CN108819357B - 连续挤出成型纤维增强蜂窝板复合材料及其工艺 - Google Patents

连续挤出成型纤维增强蜂窝板复合材料及其工艺 Download PDF

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CN108819357B
CN108819357B CN201810375584.9A CN201810375584A CN108819357B CN 108819357 B CN108819357 B CN 108819357B CN 201810375584 A CN201810375584 A CN 201810375584A CN 108819357 B CN108819357 B CN 108819357B
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fiber reinforced
roller
fiber
woven fabric
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孙成伦
车广陆
房文超
孙俊
孟祥欣
王健
邹军
孙姝
宋小川
吴彦
王爽
于文杰
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Dalian Plastics Research Plastic Technology Development Co ltd
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Abstract

本发明涉及一种连续挤出成型纤维增强蜂窝板复合材料及其工艺。本发明利用热辊连续挤压的方法，将挤出机提供的熔融物料与纤维编织布高压贴合在一起，制成产品平整度好、粘接强度高，将纤维增强板和蜂窝芯层两者同时进行热熔、热压复合工艺，纤维增强板在线与成型的蜂窝芯层一次贴合完成，不仅实现了纤维增强板的连续化生产，并可连续生产任意选择长度的蜂窝板产品，提高了生产效率，节省人力物力，降低了单位产品的能耗。本发明提供的纤维增强板综合性能优异，还可以根据的需要添加功能助剂，以适应多领域需求，具有广阔的应用前景。

Description

连续挤出成型纤维增强蜂窝板复合材料及其工艺
技术领域
本发明属于复合材料技术领域，具体涉及一种连续挤出成型纤维增强蜂窝板复合材料的加工工艺。
背景技术
纤维增强板具有质量轻、强度高等优点，在复合材料制品领域受到广泛的关注。传统的纤维增强板制作方法有两种：第一种是模压法，方法是在压制模具里依次放置树脂原料、纤维布、树脂原料，经过加温、加压一定时间以后，经冷却定型可制成块状纤维增强板。这种方法效率低而且不能连续生产大块产品。第二种是浸渍法，将树脂放入加热槽中加热至液态，纤维布通过槽中液态树脂使纤维布上充分挂上树脂，再经过冷压定型制成纤维增强板。这种方法存在很多局限性，如采用高粘度树脂作为原料在浸入纤维时操作难度大，而采用低粘度树脂其结合力差，导致制成纤维增强板存在脆性大、强度低、性能差等缺陷。另一种加工手段是将增强板与蜂窝板复合使用胶黏的方法成型，其工艺成型是分段进行的，不仅效率低、能耗大，更无法连续生产无限长的产品。
发明内容
为弥补现有技术的不足，本发明提供一种连续挤出成型纤维增强蜂窝板复合材料及其工艺。该工艺实现了连续同时挤出制备纤维增强板和蜂窝板，在加工过程中将纤维增强板和蜂窝板贴合，连续成型，产品长度不受限制，提高了生产效率，节省人力物力，降低了单位产品的能耗。
