CN109423609B - 碳纤维芯材镀以合金膜的复合材的制造方法 - Google Patents
碳纤维芯材镀以合金膜的复合材的制造方法 Download PDFInfo
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical group C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 62
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- 238000004544 sputter deposition Methods 0.000 claims description 27
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 9
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
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- 229910017052 cobalt Inorganic materials 0.000 claims description 3
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Abstract
本发明关于一种碳纤维芯材镀以合金膜的复合材的制造方法，包括下列步骤：于一碳纤维芯材周围镀上一合金膜以形成一碳纤维合金膜包覆线，该合金膜包括：一高熵合金及液态金属合金膜或金属玻璃膜；将多数碳纤维合金膜包覆线交错编织成一碳纤维合金膜包覆线的片材；将多数片材相互堆栈，加以振动、加热以热压成一复合材产品。由于碳纤维芯材镀以合金膜具有高强度、耐腐蚀性、抗高温性、胶结强度佳的优点，故可增进复合材产品的强度并增长其使用寿命。
Description
技术领域
本发明涉及一种碳纤维芯材镀以合金膜的复合材的制造方法，属于材料技术领域。
背景技术
由于碳纤维补强复合材具有以下诸优点：低密度、高强度、以及结合补强碳纤维的强度与热塑聚合物(thermoplastic polymer)的韧度，近年来碳纤维补强复合材的成长速度极快。其中，环氧树脂以碳纤维补强具有良好的机械特性，而广泛用来制作飞机的结构零件及许多工程产品。
然而，以碳纤维补强的环氧树脂有其缺点，即于碳纤维补强复合材中会有〝空穴〞的存在，此可能于制作过程中，混入空气所致。这些〝空穴〞会造成多孔性，使碳纤维与环氧树脂之间的界面粘性不佳，造成碳纤维与环氧树脂间的脱胶、剥离，使最终产品容易破碎。
发明内容
有鉴于此，本发明的目的在于提供一种碳纤维芯材镀以合金膜的复合材的制造方法。
为了达成上述的目的，本发明提供了一种将碳纤维镀以合金膜的复合材的制造方法，其步骤如下：
于一碳纤维芯材周围镀上一合金膜以形成一碳纤维合金膜包覆线，该合金膜包括：一高熵合金及液态金属合金膜或金属玻璃膜；
将多数碳纤维合金膜包覆线交错编织成一碳纤维合金膜包覆线的片材；
将多数片材相互堆栈，加以振动、加热以热压成一复合材产品。
进一步地，其中该高熵合金及液态金属合金选自多数金属元素与多数非金属元素的混合，其通式如下：
金属元素：AlaCobCrcCudFeeMnfMogNihTiiWjAgkAulGamSnnZnoZrp),与非金属元素：(BqCrPsSit)，式中各元素的原子百分比(atomic percentage,％)如下所示：
Al：a＝1～50％；Co：b＝0～50％；Cr：c＝0～50％；
Cu：d＝0～70％；Fe：e＝0～50％；Mn：f＝1～35％；
Mo：g＝0～35％；Ni：h＝0～50％；Ti：i＝0～50％；
W：j＝1～35％；Ag：k＝0～20％；Au：l＝0～30％；
Ga：m＝0～10％；Sn：n＝0～10％；Zn：o＝0～20％；
Zr：p＝0～50％；B：q＝0～20％；C：r＝0～20％；
P：s＝0～20％；Si：t＝0～20％.
