酯硬质泡沫芯材表面的金属层的厚度优选为1~20μm;
本发明提供的屏蔽方舱壁板包括置于所述蜂窝夹心层上下两侧的第一面板层1和第二面板层3;所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。所述第一面板层和第二面板层分别作为内面板和外面板。所述表面金属化纤维织物中的金属优选选自铜、镍、银、铁、铁镍合金、锡镍合金和镍钴合金中的一种或多种。在本发明的具体实施例中,所述表面金属化纤维织物中的金属为铜、镍、银和铁镍合金中的一种或多种。所述第一面板层中优选还包括树脂,所述树脂优选选自环氧树脂、聚酰亚胺树脂、氰酸酯树脂和聚四氟乙烯树脂中的一种或多种。所述第一面板层和第二面板层均由表面金属化纤维织物通过树脂复合压制而成。
在本发明中,每层所述表面金属化纤维织物表面的金属层的厚度为1~10μm。所述表面金属化纤维织物的组织结构优选为平纹或斜纹。
在本发明中,所述第一面板层的厚度优选为0.5~3mm;第二面板层的厚度优选为0.5~3mm。在本发明具体实施例中,所述第一面板层的厚度具体为1mm、1.2mm或1.5mm。所述第二面板层的厚度具体为1mm、1.2mm或1.5mm。
在本发明中,所述第一面板层中表面金属化纤维织物的基材优选选自碳纤维、玻璃纤维和芳纶纤维中的一种或多种。
所述第二面板层中表面金属化纤维织物的基材优选选自碳纤维、玻璃纤维和芳纶纤维中的一种或多种。
本发明提供了一种上述技术方案所述方舱壁板的制备方法,包括以下步骤:
将蜂窝芯材层、第一面板层和第二面板层粘接,得到具有宽频屏蔽功能的轻量化的方舱壁板;
所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;
所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。
在本发明中,所述蜂窝芯材层优选按照以下方法制得:
将表面金属化原料纸或表面金属化聚氨酯硬质泡沫经涂胶、叠合、热压、拉伸、浸胶固化,得到蜂窝芯材层;
所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材。
在本发明中,所述表面金属化原料纸蜂窝芯材表面的金属层的厚度优选为1~15微米;所述表面金属化聚氨酯硬质泡沫芯材表面的金属层的厚度优选为1~20微米。所述蜂窝芯材层采用表面金属化方法对蜂窝芯材基材进行表面金属化;所述表面金属化方法优选选自化学镀、电镀、真空镀、喷涂、浸渍或涂布。
在本发明的一个实施例中,所述蜂窝芯材的制备过程为:
采用表面金属化方法在纤维原料双面镀覆金属;然后依次经过涂胶、叠合、热压、拉伸和浸胶固化,得到表面金属化原料纸蜂窝芯材。
涂胶压制:在金属化纤维布表面等间距涂布树脂条胶,然后将多层涂胶后的纤维布错层叠合,热压固化,热压固化的温度优选为100~200℃,热压固化的压力优选为0.1~1MPa;
拉伸定型:将上述蜂窝叠板进行拉伸,当蜂窝孔达到工艺要求尺寸后,将拉伸后的蜂窝固定于工装上并放入烘箱中定型。所述拉伸定型的温度优选为100~300℃,拉伸定型的时间优选为10~60min;
浸胶固化:将上述蜂窝块浸渍在树脂中进行浸胶固化,制得表面金属化蜂窝块。浸胶固化的温度120~200℃,更优选为120~160℃;时间优选为10~100min,更优选为15~90min。
所述纤维原料选自碳纤维、芳纶纤维和玻璃纤维中的一种或多种;所述表面金属化方法选自化学镀、电镀、真空镀、喷涂、浸渍或涂布。上述浸胶固化的温度120~200℃,更优选为120~160℃;时间优选为10~100min,更优选为15~90min。在本发明具体实施例中,所述表面金属化的纤维原料经拉伸后浸胶固化的温度为160℃,时间为60min;或温度为150℃,时间为15min;或温度为120℃,时间为90min。
