CN108839398B - 一种具有碳纤维-多孔尼龙复合结构的螺旋桨及其制备方法 - Google Patents

一种具有碳纤维-多孔尼龙复合结构的螺旋桨及其制备方法 Download PDF

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CN108839398B
CN108839398B CN201810551756.3A CN201810551756A CN108839398B CN 108839398 B CN108839398 B CN 108839398B CN 201810551756 A CN201810551756 A CN 201810551756A CN 108839398 B CN108839398 B CN 108839398B
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刘向
梁瑶
武素梅
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Beijing Wonderroad Magnesium Technology Co Ltd
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Abstract

本发明提供一种具有碳纤维‑多孔尼龙复合结构的螺旋桨，其结构特征在于在所述螺旋桨从内到外依次增设如下层结构，具体包括：多孔尼龙‑环氧树脂复合层，由剪切至预设尺寸的多孔尼龙网布表面涂覆环氧树脂和固化剂的混合物固化后得到；碳纤维‑环氧树脂复合层，由碳纤维预浸料包覆多孔尼龙‑环氧树脂复合层外部对螺旋桨进行整体铺层后，并将铺层后的整体结构置于模具中加热固化碳纤维预浸料得到；碳纤维面胶层，设置在经打磨抛光处理后的碳纤维‑环氧树脂复合层表面。本发明还公开了该碳纤维复合材料螺旋桨的制备方法。本发明的结构在抗冲击性能方面有明显的提高，且重量大幅降低，得到的碳纤维复合材料螺旋桨在无人机等领域具有广泛的应用前景。