本发明采用如下技术方案：将熔融树脂与纤维编织布的一面进行热压复合，再将纤维编织布的另一面与熔融树脂贴合在蜂窝芯层上下面，热压复合制得纤维增强蜂窝复合材料。
该纤维增强蜂窝复合材料成分组成包括树脂、纤维编织布、填充料和功能性助剂，所述树脂包括PP、HDPE、POE、PC、PVC或PET中一种及两种以上。纤维编织布包括玻璃纤维编织布、涤纶纤维编织布、丙纶纤维编织布或棉麻纤维编织布中一种及两种以上；填充料包括滑石粉、碳酸钙或云母中一种或两种以上；功能性助剂包括偶联剂、增韧剂、抗氧剂、抗静电剂、紫外线吸收剂或颜料中的一种或两种以上。
进一步的，上述方法包括以下步骤：
S1.制备上表面复合材料、下表面复合蜂窝板和蜂窝芯层材料：
将纤维编织布于放卷装置Ⅰ放卷，通过导辊Ⅰ引入烘箱Ⅰ加热，然后通过导辊Ⅱ导入复合辊Ⅰ中，与机头Ⅰ挤出的熔融物料A高压复合定型后进入复合辊Ⅱ，再与机头Ⅱ挤出的熔融物料B复合制成下表面复合材料；
机头Ⅲ挤出的熔融物料C通过成型辊Ⅰ吸塑成型制成蜂窝芯层材料；
将下表面复合材料和蜂窝芯层材料通过复合辊Ⅱ高压复合，然后经剥离辊Ⅰ剥离制得下表面复合蜂窝板；
将纤维编织布于放卷装置Ⅱ放卷，通过导辊Ⅲ引入烘箱Ⅱ加热，然后通过导辊Ⅳ导入复合辊Ⅳ中，与机头Ⅴ挤出的熔融物料E高压复合定型制成上表面复合材料。
上述步骤S1中，上表面复合材料、下表面复合蜂窝板和蜂窝芯层材料的制备是连续同时挤出的，在此不限定制备顺序。
S2.制备纤维增强蜂窝板：
将下表面复合蜂窝板、机头Ⅳ挤出的熔融物料D、上表面复合材料经过复合辊Ⅲ，制成双面复合纤维增强蜂窝板，再依次经过烘箱Ⅲ、牵引装置、裁断机，最终获得不同长度规格的纤维增强蜂窝板产品。
优选的，所述的熔融物料A、B、D、E的组成均为：均聚聚丙烯20％～30％，共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％。
优选的，所述的熔融物料C的组成为：均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
本发明第二个目的请求保护折叠纤维增强蜂窝板的制备方法，具体包括以下步骤：
S1.制备上表面复合材料、下表面复合材料和折叠蜂窝芯层材料：
将纤维编织布于放卷装置Ⅰ放卷，通过导辊Ⅰ引入烘箱Ⅰ加热，然后通过导辊Ⅱ导入复合辊Ⅰ中，纤维编织布与机头Ⅰ挤出的熔融物料A高压复合定型后经导辊Ⅴ导入复合辊Ⅲ，与机头Ⅱ’挤出的熔融物料B’制成下表面复合材料；
机头Ⅲ’挤出的熔融物料C’通过成型辊Ⅱ吸塑成型，依次经过牵引辊、折叠成型装置制成折叠蜂窝芯层材料；
将纤维编织布于放卷装置Ⅱ放卷，通过导辊Ⅲ引入烘箱Ⅱ加热，然后通过导辊Ⅳ导入复合辊Ⅳ中，与机头Ⅴ挤出的熔融物料E高压复合定型后进入复合辊Ⅲ，再与机头Ⅳ挤出的熔融物料复合制成上表面复合材料。
上述步骤S1中，上表面复合材料、下表面复合蜂窝板和蜂窝芯层材料的制备是连续同时挤出的，在此不限定制备顺序。
S2.制备折叠纤维增强蜂窝板：
将下表面复合材料、折叠蜂窝芯层材料和上表面复合材料通过复合辊Ⅲ热压复合，制成双面复合纤维增强蜂窝板，再依次经过烘箱Ⅲ、牵引装置、裁断机，最终获得不同长度规格的折叠纤维增强蜂窝板产品。
优选的，所述的熔融物料A、B’、D、E的组成均为：均聚聚丙烯20％～30％，共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％。
