CN109291607B - 一种天然麻纤维增强复合材料的模压-轧制复合成型工艺方法 - Google Patents
一种天然麻纤维增强复合材料的模压-轧制复合成型工艺方法 Download PDFInfo
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Abstract
本发明提供了一种天然麻纤维增强复合材料的模压‑轧制复合成型工艺方法。其中天然麻纤维必须进行脱胶与改性处理,其中基材可以是聚丙烯、聚乳酸、聚乙烯、尼龙6、尼龙66纤维等。将天然麻纤维与热塑性树脂基纤维固相共混,通过气流铺网或者梳理铺网和针刺固结而成毡材(预制体),在轧制成型的基础上增设成型模具,调节压辊之间的间隙,进行复合成型。由于闭式模具作用,将沿轧制方向的剪切力一部分转化成法相方向的压力,增加压下量,也可以有效避免轧制过程中试样边缘的开裂,从而制备不同厚度的麻纤维复合板材。模具内部带有形状各异的型腔,方便成型各种形状的制品。
Description
技术领域
本发明属于汽车内饰件制造领域,涉及了一种麻纤维增强复合材料的复合成型工艺。
背景技术
近年来,随着汽车轻量化的推进和低成本的需求,麻纤维增强复合材料在汽车内饰件制造中的作用越来越大。目前,各汽车工业大国已大量使用天然麻纤维复合材料。其中产品包括轿车的门内板、行李箱、顶棚、座椅背板、衣帽架、仪表盘,也有卡车和客车的车厢内衬板、门板、顶棚、座椅背板等。因天然麻纤维复合材料在重量和成本方面所具有的优势,已被尝试用于汽车外部部件(如挡泥板衬和扰流板)。为了扩大麻纤维复合材料在汽车领域的应用,提高复合材料的力学性能是当务之急。
现有的天然麻纤维增强复合材料的成型工艺主要采用模压方法,模压的压力为垂直向下的压力,完全借助液压机,在达到一定程度后复合材料的内部组织的致密度很难进一步提高,因此材料的力学性能也难以进一步提高。
发明内容
为了解决上述问题,提供一种高效的、高性能天然麻纤维增强复合材料的成型工艺方法,本发明所采用的技术方案技术具体如下:
1)首先将长度为6.5~7.5cm的天然麻纤维和热塑性树脂纤维进行固相共混30~60s,再通过气流铺网或梳理铺网,以及针刺固结,制备出天然麻纤维和热塑性树脂纤维的混合毡材(预制体);
2)将热塑性纤维无纺布和/或热塑性树脂薄膜置于混合毡材的上下表面;
3)在将步骤2)得到的混合毡材裁剪成最终产品所要求的尺寸后,将混合毡材放入模具中,与模具一起加热,加热温度设定为130~300℃,加热时间为1~8min;模具材料采用热作模具钢。
4)将模具转移至轧机上,进行轧制,将轧辊温度升高至70~100℃,调节辊缝距离进行轧制,轧辊速度100-300转/min,辊缝的厚度等于模具厚度。轧制结束后脱模得到最终产品,板材厚度1-5mm。
所述的天然麻纤维为汉麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、剑麻纤维中的中的一种或几种的混合物。
热塑性树脂薄膜或纤维为聚丙烯、聚乳酸、聚乙烯、尼龙6或尼龙66的树脂薄膜或纤维。
优选地,在步骤2)和步骤3)之间还包含有阻燃处理步骤,具体如下:将混合毡材浸入配制好的阻燃剂溶液中,然后取出后热风干燥。该步骤中添加了阻燃剂,能够改善复合板材的阻燃性能。
本发明的有益效果:
通过本发明提供的技术,可以实现汽车内饰件的轻量化和健康安全性。轧机的使用,不需要借助液压机,减少了能源的消耗,提高了生产效率。模具的使用,将沿轧制方向的剪切力一部分转化成法相方向的压力,增加压下量,使内部组织致密,力学性能提高。而且模具内部带有形状各异的型腔,方便成型各种形状的制品。
附图说明
图1为麻纤维增强复合材料模压-轧制复合成型工艺流程图;
图2为轧制设备示意图:其中,(a)为主视图;(b)为侧视图;(c)为俯视图;