进一步地，其中该金属玻璃选自：以铁为基的金属玻璃，以镍为基的金属玻璃，以钛为基的金属玻璃，以铝为基的金属玻璃，以镁为基的金属玻璃，以钴为基的金属玻璃，及以多数元素为基的金属玻璃。
进一步地，其中该合金或该金属玻璃作为一靶材，以应用于卷轮对卷轮溅镀制程中，将合金膜或金属玻璃膜溅镀于碳纤维芯材上。
进一步地，其中该溅镀制程通过一卷轮对卷轮溅镀装置加以制作，该卷轮对卷轮溅镀装置包括：一上靶材置于一上溅镀器；一下靶材置于一下溅镀器；一第一卷轮其上绕以碳纤维芯材，并置于该溅镀装置的进料端；以及一第二卷轮设于该溅镀装置的接收端，以接收通经该上、下靶材且被溅镀而形成的碳纤维合金膜包覆线。
进一步地，其中自该第一卷轮释出的碳纤维芯材作为一基材，于通经该溅镀装置的上、下靶材之间时被溅镀，该溅镀装置置于一真空室中。
进一步地，其中该步骤C中，该振动加热的热压步骤将通过一振动热压机，包括上、下半模加以制作，将碳纤维合金膜包覆线的片材置于该上、下半模内，加以夹压；至少一半模装有振动器及加热器以振动热压该上、下半模所夹压的片材；以及一升降装置以升降、开合该两半模。
进一步地，其中该碳纤维合金包覆线片材相互堆栈，且夹压于上、下半模之间，该热压机置于一真空室中。
进一步地，其中该加热器用来加热该片材至接近该高熵合金及液态金属合金或金属玻璃的玻璃转换温度。
进一步地，其中该振动器用来振动介于该上、下半模间的片材，以摩擦加热熔融该合金或金属玻璃，而于停止该振动器后，迅速降温，于加压下维持该等碳纤维合金膜包覆线的片材在非晶形状态下。
进一步地，其中该上、下半模为一成型模具，其间有一模穴以夹压、模制成成型产品。
进一步地，其中该多数碳纤维合金膜包覆线的片材加以热压制作成：锭块，块状，板状，以及工件，并进一步加工制作为管、缆索、结构产品及工程产品。
本发明的另一目的旨在提供一复合材产品，将合金膜镀覆于碳纤维芯材上，以形成一复合材产品。
本发明具有以下诸特性或优点：由于碳纤维芯材镀以合金膜具有高强度、耐腐蚀性、抗高温性、胶结强度佳的优点，故可增进复合材产品的强度并增长其使用寿命。
附图说明
图1为本发明制作碳纤维合金膜包覆线的流程图。
图2为图1的断面图。
具体实施方式
下面结合具体实施例对本发明作进一步详细描述，但不作为对本发明的限定。在下述说明中，不同的“一实施例”或“实施例”指的不一定是同一实施例。此外，一或多个实施例中的特定特征、结构、或特点可由任何合适形式组合。
依本发明，碳纤维合金膜包覆线于碳纤维芯材上镀覆以合金膜，此合金包括：高熵(entropy)合金，液态金属合金，或金属玻璃。
该等高熵合金与液态金属合金可选自：多数金属元素与多数非金属元素混合，其通式如下：
金属元素：AlaCobCrcCudFeeMnfMogNihTiiWjAgkAulGamSnnZnoZrp),非金属元素：(BqCrPsSit),
以上两种元素混合，其中各元素的原子百分比(％)示如下：
Al：a＝1～50％；Co：b＝0～50％；Cr：c＝0～50％；
Cu：d＝0～70％；Fe：e＝0～50％；Mn：f＝1～35％；
Mo：g＝0～35％；Ni：h＝0～50％；Ti：i＝0～50％；
W：j＝1～35％；Ag：k＝0～20％；Au：l＝0～30％；
Ga：m＝0～10％；Sn：n＝0～10％；Zn：o＝0～20％；
Zr：p＝0～50％；B：q＝0～20％；C：r＝0～20％；
P：s＝0～20％；Si：t＝0～20％。
本发明中，元素与原子百分比系未加限定，可依所要制造的产品需要，依适当比例加以调配。
该金属玻璃可选自：以铁为基的金属玻璃，以镍为基的金属玻璃，以钛为基的金属玻璃，以铝为基的金属玻璃，以镁为基的金属玻璃，以钴为基的金属玻璃，以及其它的金属玻璃，包括以多数元素为基的金属玻璃，本发明未予限制。
上述的合金或金属玻璃可作为靶材，以进行下述的卷轮对卷轮(roll-to-roll)的溅镀制程：
如图1及2所示，安装一卷轮对卷轮的溅镀装置，上靶材T1置于上溅镀器S1，下靶材T2则置于下溅镀器S2。第一卷轮R1其上绕有碳纤维芯材C，安装于溅镀装置的进料端，第二卷轮R2置于溅镀装置的接收端，用来卷收通径上、下溅镀器S1，S2之间的碳纤维合金膜包覆线。
当碳纤维芯材C自第一卷轮R1释出后，拉经上、下溅镀器S1，S2的上、下靶材T1，T2之间，此芯材C作为一基材，整个溅镀装置置于一真空室(未示出)中。