优选的，所述的熔融物料C’的组成为：均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
优选的，所述高压为368Kgf/cm2。
优选的，所述成型辊、复合辊的温度为60-80℃。
本发明另一个目的请求保护采用上述方法制备的纤维增强蜂窝板。该复合板为七层结构，以蜂窝芯层为中间层，在中间层的两侧从内到外依次是树脂粘结层、纤维编织布、树脂面层。
本发明利用热辊连续挤压的方法，将挤出机提供的熔融物料与纤维编织布高压贴合在一起，制成产品平整度好、粘接强度高，同时，充分利用高粘度树脂在热熔、热压过程中的分子结构特点，调整工艺及参数，使经过热压制成纤维增强板强度高、表面光洁度高。将纤维增强板和蜂窝芯层两者同时进行热熔、热压复合工艺，纤维增强板在线与成型的蜂窝芯层一次贴合完成，不仅实现了纤维增强板的连续化生产，并可连续生产任意选择长度的蜂窝板产品，提高了生产效率，节省人力物力，降低了单位产品的能耗。本发明提供的纤维增强板综合性能优异，还可以根据的需要添加功能助剂，以适应多领域需求，具有广阔的应用前景。
附图说明
图1为本发明纤维增强蜂窝板复合材料结构示意图；
图2为纤维增强蜂窝板复合材料工艺流程图；
图3为折叠纤维增强蜂窝板复合材料工艺流程图。
其中，1、放卷装置Ⅰ，2、导辊Ⅰ，3、烘箱Ⅰ，4、导辊Ⅱ，5、机头Ⅰ，6、复合辊Ⅰ，7、复合辊Ⅱ，8、机头Ⅱ，9、机头Ⅲ，10、成型辊Ⅰ，11、剥离辊Ⅰ，12、放卷装置Ⅱ，13、导辊Ⅲ，14、烘箱Ⅱ，15、导辊Ⅳ，16、机头Ⅴ，17、复合辊Ⅳ，18、机头Ⅳ，19、复合辊Ⅲ，20、烘箱Ⅲ，21、牵引装置，22、裁断机，23、机头Ⅲ’，24、成型辊Ⅱ，25、牵引辊，26、折叠成型装置，27、机头Ⅱ’，28、导辊Ⅴ。
具体实施方式
下面通过具体实施例详述本发明，但不限制本发明的保护范围。如无特殊说明，本发明所采用的实验方法均为常规方法，所用实验器材、材料、试剂等均可从商业渠道获得。
实施例1
本实施例以聚丙烯纤维增强蜂窝板产品为例，详细阐述本发明的工艺过程。
树脂面层的原料(熔融物料A、B、D、E)组成为：均聚聚丙烯20％～30％，共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％。
蜂窝芯层的原料(熔融物料C)组成为：均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
纤维编织布选择无碱玻璃纤维布，每平方米克重标准：300、400、600。
生产工艺具体为：
S1.制备上表面复合材料、下表面复合蜂窝板和蜂窝芯层材料：
(1)将纤维编织布放卷，通过导辊Ⅰ2引入烘箱Ⅰ3于80-120℃加热，然后通过导辊Ⅱ4导入60-80℃复合辊Ⅰ6中，与机头Ⅰ5挤出的熔融物料A高压复合定型后进入复合辊Ⅱ7，再与机头Ⅱ8挤出的熔融物料B复合制成下表面复合材料；
(2)机头Ⅲ9挤出的熔融物料C通过成型辊Ⅰ10吸塑成型制成蜂窝芯层材料；成型辊Ⅰ10的温度是60-80℃；熔融物料C的组成为：
均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
(3)将下表面复合材料和蜂窝芯层材料通过复合辊Ⅱ7高压(368Kgf/cm2)复合，然后经剥离辊Ⅰ11剥离制得下表面复合蜂窝板；