Description

一种具有碳纤维-多孔尼龙复合结构的螺旋桨及其制备方法
技术领域
本发明涉及一种动力装置，尤其涉及一种具有碳纤维-多孔尼龙复合结构的螺旋桨及其制备方法。
背景技术
螺旋桨是一种动力装置，靠着桨叶的旋转，能将发电机的功率转化为推动力，用碳纤维复合材料制作螺旋桨，具有重量轻、强度高、旋转噪音低、韧性好，有较强的抗腐蚀能力。碳纤维螺旋桨已经得到了广泛的应用，从无人机到其他相关领域，螺旋桨的寿命也得到了很大的提高。
目前制备碳纤维螺旋桨的方法大多是真空加热模压法一体成型技术，但此类方法存在着碳纤维螺旋桨的抗冲击力不够，脆性较大，当螺旋桨在高转速的情况下，碰到外界物体上容易折断等问题。实用新型专利(公开号为CN206456532U)“一种碳纤维船用螺旋桨叶片”公开了一种碳纤维船用螺旋桨叶片，采用对称和变厚度结构铺层，有效增加碳纤维螺旋桨叶片的强度性能，是一种有效多层碳纤维的制备方法，但并没有报道如何制备多层碳纤维复合材料的方法。
因此，有必要提供一种新的螺旋桨叶结构及其制备方法，用以解决现有技术中的不足。
发明内容
根据上述提出的技术问题，而提供一种具有碳纤维-多孔尼龙复合结构的螺旋桨及其制备方法。本发明主要利用在铝合金磨具内部铺设具有碳纤维-多孔尼龙复合的多层结构制备螺旋桨叶，在减轻整体重量的同时，增强了其韧性，从而有效解决了高速旋转抗冲击的问题。
本发明采用的技术手段如下：
一种具有碳纤维-多孔尼龙复合结构的螺旋桨，其特征在于，在所述螺旋桨从内到外依次增设如下层结构，具体包括：
多孔尼龙-环氧树脂复合层，由剪切至预设尺寸的多孔尼龙网布表面涂覆环氧树脂和固化剂的混合物固化后得到；
碳纤维-环氧树脂复合层，由碳纤维预浸料包覆所述多孔尼龙-环氧树脂复合层外部对所述螺旋桨进行整体铺层后，并将铺层后的整体结构置于模具中加热固化碳纤维预浸料得到；
碳纤维面胶层，设置在经打磨抛光处理后的碳纤维-环氧树脂复合层表面。
进一步地，所述碳纤维面胶层的材料采用透明的环氧树脂类材料，所述碳纤维面胶层的厚度为35μm-65μm。
进一步地，所述碳纤维-环氧树脂复合层中的碳纤维为固化后的碳纤维预浸料。
进一步地，所述多孔尼龙-环氧树脂复合层中的多孔尼龙材料为芳香族聚酰胺。
本发明还公开了一种上述的具有碳纤维-多孔尼龙复合结构的螺旋桨的制备方法，其特征在于包括如下步骤：
S1、剪切多孔尼龙网布到预设尺寸，将环氧树脂和固化剂的混合物涂覆到多孔尼龙网布上，等待环氧树脂固化得到多孔尼龙-环氧树脂复合层；
S2、待多空尼龙网布上的环氧树脂固化后，将碳纤维预浸料包覆多孔尼龙-环氧树脂复合层的外部，对螺旋桨表面进行整体铺层，然后将铺层后的整体结构放入模具中；
S3、加热碳纤维预浸料，待固化后放置到自然冷却，得到包覆多孔尼龙-环氧树脂复合层的碳纤维-环氧树脂复合层；
S4、打磨抛光处理碳纤维-环氧树脂复合层的表面，然后涂抹一层碳纤维面胶，得到具有碳纤维-多孔尼龙复合结构的螺旋桨。
进一步地，所述步骤S1中的环氧树脂固化时间为6-12小时。
进一步地，所述步骤S2中的模具为不锈钢模具或者铝合金模具，其中铝合金模具的熔点不低于600℃。
进一步地，所述步骤S3中的碳纤维预浸料K数为3K，碳纤维K数是指碳纤维丝束中单丝数量，1K＝1000(根)、3K＝3000(根)，固化温度为100-120℃，固化时间为2小时。
较现有技术相比，本发明以碳纤维-多孔尼龙复合多层结构代替传统的碳纤维一体化单一的结构，当螺旋桨受到外力作用时，多孔尼龙复合层可以有效地保持整体结构。因此，本发明提供的复合结构比传统的单一结构在抗冲击性能方面有明显的提高；同时，与传统的碳纤维螺旋桨相比，其重量降低了1/3；基于此，本发明提供的碳纤维-多孔尼龙复合结构螺旋桨在无人机等轻量化领域具有广泛的应用前景。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图做以简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1为本发明具有碳纤维-多孔尼龙复合结构的螺旋桨的层结构示意图。
图中：Ⅰ、碳纤维面胶层；Ⅱ、碳纤维-环氧树脂复合层；Ⅲ、多孔尼龙-环氧树脂复合层。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
如图1所示，一种具有碳纤维-多孔尼龙复合结构的螺旋桨，在所述螺旋桨从内到外依次增设如下层结构，具体包括：
多孔尼龙-环氧树脂复合层Ⅲ，由剪切至预设尺寸的多孔尼龙网布表面涂覆环氧树脂和固化剂的混合物固化后得到；所述多孔尼龙-环氧树脂复合层Ⅲ中的多孔尼龙材料为芳香族聚酰胺。
碳纤维-环氧树脂复合层Ⅱ，由碳纤维预浸料包覆所述多孔尼龙-环氧树脂复合层Ⅲ外部对所述螺旋桨进行整体铺层后，并将铺层后的整体结构置于模具中加热固化碳纤维预浸料得到；
碳纤维面胶层Ⅰ，设置在经打磨抛光处理后的碳纤维-环氧树脂复合层表面。所述碳纤维面胶层Ⅰ的材料采用透明的环氧树脂类材料，所述碳纤维面胶层的厚度为35μm-65μm。
实施例1
本发明还公开了一种上述的具有碳纤维-多孔尼龙复合结构的螺旋桨的制备方法，包括如下步骤：
S1、涂环氧树脂浸渍胶：剪切多孔尼龙网布到预设尺寸，将环氧树脂和固化剂的混合物涂覆到多孔尼龙网布上，等待环氧树脂固化得到多孔尼龙-环氧树脂复合层；
S2、铺层与模具固定：待多空尼龙网布上的环氧树脂浸渍胶12小时固化后，将碳纤维预浸料包覆多孔尼龙-环氧树脂复合层的外部，对螺旋桨表面进行整体铺层，包覆3-4层；然后选择铝合金材料作为部件的模具材料，将铝合金模具涂抹一层脱模机，将铺层后的整体结构放入模具中压合；
S3、加热预浸料与固化：将模具放入真空热罐中，加热碳纤维预浸料，待固化后放置到自然冷却，碳纤维预浸料K数为3K，固化温度为100-120℃，固化2小时，得到包覆多孔尼龙-环氧树脂复合层的碳纤维-环氧树脂复合层；
S4、表面处理：打磨抛光处理碳纤维-环氧树脂复合层的表面，然后涂抹一层厚度为50μm左右碳纤维面胶，得到具有碳纤维-多孔尼龙复合结构的螺旋桨。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。

