CN109177345A - 一种新型轻质夹层复合材料及其制备方法 - Google Patents

一种新型轻质夹层复合材料及其制备方法 Download PDF

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CN109177345A
CN109177345A CN201810642361.4A CN201810642361A CN109177345A CN 109177345 A CN109177345 A CN 109177345A CN 201810642361 A CN201810642361 A CN 201810642361A CN 109177345 A CN109177345 A CN 109177345A
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layer
composite material
preparation
vimp
resin
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王冬至
王平
王经元
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University of Jinan
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
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    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
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Abstract

本发明公开了一种新型轻质夹层复合材料及其制备方法，包括上蒙皮层、中间夹层以及下蒙皮层，利用中间夹层材料制备、预成型体、组装VIMP成型结构、注胶以及共固化成型方法制备而成。本发明结构设计合理，工艺简单，操作方便，成本低廉，制备的轻质复合夹层材料不仅质量轻，还拥有优异的抗压能力、抗冲击能力以及耐疲劳性能。

Description

一种新型轻质夹层复合材料及其制备方法
技术领域
本发明涉及轻质夹层复合材料，尤其是一种新型轻质夹层复合材料及其制备方法。
背景技术
铁路运输是21世纪各国主要交通运输方式之一，并且随着其运行速度的不断提高，铁路运输逐渐成为人们出行的首选交通方式。我国铁路运输能力比较有限，再加上我国幅员辽阔，人口众多且较分散，更增加了铁路运输的负担。同时，随着我国国民经济的飞速发展，综合国力的空前提高，对传统的铁路运输提出了更高的要求：更快速度、更大运输能力、更高安全性和可靠性。中国已开始进入高速列车时代，人们对高铁动车的方便、快捷提出更高要求的同时，也对乘坐高铁列车的安全、舒适、可靠提出了越来越高的期望。
传统的结构材料难以满足高速列车的性能需求，结构与材料的多元化应用势在必行。夹层复合材料拥有抗弯刚度大，结构重量轻，即夹层结构具有高的比强度和比模量，而且耐疲劳、抗振动性能好，隔音、隔热等性能优异，一直是工程应用中重要的结构材料。但是，传统夹层结构复合材料多采用泡沫、蜂窝等夹层材料，侧压性能严重不足，限制了其应用。纤维增强材料是一种新型复合材料，具有轻质高强、耐腐蚀、绝缘、保温、隔音、防水等优良性能。传统的纤维增强复合材料(纱、布、毡等)往往是单层运用在开模成型手糊工艺中，生产效率低、成本高、环境污染严重、对人体伤害大、制品性能差，树脂和纤维结合效果差，易产生气泡、干斑等多种缺陷，严重影响制品的力学性能。因而我们亟需寻求一种高效的制备高质量的轻质夹层复合材料的方法。
发明内容
为了克服现有技术中夹层复合材料存在的抗压能力不足、面板和芯材易分层、耐疲劳性能差等缺陷，本发明提供一种新型轻质夹层复合材料及其制备方法。
本发明解决其技术问题所采用的技术方案是：一种新型轻质夹层复合材料，包括上蒙皮层、中间夹层以及下蒙皮层，所述上蒙皮层与中间夹层之间设有加强筋结构，所述中间夹层设于上蒙皮层和下蒙皮层之间；所述中间夹层包括上面板层、中间芯子层、下面板层，所述上面板层、中间芯子层以及下面板层通过编织成为一个整体；
一种新型轻质夹层复合材料的制备方法，按照如下步骤制备：
步骤一，中间夹层材料制备：首先将纤维材料进行两次开松处理，然后利用织造处理，最后通过设定比例的牵伸达到所要求的单重，利用热定型处理制成所需的中间夹层材料；
步骤二，预成型体：在刚性模具上依次铺放上蒙皮层材料、加强筋结构复合材料、中间夹层材料以及下面蒙皮层材料，得到预成型体；
步骤三，组装VIMP成型结构：在步骤二得到的预成型体上依次铺放脱模布、导流网，并设置注胶口和溢胶口，然后在刚性模具的外围包覆真空袋膜形成模腔，将预成型体、脱模布、导流网、注胶口、溢胶口均密封于模腔内，最后将注胶口、溢胶口分别连接至VIMP工艺用的注胶结构和抽真空结构上，得到VIMP成型结构；
步骤四，注胶：首先检查VIMP成型结构的气密性，然后通过抽真空的方式向VIMP成型结构的模腔中注入树脂，直至树脂填充完毕；
步骤五，共固化成型：将步骤四填充树脂的VIMP成型结构进行共固化成型，即得轻质夹层复合材料。
上述的一种新型轻质夹层复合材料及其制备方法，所述步骤一中的纤维材料为碳纤维、玻璃纤维、金属纤维、石英纤维以及芳纶纤维中的一种或者多种。
上述的一种新型轻质夹层复合材料及其制备方法，所述步骤四中的树脂为酚醛树脂、聚酯树脂、氰酸酯树脂以及环氧树脂中的一种。
上述的一种新型轻质夹层复合材料及其制备方法，所述步骤五中的共固化时间为2～15h，共固化温度为20～200℃。
上述的一种新型轻质夹层复合材料及其制备方法，所述上蒙皮层的厚度为2～5mm，所述中间夹层的厚度为45～50mm，所述下蒙皮层的厚度为2～4mm。
与现有技术相比本发明具有以下优点和突出性效果：