(4)将纤维编织布放卷，通过导辊Ⅲ13引入烘箱Ⅱ14于80-120℃加热，然后通过导辊Ⅳ15导入60-80℃复合辊Ⅳ17中，与机头Ⅴ16挤出的熔融物料E高压复合定型制成上表面复合材料。
步骤(1)、(2)、(3)、(4)可同时进行。
S2.将下表面复合蜂窝板、机头Ⅳ18挤出的熔融物料D、上表面复合材料经过60-80℃复合辊Ⅲ19，制成双面复合纤维增强蜂窝板，再依次经过80-120℃烘箱Ⅲ20、牵引装置21、裁断机22，最终获得不同长度规格的纤维增强蜂窝板产品。
实施例2
本实施例以聚丙烯折叠纤维增强蜂窝板产品为例，详细阐述本发明的工艺过程。
树脂面层的原料(熔融物料A、B’、D、E)组成为：均聚聚丙烯20％～30％，,共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％。
蜂窝芯层的原料(熔融物料C’)组成为：均聚聚丙烯40％～50％，滑石粉填充料30％～40％，增韧剂15％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
纤维编织布选择无碱玻璃纤维布，每平方米克重标准：300、400、600。
S1.制备上表面复合材料、下表面复合材料和折叠蜂窝芯层材料：
(1)将纤维编织布于放卷装置Ⅰ1放卷，通过导辊Ⅰ2引入烘箱Ⅰ3于80-120℃加热，然后通过导辊Ⅱ4导入60-80℃复合辊Ⅰ6中，玻璃纤维编织布与机头Ⅰ5挤出的熔融物料A高压复合定型经导辊Ⅴ28导入复合辊Ⅲ19，与机头Ⅱ’27挤出的熔融物料B’制成下表面复合材料；
(2)机头Ⅲ’23挤出的熔融物料C’通过成型辊Ⅱ24吸塑成型，依次经过牵引辊25、折叠成型装置26制成折叠蜂窝芯层材料；
熔融物料C’的组成为：均聚聚丙烯40％～50％，滑石粉填充料30％～40％，增韧剂15％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
(3)将纤维编织布放卷，通过导辊Ⅲ13引入烘箱Ⅱ14于80-120℃加热，然后通过导辊Ⅳ15导入60-80℃复合辊Ⅳ17中，与机头Ⅴ16挤出的熔融物料E高压复合定型后进入60-80℃复合辊Ⅲ19，再与机头Ⅳ18挤出的熔融物料D复合制成上表面复合材料；
步骤(1)、(2)、(3)、(4)连续同时挤出。
S2.制备折叠纤维增强蜂窝板：
将下表面复合材料、折叠蜂窝芯层材料和上表面复合材料通过60-80℃复合辊Ⅲ19热压复合，制成双面复合纤维增强蜂窝板，再依次经过80-120℃烘箱Ⅲ20、牵引装置21、裁断机22，最终获得不同长度规格的纤维增强蜂窝板产品。
对实施例1、2生产的产品进行性能测试，经对比发现，普通聚丙烯片材抗拉强度30Mpa～40Mpa，实施例1制备的玻璃纤维增强聚丙烯片材抗拉强度160Mpa～280Mpa，实施例2制备的聚丙烯折叠纤维增强蜂窝板抗拉强度160Mpa～280Mpa，相比于普通聚丙烯片材抗拉强度提高了3～6倍。

Claims (5)

1.连续挤出成型纤维增强蜂窝板复合工艺，其特征在于，将熔融树脂与纤维编织布的一面进行热压复合，再将纤维编织布的另一面与熔融树脂贴合在蜂窝芯层上下面，热压复合制得纤维增强蜂窝复合材料；
具体包括以下步骤：
S1. 制备上表面复合材料、下表面复合蜂窝板和蜂窝芯层材料：
将纤维编织布于放卷装置Ⅰ（1）放卷，通过导辊Ⅰ（2）引入烘箱Ⅰ（3）加热，然后通过导辊Ⅱ（4）导入复合辊Ⅰ（6）中，与机头Ⅰ（5）挤出的熔融物料A高压复合定型后进入复合辊Ⅱ（7），再与机头Ⅱ（8）挤出的熔融物料B复合制成下表面复合材料；