Claims (7)

1.一种具有碳纤维-多孔尼龙复合结构的螺旋桨，其特征在于，在所述螺旋桨从内到外依次增设如下层结构，具体包括：
多孔尼龙-环氧树脂复合层，由剪切至预设尺寸的多孔尼龙网布表面涂覆环氧树脂和固化剂的混合物固化后得到；
碳纤维-环氧树脂复合层，由碳纤维预浸料包覆所述多孔尼龙-环氧树脂复合层外部对所述螺旋桨进行整体铺层后，并将铺层后的整体结构置于模具中加热固化碳纤维预浸料得到；
碳纤维面胶层，设置在经打磨抛光处理后的碳纤维-环氧树脂复合层表面。
2.根据权利要求1所述的具有碳纤维-多孔尼龙复合结构的螺旋桨，其特征在于，所述碳纤维面胶层的材料采用透明的环氧树脂类材料，所述碳纤维面胶层的厚度为35μm-65μm。
3.根据权利要求1所述的具有碳纤维-多孔尼龙复合结构的螺旋桨，其特征在于，所述多孔尼龙-环氧树脂复合层中的多孔尼龙材料为芳香族聚酰胺。
4.一种如权利要求1-3任意一项权利要求所述的具有碳纤维-多孔尼龙复合结构的螺旋桨的制备方法，其特征在于包括如下步骤：
S1、剪切多孔尼龙网布到预设尺寸，将环氧树脂和固化剂的混合物涂覆到多孔尼龙网布上，等待环氧树脂固化得到多孔尼龙-环氧树脂复合层；
S2、待多空尼龙网布上的环氧树脂固化后，将碳纤维预浸料包覆多孔尼龙-环氧树脂复合层的外部，对螺旋桨表面进行整体铺层，然后将铺层后的整体结构放入模具中；
S3、加热碳纤维预浸料，待固化后放置到自然冷却，得到包覆多孔尼龙-环氧树脂复合层的碳纤维-环氧树脂复合层；
S4、打磨抛光处理碳纤维-环氧树脂复合层的表面，然后涂抹一层碳纤维面胶，得到具有碳纤维-多孔尼龙复合结构的螺旋桨。
5.根据权利要求4所述的制备方法，其特征在于，所述步骤S1中的环氧树脂固化时间为6-12小时。
6.根据权利要求4所述的制备方法，其特征在于，所述步骤S2中的模具为不锈钢模具或者铝合金模具，其中铝合金模具的熔点不低于600℃。
7.根据权利要求4所述的制备方法，其特征在于，所述步骤S3中的碳纤维预浸料K数为3K，固化温度为100-120℃，固化时间为2小时。
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