本发明的有益效果是，本发明新型轻质夹层复合材料及其制备方法采用高性能的纤维增强复合材料进行一体化成型，不仅减轻了夹层复合材料的质量，还提高了夹层复合材料的结构的承载能力；有效地消除了传统层复合材料存在的抗压能力不足、面板和芯材易分层、耐疲劳性能差的缺陷。本发明结构设计合理，工艺简单，操作方便，成本低廉，制备的轻质复合夹层材料不仅质量轻，还拥有优异的抗压能力、抗冲击能力以及耐疲劳性能。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1为本发明示意图。
图中1.上蒙皮层，2.中间夹层，3.下蒙皮层。
具体实施方式
为了更清楚地说明本发明的具体结构、工作原理的内容，下面结合附图对本发明做进一步的说明，但是以下实施例仅用于说明本发明，不用来限制本发明的范围。对于本领域的普通技术人员来讲，在不付出创造性劳动的前提下，根据此附图和实施例获得其他的实施例，都属于本发明的保护范围。
【实施例1】
一种新型轻质夹层复合材料，包括上蒙皮层1、中间夹层2以及下蒙皮层3，所述上蒙皮层1与中间夹层2之间设有加强筋结构，所述中间夹层2设于上蒙皮层1和下蒙皮层3之间；所述中间夹层2包括上面板层、中间芯子层、下面板层，所述上面板层、中间芯子层以及下面板层通过编织成为一个整体；
一种新型轻质夹层复合材料的制备方法，按照如下步骤制备：
步骤一，中间夹层材料制备：首先将纤维材料进行两次开松处理，然后利用织造处理，最后通过设定比例的牵伸达到所要求的单重，利用热定型处理制成所需的中间夹层材料；
步骤二，预成型体：在刚性模具上依次铺放上蒙皮层材料、加强筋结构复合材料、中间夹层材料以及下面蒙皮层材料，得到预成型体；
步骤三，组装VIMP成型结构：在步骤二得到的预成型体上依次铺放脱模布、导流网，并设置注胶口和溢胶口，然后在刚性模具的外围包覆真空袋膜形成模腔，将预成型体、脱模布、导流网、注胶口、溢胶口均密封于模腔内，最后将注胶口、溢胶口分别连接至VIMP工艺用的注胶结构和抽真空结构上，得到VIMP成型结构；
步骤四，注胶：首先检查VIMP成型结构的气密性，然后通过抽真空的方式向VIMP成型结构的模腔中注入树脂，直至树脂填充完毕；
步骤五，共固化成型：将步骤四填充树脂的VIMP成型结构进行共固化成型，即得轻质夹层复合材料。
所述步骤一中的纤维材料为碳纤维；所述步骤四中的树脂为酚醛树脂；所述步骤五中的共固化时间为10h，共固化温度为100℃；所述上蒙皮层1的厚度为2mm，所述中间夹层2的厚度为45mm，所述下蒙皮层3的厚度为2mm。
【实施例2】
一种新型轻质夹层复合材料，包括上蒙皮层1、中间夹层2以及下蒙皮层3，所述上蒙皮层1与中间夹层2之间设有加强筋结构，所述中间夹层2设于上蒙皮层1和下蒙皮层3之间；所述中间夹层2包括上面板层、中间芯子层、下面板层，所述上面板层、中间芯子层以及下面板层通过编织成为一个整体；
一种新型轻质夹层复合材料的制备方法，按照如下步骤制备：
步骤一，中间夹层材料制备：首先将纤维材料进行两次开松处理，然后利用织造处理，最后通过设定比例的牵伸达到所要求的单重，利用热定型处理制成所需的中间夹层材料；
步骤二，预成型体：在刚性模具上依次铺放上蒙皮层材料、加强筋结构复合材料、中间夹层材料以及下面蒙皮层材料，得到预成型体；
步骤三，组装VIMP成型结构：在步骤二得到的预成型体上依次铺放脱模布、导流网，并设置注胶口和溢胶口，然后在刚性模具的外围包覆真空袋膜形成模腔，将预成型体、脱模布、导流网、注胶口、溢胶口均密封于模腔内，最后将注胶口、溢胶口分别连接至VIMP工艺用的注胶结构和抽真空结构上，得到VIMP成型结构；
步骤四，注胶：首先检查VIMP成型结构的气密性，然后通过抽真空的方式向VIMP成型结构的模腔中注入树脂，直至树脂填充完毕；
步骤五，共固化成型：将步骤四填充树脂的VIMP成型结构进行共固化成型，即得轻质夹层复合材料。
所述步骤一中的纤维材料为碳纤维和玻璃纤维；所述步骤四中的树脂为聚酯树脂；所述步骤五中的共固化时间为8h，共固化温度为150℃；所述上蒙皮层1的厚度为5mm，所述中间夹层2的厚度为50mm，所述下蒙皮层3的厚度为4mm。
【实施例3】
一种新型轻质夹层复合材料，包括上蒙皮层1、中间夹层2以及下蒙皮层3，所述上蒙皮层1与中间夹层2之间设有加强筋结构，所述中间夹层2设于上蒙皮层1和下蒙皮层3之间；所述中间夹层2包括上面板层、中间芯子层、下面板层，所述上面板层、中间芯子层以及下面板层通过编织成为一个整体；
一种新型轻质夹层复合材料的制备方法，按照如下步骤制备：
步骤一，中间夹层材料制备：首先将纤维材料进行两次开松处理，然后利用织造处理，最后通过设定比例的牵伸达到所要求的单重，利用热定型处理制成所需的中间夹层材料；
步骤二，预成型体：在刚性模具上依次铺放上蒙皮层材料、加强筋结构复合材料、中间夹层材料以及下面蒙皮层材料，得到预成型体；
步骤三，组装VIMP成型结构：在步骤二得到的预成型体上依次铺放脱模布、导流网，并设置注胶口和溢胶口，然后在刚性模具的外围包覆真空袋膜形成模腔，将预成型体、脱模布、导流网、注胶口、溢胶口均密封于模腔内，最后将注胶口、溢胶口分别连接至VIMP工艺用的注胶结构和抽真空结构上，得到VIMP成型结构；
步骤四，注胶：首先检查VIMP成型结构的气密性，然后通过抽真空的方式向VIMP成型结构的模腔中注入树脂，直至树脂填充完毕；
步骤五，共固化成型：将步骤四填充树脂的VIMP成型结构进行共固化成型，即得轻质夹层复合材料。
所述步骤一中的纤维材料为芳纶纤维；所述步骤四中的树脂为环氧树脂；所述步骤五中的共固化时间为12h，共固化温度为80℃；所述上蒙皮层1的厚度为4mm，所述中间夹层2的厚度为46mm，所述下蒙皮层3的厚度为3mm。
以上实施例仅为本发明的示例性实施例，不用于限制本发明，本发明的保护范围由权利要求书限定。本领域技术人员可以在本发明的实质和保护范围内，对本发明做出各种修改或等同替换，这种修改或等同替换也应视为落在本发明的保护范围内。