在本发明的另一个实施例中,所述蜂窝芯材的制备过程为:
将聚氨酯硬质泡沫板浸渍在导电金属胶液后取出干燥,将浸渍有导电金属胶液的泡沫板放入烘箱中进行固化,得到表面金属化聚氨酯硬质泡沫芯材。
所述第一面板层和第二面板层均优选采用树脂基复合材料成型工艺将金属化纤维织物制成复合材料面板;成型工艺可以采用手糊成型、真空袋压成型、模压成型或层压成型。在本申请中,所述第一面板层优选采用层压成型、手糊成型或真空袋压成型。
在本发明具体实施例中,所述第一面板层优选按照以下方法制得:
将表面金属化纤维织物浸渍在树脂中,在平板模具上铺贴一层浸渍过树脂的金属化纤维织物;
重复上述铺层,直至达到所需厚度后固化,涂覆控温涂层,得到第一面板层。
在本发明中,所述表面金属化纤维织物可以采用金属化纤维长丝编织制得;也可以采用纤维织物金属化工艺制备而成。
表面金属化纤维织物表面金属化的方法选自化学镀、电镀或真空镀。
表面金属化纤维织物表面金属层的厚度优选为1μm~10μm。
在本发明的一个实施例中,所述表面金属化纤维织物具体为:采用化学镀工艺在平纹碳纤维织物表面镀一层金属镍;在本发明的一个实施例中,采用涂覆工艺在芳纶纤维织物表面喷涂镀银玻璃微珠导电涂料,然后采用电镀工艺镀铁镍合金金属层;在本发明的一个实施例中,采用真空蒸镀工艺在斜纹碳纤维与玻璃纤维织物表面沉积金属铜。
在本发明中,达到所需厚度后固化的温度优选为100~150℃,更优选为120~150℃;时间优选为40~100min,更优选为50~90min。在本发明的具体实施例中,达到所需厚度后固化的温度为120℃、150℃或140℃;时间为90min、50min或80min。
在本发明中,所述第二面板层与上述技术方案所述的第一面板层的制备工艺一致,在此不再赘述。
为了进一步说明本发明,下面结合实施例对本发明提供的一种具有宽频屏蔽功能的轻量化的方舱壁板及其制备方法进行详细地描述,但不能将它们理解为对本发明保护范围的限定。
实施例1
(1)采用化学镀工艺在平纹碳纤维织物表面镀一层金属镍,所镀金属镍层厚度为2μm;
(2)将金属化碳纤维织物与环氧树脂浸渍,形成预浸料,然后在平板模具上采用手糊工艺铺贴金属化碳纤维织物预浸料,固化温度为120℃,固化时间为90min,固化成型后脱模得到所需的内面板和外面板,内面板和外面板的厚度均为1.2mm;
(3)采用真空蒸镀工艺在芳纶纸双面镀金属铁,金属层厚度为100nm,然后再化学镀银,金属层厚度为1μm;
(4)将上述的金属化芳纶纸经涂胶、叠合、热压、拉伸和浸胶固化形成金属化芳纶纸蜂窝芯材,其中,热压的温度为100~200℃,热压的压力为0.1~1MPa;拉伸的温度为100~300℃,拉伸的时间为10~60min;浸胶固化的温度为160℃,浸胶固化的时间为60min;
(5)将蜂窝芯材和面板粘接成夹层结构,加热加压使之固化成一体,得到具有宽频屏蔽功能的轻量化的方舱壁板。
本发明对实施例1制备的方舱壁板的宽频屏蔽功能进行测试,测试结果为:在100KHz~20MHz≥40dB,20MHz~40GHz≥60dB。
实施例2
(1)采用涂覆工艺在芳纶纤维织物表面喷涂镀银玻璃微珠导电涂料,固含量为30%,该金属层厚度为5μm;然后采用电镀工艺镀铁镍合金金属层,该金属层厚度为2μm;
(2)将金属化芳纶纤维织物与聚四氟乙烯树脂浸渍,形成预浸料后采用层压成型工艺得到所需的内面板和外面板,固化温度为150℃,固化时间为50min,内面板和外面板的厚度均为1.5mm;
