CN108673968A - 一种汽车用复合材料层压板 - Google Patents

一种汽车用复合材料层压板 Download PDF

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CN108673968A
CN108673968A CN201810285223.5A CN201810285223A CN108673968A CN 108673968 A CN108673968 A CN 108673968A CN 201810285223 A CN201810285223 A CN 201810285223A CN 108673968 A CN108673968 A CN 108673968A
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resin
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CN108673968B (zh
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苏彤
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Beijing mechanical and electrical engineering general design department
Li Ruikuan
Wang Tao
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Shenzhen Wanjia Interactive Technology Co Ltd
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Abstract

本发明涉及一种汽车用复合材料层压板，预先将混合物树脂进行预处理，加入含有稀土元素的纳米级合金粉末，再将树脂均匀覆盖涂布在碳纤维布上，然后将半成品碳纤维布与PA6膜片交替叠放，合模热压制成层压板，解决了纳米粒子添加后树脂粘度増加、分散性变差的技术难题，实现了复合材料的协同增强、増韧，显著提髙了碳纤维复合材料界面性能和层间力学性能。

Description

一种汽车用复合材料层压板
技术领域
本发明涉及层状材料领域，具体的说，是涉及一种汽车用复合材料层压板。
背景技术
CFRP其轻质、髙强、高模、耐高温等性能优势，成为国防军工、航天航空、新能源及离科技产业的重要基础材料，是新材料领域占第一位的战略关键材料。树脂基体是CFRP中最薄弱、且最先受到破坏的组分，对复合材料的整体性能发挥起着至关重要的作用。随着碳纤维/环氧树脂复合材料在航空、航天、能源、交通领域应用范围的不断拓展，对配套树脂基体的强度和初性提出了更高要求。
当粒子粒径处于纳米级别时，其表面能较常规的粒子大好多倍，导致其极其容易产生团聚现象。也就说当纳米粒子加入聚合物中后，其自身的特性，导致不容易分散，与聚合物基体不能很好的混合，即发生相分离。由于其自团聚而难以在基体中以纳米级颗粒大小存在，纳米复合材料的很多好的功能特性则无法表现出来。所以采用新的成型工艺，制备具有很好稳定性并且颗粒以纳米级别分散的功能纳米复合材料是目前发展的关键。成型工艺主关键有两点：一是制备出单分散性能很好且与基体具有很好相容性的纳米粒子，二是该纳米粒子能够以单个粒子形式与基体材料混合均匀。
目前的汽车用复合材料层压板产品，尽管可以通过表面化学处理，将增强材料与树脂基体进行简单的溶液混合、熔融混合或原位复合，但未考虑到混合物树脂分子及增强剂之间的相互作用及不同加工工艺的特点，增强成分在树脂基体中也未能达到良好的分散状态，导致很多情况下树脂基体及其碳纤维増强复合材料的力学性能并没有明显变化，甚至下降，并且在同时提髙材料的强度和韧性方面一直存在着难以解决的矛盾。如何通过调整和控制混合物树脂的成分，使其中增强剂能够发挥更大的作用，在分散及界面结合性能中起到更好的效果，匹配不同的加工工艺特点，进而能够改善复合材料的综合性能是亟待解决的问题。
发明内容
为了解决上述技术问题，本发明提供了一种汽车用复合材料层压板，所述层压板为包含有纳米合金粉末的混合物树脂所覆盖的碳纤维布与PA6膜片交替叠放模压制板而制得的，所述层压板的制备方法包括以下步骤：
1)用无水乙醇溶剂多次洗涤纳米合金粉末，按照一定比例将其加入到熔融状态的混合物树脂中，搅拌0.5～1h直至混合均匀，再将碳纤维布浸入到混匀后的所述混合物树脂中，使树脂均匀覆盖在所述碳纤维布上，取出后冷却成型，在烘箱中干燥，制得半成品碳纤维布；
2)将所述半成品碳纤维布和PA6膜片按照交替叠放的次序放入模具中，合模升温至设定温度，启动热压机加压并继续升温，然后保压0.5～1h，冷却至PA6树脂的玻璃化转变温度Tg以下，脱模后采用常规方法制板，即可获得复合材料层压板。
所述混合物树脂的制备步骤为，配制环氧树脂、IPDA固化剂与聚乙烯树脂的质量比为100:60-80:8-12的树脂-橡胶体系，然后机械搅拌1-2h，加入占总量0.5～1wt％的DMP-30促进剂，超声反应2-4h，将混合好的上述有机原料加热熔融，获得熔融状态的混合物树脂。
所述纳米合金粉末的成份按照重量百分比包括：Al 8～12％、Ti 5.0～8.5％、Ag1.0～2.0％、Au 0.5～0.8％，Ce 0.1～0.5％，Pr 0.1～0.2％，余量为铜。
所述复合材料层压板的拉伸强度和弯曲强度分别为1200～1250MPa和1250～1300MPa。
添加所述纳米合金粉末，使得所述复合材料层压板产品的层剪强度提高了10～13％，压缩强度提髙了15～18％。