机头Ⅲ（9）挤出的熔融物料C通过成型辊Ⅰ（10）吸塑成型制成蜂窝芯层材料；
将下表面复合材料和蜂窝芯层材料通过复合辊Ⅱ（7）高压复合，然后经剥离辊Ⅰ（11）剥离制得下表面复合蜂窝板；
将纤维编织布于放卷装置Ⅱ（12）放卷，通过导辊Ⅲ（13）引入烘箱Ⅱ（14）加热，然后通过导辊Ⅳ（15）导入复合辊Ⅳ（17）中，与机头Ⅴ（16）挤出的熔融物料E高压复合定型制成上表面复合材料；
S2. 制备纤维增强蜂窝板：
将下表面复合蜂窝板、机头Ⅳ（18）挤出的熔融物料D、上表面复合材料经过复合辊Ⅲ（19），制成双面复合纤维增强蜂窝板，再依次经过烘箱Ⅲ（20）、牵引装置（21）、裁断机（22），最终获得不同长度规格的纤维增强蜂窝板产品；
所述的熔融物料A、B、D、E的组成均为：均聚聚丙烯20％～30％，共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％；
所述的熔融物料C的组成为：均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
2.连续挤出成型折叠纤维增强蜂窝板的制备工艺，其特征在于，包括以下步骤：
S1. 制备上表面复合材料、下表面复合材料和折叠蜂窝芯层材料：
将纤维编织布于放卷装置Ⅰ（1）放卷，通过导辊Ⅰ（2）引入烘箱Ⅰ（3）加热，然后通过导辊Ⅱ（4）导入复合辊Ⅰ（6）中，纤维编织布与机头Ⅰ（5）挤出的熔融物料A高压复合定型后经导辊Ⅴ（28）导入复合辊Ⅲ（19），与机头Ⅱ’（27）挤出的熔融物料B’制成下表面复合材料；
机头Ⅲ’（23）挤出的熔融物料C’通过成型辊Ⅱ（24）吸塑成型，依次经过牵引辊（25）、折叠成型装置（26）制成折叠蜂窝芯层材料；
将纤维编织布于放卷装置Ⅱ（12）放卷，通过导辊Ⅲ（13）引入烘箱Ⅱ（14）加热，然后通过导辊Ⅳ（15）导入复合辊Ⅳ（17）中，与机头Ⅴ（16）挤出的熔融物料E高压复合定型后进入复合辊Ⅲ（19），再与机头Ⅳ（18）D挤出的熔融物料复合制成上表面复合材料；
S2. 制备折叠纤维增强蜂窝板：
将下表面复合材料、折叠蜂窝芯层材料和上表面复合材料通过复合辊Ⅲ（19）热压复合，制成双面复合折叠纤维增强蜂窝板，再依次经过烘箱Ⅲ（20）、牵引装置（21）、裁断机（22），最终获得不同长度规格的折叠纤维增强蜂窝板产品；
所述的熔融物料A、B’、D、E的组成均为：均聚聚丙烯20％～30％，共聚聚丙烯40％～50％，滑石粉填充料10％～15％，增韧剂10％，偶联剂1.5％、抗氧剂1％、抗静电剂1％、紫外线吸收剂1％、颜料0.5％；
所述的熔融物料C’的组成为：均聚聚丙烯45％～50％，共聚聚丙烯20％～25％，滑石粉填充料25％～35％，偶联剂2.5％、抗氧剂1％、抗静电剂1％、颜料0.5％。
3.根据权利要求1或2任一种所述的工艺，其特征在于，所述高压为368Kgf/cm2。
4.根据权利要求1或2任一种所述的工艺，其特征在于，所述成型辊、复合辊的温度为60-80℃。
5.如权利要求1或2任一种工艺制备的纤维增强蜂窝板，其特征在于，该纤维增强蜂窝板为七层结构，以蜂窝芯层为中间层，在中间层的两侧从内到外依次是树脂粘结层、纤维编织布、树脂面层。
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