Claims (5)

1.一种新型轻质夹层复合材料，包括上蒙皮层(1)、中间夹层(2)以及下蒙皮层(3)，其特征在于：所述上蒙皮层(1)与中间夹层(2)之间设有加强筋结构，所述中间夹层(2)设于上蒙皮层(1)和下蒙皮层(3)之间；所述中间夹层(2)包括上面板层、中间芯子层、下面板层，所述上面板层、中间芯子层以及下面板层通过编织成为一个整体；
一种新型轻质夹层复合材料的制备方法，按照如下步骤制备：
步骤一，中间夹层材料制备：首先将纤维材料进行两次开松处理，然后利用织造处理，最后通过设定比例的牵伸达到所要求的单重，利用热定型处理制成所需的中间夹层材料；
步骤二，预成型体：在刚性模具上依次铺放上蒙皮层材料、加强筋结构复合材料、中间夹层材料以及下面蒙皮层材料，得到预成型体；
步骤三，组装VIMP成型结构：在步骤二得到的预成型体上依次铺放脱模布、导流网，并设置注胶口和溢胶口，然后在刚性模具的外围包覆真空袋膜形成模腔，将预成型体、脱模布、导流网、注胶口、溢胶口均密封于模腔内，最后将注胶口、溢胶口分别连接至VIMP工艺用的注胶结构和抽真空结构上，得到VIMP成型结构；
步骤四，注胶：首先检查VIMP成型结构的气密性，然后通过抽真空的方式向VIMP成型结构的模腔中注入树脂，直至树脂填充完毕；
步骤五，共固化成型：将步骤四填充树脂的VIMP成型结构进行共固化成型，即得轻质夹层复合材料。
2.根据权利要求1所述的一种新型轻质夹层复合材料及其制备方法，其特征在于，所述步骤一中的纤维材料为碳纤维、玻璃纤维、金属纤维、石英纤维以及芳纶纤维中的一种或者多种。
3.根据权利要求1所述的一种新型轻质夹层复合材料及其制备方法，其特征在于，所述步骤四中的树脂为酚醛树脂、聚酯树脂、氰酸酯树脂以及环氧树脂中的一种。
4.根据权利要求1所述的一种新型轻质夹层复合材料及其制备方法，其特征在于，所述步骤五中的共固化时间为2～15h，共固化温度为20～200℃。
5.根据权利要求1所述的一种新型轻质夹层复合材料及其制备方法，其特征在于，所述上蒙皮层(1)的厚度为2～5mm，所述中间夹层(2)的厚度为45～50mm，所述下蒙皮层(3)的厚度为2～4mm。
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