本发明的优点是：预先将混合物树脂进行预处理，加入含有稀土元素的纳米级合金粉末，再将树脂均匀覆盖涂布在碳纤维布上，然后将半成品碳纤维布与PA6膜片交替叠放，合模热压制成层压板，本发明结合了纳米合金粉末增强及碳纤维与膜片交替叠放模压成型的加工工芝特点，通过调整混合物树脂成分和纳米合金粉末成分，不仅实现了原有增强体的力学增强作用，同时解决了纳米粒子添加后树脂粘度増加、分散性变差的技术难题，实现了复合材料的协同增强、増韧，显著提髙了碳纤维复合材料界面性能和层间力学性能。
具体实施方式
下面结合实施例和对比例对本专利进一步详细说明。
实施例1：
一种汽车用复合材料层压板，所述层压板为包含有纳米合金粉末的混合物树脂所覆盖的碳纤维布与PA6膜片交替叠放模压制板而制得的，所述层压板的制备方法包括以下步骤：
1)用无水乙醇溶剂多次洗涤纳米合金粉末，按照一定比例将其加入到熔融状态的混合物树脂中，搅拌0.5h直至混合均匀，再将碳纤维布浸入到混匀后的所述混合物树脂中，使树脂均匀覆盖在所述碳纤维布上，取出后冷却成型，在烘箱中干燥，制得半成品碳纤维布。所述纳米合金粉末的成份按照重量百分比包括：Al 7％、Ti 6％、Ag 1.0％、Au 0.6％，Ce 0.3％，Pr0.1％，余量为铜。所述混合物树脂的制备步骤为，配制环氧树脂、IPDA固化剂与聚乙烯树脂的质量比为100:70:9的树脂-橡胶体系，然后机械搅拌2h，加入占总量0.8wt％的DMP-30促进剂，超声反应4h，将混合好的上述有机原料加热熔融，获得熔融状态的混合物树脂。
2)将所述半成品碳纤维布和PA6膜片按照交替叠放的次序放入模具中，合模升温至设定温度，启动热压机加压并继续升温，然后保压0.5h，冷却至PA6树脂的玻璃化转变温度Tg以下，脱模后采用常规方法制板，即可获得复合材料层压板。
所述复合材料层压板的拉伸强度和弯曲强度分别为1220MPa和1280MPa。添加所述纳米合金粉末，使得所述复合材料层压板产品的层剪强度提高了10％，压缩强度提髙了16％。
实施例2：
一种汽车用复合材料层压板，所述层压板为包含有纳米合金粉末的混合物树脂所覆盖的碳纤维布与PA6膜片交替叠放模压制板而制得的，所述层压板的制备方法包括以下步骤：
1)用无水乙醇溶剂多次洗涤纳米合金粉末，按照一定比例将其加入到熔融状态的混合物树脂中，搅拌1h直至混合均匀，再将碳纤维布浸入到混匀后的所述混合物树脂中，使树脂均匀覆盖在所述碳纤维布上，取出后冷却成型，在烘箱中干燥，制得半成品碳纤维布。所述纳米合金粉末的成份按照重量百分比包括：Al 10％、Ti 7.5％、Ag 2.0％、Au 0.8％，Ce 0.3％，Pr 0.1％，余量为铜。所述混合物树脂的制备步骤为，配制环氧树脂、IPDA固化剂与聚乙烯树脂的质量比为100:80:10的树脂-橡胶体系，然后机械搅拌1h，加入占总量1wt％的DMP-30促进剂，超声反应3h，将混合好的上述有机原料加热熔融，获得熔融状态的混合物树脂。
2)将所述半成品碳纤维布和PA6膜片按照交替叠放的次序放入模具中，合模升温至设定温度，启动热压机加压并继续升温，然后保压1h，冷却至PA6树脂的玻璃化转变温度Tg以下，脱模后采用常规方法制板，即可获得复合材料层压板。
所述复合材料层压板的拉伸强度和弯曲强度分别为1250MPa和1300MPa。添加所述纳米合金粉末，使得所述复合材料层压板产品的层剪强度提高了13％，压缩强度提髙了18％。
实施例3：
一种汽车用复合材料层压板，所述层压板为包含有纳米合金粉末的混合物树脂所覆盖的碳纤维布与PA6膜片交替叠放模压制板而制得的，所述层压板的制备方法包括以下步骤：
1)用无水乙醇溶剂多次洗涤纳米合金粉末，按照一定比例将其加入到熔融状态的混合物树脂中，搅拌1h直至混合均匀，再将碳纤维布浸入到混匀后的所述混合物树脂中，使树脂均匀覆盖在所述碳纤维布上，取出后冷却成型，在烘箱中干燥，制得半成品碳纤维布。所述纳米合金粉末的成份按照重量百分比包括：Al 8％、Ti 5.5％、Ag 1.5％、Au 0.8％，Ce0.5％，Pr0.2％，余量为铜。所述混合物树脂的制备步骤为，配制环氧树脂、IPDA固化剂与聚乙烯树脂的质量比为100:60-8的树脂-橡胶体系，然后机械搅拌1h，加入占总量0.5wt％的DMP-30促进剂，超声反应2h，将混合好的上述有机原料加热熔融，获得熔融状态的混合物树脂。
2)将所述半成品碳纤维布和PA6膜片按照交替叠放的次序放入模具中，合模升温至设定温度，启动热压机加压并继续升温，然后保压0.5h，冷却至PA6树脂的玻璃化转变温度Tg以下，脱模后采用常规方法制板，即可获得复合材料层压板。
所述复合材料层压板的拉伸强度和弯曲强度分别为1200MPa和1250MPa。添加所述纳米合金粉末，使得所述复合材料层压板产品的层剪强度提高了10％，压缩强度提髙了15％。
对比例1：
本发明的制作方法中，当改变层压板结构和成分配比时，特别是有机树脂相混合物和纳米合金粉末的成分含量改变时，将影响复合材料的层间性能，进而导致层压板的界面性能和层间力学性能下降。
对比例2：
当热压步骤中的压力和温度参数发生改变时，特别是加压和温度控制方式改变，将导致复合材料出现空隙、分层等缺陷，进而降低层压板产品的整体使用寿命和力学性能。
由实施例1-3和对比例1和2可以看出，本发明预先将混合物树脂进行预处理，加入含有稀土元素的纳米级合金粉末，再将树脂均匀覆盖涂布在碳纤维布上，然后将半成品碳纤维布与PA6膜片交替叠放，合模热压制成层压板，本发明结合了纳米合金粉末增强及碳纤维与膜片交替叠放模压成型的加工工芝特点，通过调整混合物树脂成分和纳米合金粉末成分，不仅实现了原有增强体的力学增强作用，同时解决了纳米粒子添加后树脂粘度増加、分散性变差的技术难题，实现了复合材料的协同增强、増韧，显著提髙了碳纤维复合材料界面性能和层间力学性能。
尽管已经示出和描述了本专利的实施例，本领域的普通技术人员可以理解：在不脱离本专利的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本专利的范围由权利要求及其等同物限定。