(3)将聚氨酯硬质泡沫板浸渍在导电银胶液2h后取出干燥,将浸渍有导电银胶液的聚氨酯硬质泡沫板放入烘箱中进行固化,得到聚氨酯硬质泡沫板芯材,其中固化温度为150℃,固化时间为15min;
(4)将聚氨酯硬质泡沫板芯材和内面板、外面板面板粘接成夹层结构,加热加压使之固化成一体,得到具有宽频屏蔽功能的轻量化的方舱壁板。
本发明对实施例2制备的方舱壁板的宽频屏蔽功能进行测试,测试结果为:100KHz~20MHz≥45dB,20MHz-40GHz≥65dB。
实施例3
(1)采用真空蒸镀工艺在斜纹碳纤维与玻璃纤维织物表面沉积金属铜,金属铜层厚度为1μm,再电镀金属;
(2)将金属化碳纤维织物和玻璃纤维织物与聚酰亚胺树脂浸渍,形成预浸料后在平板模具上交替铺贴一层金属化碳纤维织物预浸料和金属化玻璃纤维织物预浸料,真空袋压固化成型后脱模得到所需的内面板和外面板,固化温度为140℃,固化时间为80min,内面板和外面板的厚度均为1mm;
(3)将玻纤布采用刮涂的工艺,双面涂覆镀银铜粉导电涂料,金属层厚度为12μm;
(4)将金属化玻纤布涂胶、叠合、热压、拉伸和浸胶固化形成蜂窝芯材,其中,热压的温度为100~200℃,热压的压力为0.1~1MPa;拉伸的温度为100~300℃,拉伸的时间为10~60min;浸胶固化的温度为120℃,浸胶固化的时间为90min;
(5)将蜂窝芯材、内面板和外面板粘接成夹层结构,加热加压使之固化成一体,得到具有宽频屏蔽功能的轻量化的方舱壁板。
本发明对实施例3制备的方舱壁板的宽频屏蔽功能和屏蔽功能进行测试,测试结果为:100KHz~20MHz≥30dB,20MHz~40GHz≥65dB。
由以上实施例可知,本发明提供了一种具有宽频屏蔽功能的轻量化的方舱壁板,包括蜂窝芯材层和设置在所述蜂窝芯材层上下表面的第一面板层和第二面板层;所述蜂窝芯材层为表面金属化原料纸蜂窝芯材或表面金属化聚氨酯硬质泡沫芯材;所述第一面板层和第二面板层中均包括多层表面金属化纤维织物。该方舱壁板采用表面金属化的蜂窝芯材,利用蜂窝的多次反射;面板层中多层表面金属化纤维织物的设置对电磁波的多次反射损耗,均能提高壁板的屏蔽性能;金属化纤维织物表面的金属可以根据屏蔽波段需要设计导电或导磁金属或者二者复合,使得方舱壁板具有低频到高频的宽频屏蔽功能。另外,表面金属化纤维织物取代传统的金属面板,使得方舱壁板质量轻。实验结果表明:方舱壁板的屏蔽功能100KHz~20MHz≥30dB,20MHz~40GHz≥60dB。
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 (1)
1.一种具有宽频屏蔽功能的轻量化的方舱壁板,由以下方法制得:
(1)采用涂覆工艺在芳纶纤维织物表面喷涂镀银玻璃微珠导电涂料,固含量为30%,该涂层厚度为5μm;然后采用电镀工艺镀铁镍合金金属层,该金属层厚度为2μm;
(2)将金属化芳纶纤维织物与聚四氟乙烯树脂浸渍,形成预浸料后采用层压成型工艺得到所需的内面板和外面板,固化温度为150℃,固化时间为50min,内面板和外面板的厚度均为1.5mm;
(3)将聚氨酯硬质泡沫板浸渍在导电银胶液2h后取出干燥,将浸渍有导电银胶液的聚氨酯硬质泡沫板放入烘箱中进行固化,得到聚氨酯硬质泡沫板芯材,所述固化温度为150℃,固化时间为15min;
(4)将聚氨酯硬质泡沫板芯材和内面板、外面板粘接成夹层结构,加热加压使之固化成一体,得到具有宽频屏蔽功能的轻量化的方舱壁板。
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