图3为模具设备示意图:其中,(a)为主视图;(b)为侧视图;(c)为俯视图。
具体实施方式
下面以具体实施例的方式对本发明技术方案做进一步解释与说明,但本发明不限于这些实施例。
实施例1
1)对汉麻纤维进行深冷机械联合脱胶处理,具体实施的步骤可以参考CN106591961B;
2)将平均长度为7cm的汉麻纤维和聚丙烯纤维按照2:3的比例进行均匀混合1min,然后输送到梳理机进行梳理,再送入铺网机中铺网,将铺好的网折叠后送入主针刺机中进行针刺,制备出毡材;
3)将毡材浸入配制好的15wt%聚磷酸铵溶液中30min,然后取出后热风干燥;
4)将聚丙烯纤维无纺布置于毡材的上下表面,以增加复合材料的力学性能;
5)将处理的毡材裁剪成要求的尺寸后,放入模具中一起加热,加热温度为220℃,加热时间为2min,模具材料采用H13;
6)将模具放到轧机上进行轧制,轧辊温度为100℃,调节辊缝距离进行轧制。脱模后即可得到麻纤维增强复合材料,产品厚度为2mm。
实施例2
1)首先将长度约为7cm的黄麻纤维、亚麻纤维和聚乳酸纤维按照1:1:2的比例进行固相共混,然后通过气流输送至梳理机进行梳理,再将纤维送入铺网机中交叉铺网,针刺固结,制备出毡材(预制体);
2)将毡材浸入配制好的15wt%阻燃剂溶液中20min,然后取出后热风干燥,其中阻燃剂为硫酸铵;
3)将处理的毡材裁剪成要求的尺寸后,放入模具中一起加热。加热温度为200℃,加热时间为2min,之后覆上一层面饰,模具材料为H11;
4)将模具放到轧机上进行轧制,轧辊温度为90℃。脱模后即可得到麻纤维增强复合材料,产品厚度为1mm。
实施例3
1)首先将长度均为7cm的剑麻纤维和尼龙66纤维按照1:1的比例进行固相共混,再将梳理过的纤维送入铺网机中铺网,将铺好的网折叠后送入主针刺机中进行针刺,制备出毡材;
2)将毡材浸入配制好的10%四硼酸氢铵溶液中30min,然后取出后热风干燥;
3)将处理的毡材裁剪成要求的尺寸后,放入模具中一起加热。加热温度为270℃,加热时间为1min,模具材料为5CrNiMo;
4)将模具放到轧机上进行轧制,轧辊温度为100℃,调节辊缝距离进行轧制。脱模后即可得到麻纤维增强复合材料,产品厚度为1.5mm。
实施例中复合板的厚度和力学性能测试结果,见表1。
表1
Claims (2)
1.一种天然麻纤维增强复合材料的模压-轧制复合成型工艺方法,具体步骤如下:
1)首先将长度为6.5~7.5cm的天然麻纤维和热塑性树脂纤维进行固相共混30~60s,再通过气流铺网或梳理铺网,以及针刺固结,制备出天然麻纤维和热塑性树脂纤维的混合毡材(预制体);
2)将热塑性纤维无纺布和/或热塑性树脂薄膜置于混合毡材的上下表面;
3)在将步骤2)得到的混合毡材裁剪成最终产品所要求的尺寸后,将混合毡材放入模具中,与模具一起加热,加热温度设定为130~300℃,加热时间为1~8min;模具材料采用热作模具钢;
4)将模具转移至轧机上,进行轧制,将轧辊温度升高至70~100℃,调节辊缝距离进行轧制,轧辊速度100-300转/min,辊缝的厚度等于模具厚度。轧制结束后脱模得到最终产品,板材厚度1-5mm;
所述的天然麻纤维为汉麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、剑麻纤维中的中的一种或几种的混合物;
热塑性树脂薄膜或纤维为聚丙烯、聚乳酸、聚乙烯、尼龙6或尼龙66的树脂薄膜或纤维。
2.根据权利要求1所述的天然麻纤维增强复合材料的模压-轧制复合成型工艺方法,其特征在于,
在步骤2)和步骤3)之间还包含有阻燃处理步骤,具体如下:将混合毡材浸入配制好的阻燃剂溶液中,然后取出后热风干燥。
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