Claims (6)

1.一种汽车用复合材料层压板，其特征在于，所述层压板为包含有纳米合金粉末的混合物树脂所覆盖的碳纤维布与PA6膜片交替叠放模压制板而制得的，所述层压板的制备方法包括以下步骤：
1)用无水乙醇溶剂多次洗涤纳米合金粉末，按照一定比例将其加入到熔融状态的混合物树脂中，搅拌0.5～1h直至混合均匀，再将碳纤维布浸入到混匀后的所述混合物树脂中，使树脂均匀覆盖在所述碳纤维布上，取出后冷却成型，在烘箱中干燥，制得半成品碳纤维布；
2)将所述半成品碳纤维布和PA6膜片按照交替叠放的次序放入模具中，合模升温至设定温度，启动热压机加压并继续升温，然后保压0.5～1h，冷却至PA6树脂的玻璃化转变温度Tg以下，脱模后采用常规方法制板，即可获得复合材料层压板。
2.根据权利要求1所述的复合材料层压板，其特征是：所述混合物树脂的制备步骤为，配制环氧树脂、IPDA固化剂与聚乙烯树脂的质量比为100:60-80:8-12的树脂-橡胶体系，然后机械搅拌1-2h，加入占总量0.5～1wt％的DMP-30促进剂，超声反应2-4h，将混合好的上述有机原料加热熔融，获得熔融状态的混合物树脂。
3.根据权利要求1或2所述的复合材料层压板，其特征是：所述步骤2)中，开始启动热压的温度为120～140℃，保压压力为3～10MPa，保压温度为230～240℃。
4.根据权利要求1或2所述的复合材料层压板，其特征是：所述纳米合金粉末的成份按照重量百分比包括：Al 8～12％、Ti 5.0～8.5％、Ag 1.0～2.0％、Au 0.5～0.8％，Ce 0.1～0.5％，Pr 0.1～0.2％，余量为铜。
5.根据权利要求1所述的复合材料层压板，其特征是：所述复合材料层压板的拉伸强度和弯曲强度分别为1200～1250MPa和1250～1300MPa。
6.根据权利要求1至5所述的复合材料层压板，其特征是：添加所述纳米合金粉末，使得所述复合材料层压板产品的层剪强度提高了10～13％，压缩强度提髙了15～18％。
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