各溅镀器S1，S2形成一强的电场，并通入隋性气体如氩气，氩气在强电场中离子化，被加速推进至上、下靶材T1，T2，当撞击靶材T1，T2时，靶材的原子(即高熵合金及液态金属合金或金属玻璃的原子)释放出来，并游移S至基材(即碳纤维芯材C)，乃于碳纤维芯材上镀上一层原子膜，由是形成碳纤维合金膜包覆线，由第二卷轮R2加以卷收。
于溅镀制程中，靶材原子被溅镀器的电浆所轰击而变成合金气体，为非晶形(amorphous)。当沈积于碳纤维芯材C上后，合金气体固化。因时间极短，所沈积的膜并未结晶，而瞬间形成非晶形结构。于碳纤维芯材上的非晶形膜会增加溅镀产品的弹性及可挠性。
在溅镀制程中，该等高熵合金与液态金属合金或金属玻璃的靶材原子会汇集在碳纤维芯材C的基材上，使于碳纤维芯材上紧紧地包覆原子层或膜。亦即碳纤维芯材与原子层(或膜)之间紧密结合，而无空气的〝空穴〞存在，增加了外层膜与碳纤维芯材间的胶结强度，以防其破碎或剥离，尤优于习知的碳纤维补强的环氧树脂复合材产品。
卷收于第二卷轮R2上的碳纤维合金膜包覆线则再加以编织形成一交错如网状的包覆线片材。然后卷成线筒，以供进一步加工之用，也可加以裁切成适当的大小、形状或单位。
该包覆线片材可依下示步骤再加加工：
备一振动热压机(未示出)，具有：上半模，下半模，振动器(或超音波振动器)设于该上半模或下半模上，一加热器设于一半模上，以及一升降装置以抬升分离或下降结合该上、下半模。可加罩一真空室，以抽除空气，避免空气进入致劣化质量。
将前述制作的多数包覆线片材加以堆栈，并置于上、下半模之间，然后闭合两半模将片材夹压于两半模之间，以加热器加热至接近(但低于)该等合金或金属玻璃的“玻璃转换温度”(glass transition temperature,Tg)。
然后启动超音波振动器或振动器使介于上、下半模间的包覆线片材振荡以升温至超过其玻璃转换温度Tg。由于振动摩擦生热，合金或金属玻璃瞬即熔化，停掉振动器，即迅速降温，使该等碳纤维片材于受压下维持在非晶形状态。
该两半模可为一成型模具，两半模间设有模穴，可将片材压制成型，直接制成预先所设计定型的产品。
振动热压的复合材产品可为：块状、板状、锭块(ingot)或为一工件(work piece)。
此等复合材产品可再加工为管，缆索，结构产品或工程产品。
于上述振动热压过程中，片材受热、受振动、受压而密实因而排除了存在于其中的空穴、气穴或孔洞。孔穴既除，本发明产品的胶合强度因而大大提高。
因此，本发明增进了以下诸特性：高硬度、高强度(包括高压缩强度)，高韧性，高可挠性(flexibility)，耐高温性，耐剥离性，且质地轻盈。
就高压缩强度而言，本发明可达1000MPa至5000MPa，远优于碳纤维补强环氧树脂复合材的16.8～201.3MPa。
本发明可于不违本发明的精神及范围下，作适当的修饰或改变。
Claims (8)
1.一种碳纤维芯材镀以合金膜的复合材的制造方法，其特征在于，包括下列步骤：
于一碳纤维芯材周围镀上一合金膜以形成一碳纤维合金膜包覆线，该合金膜包括：一高熵合金及液态金属合金膜或金属玻璃膜；
将多数碳纤维合金膜包覆线交错编织成一碳纤维合金膜包覆线的片材；
将多数片材相互堆栈，加以振动、加热以热压成一复合材产品；
该振动加热的热压步骤将通过一振动热压机，包括上、下半模加以制作，将碳纤维合金膜包覆线的片材置于该上、下半模内，加以夹压；
至少一半模装有振动器及加热器以振动热压该上、下半模所夹压的片材；以及一升降装置以升降、开合该两半模；
该上、下半模为一成型模具，其间有一模穴以夹压、模制成成型产品；
该高熵合金及液态金属合金选自多数金属元素与多数非金属元素的混合，其通式如下：
金属元素：AlaCobCrcCudFeeMnfMogNihTiiWjAgkAulGamSnnZnoZrp),与非金属元素：(BqCrPsSit)，式中各元素的原子百分比(atomic percentage,％)如下所示：
Al：a＝1～50％；Co：b＝0～50％；Cr：c＝0～50％；
Cu：d＝0～70％；Fe：e＝0～50％；Mn：f＝1～35％；
Mo：g＝0～35％；Ni：h＝0～50％；Ti：i＝0～50％；
W：j＝1～35％；Ag：k＝0～20％；Au：l＝0～30％；
Ga：m＝0～10％；Sn：n＝0～10％；Zn：o＝0～20％；
Zr：p＝0～50％；B：q＝0～20％；C：r＝0～20％；
P：s＝0～20％；Si：t＝0～20％。
2.如权利要求1所述的制造方法，其特征在于，该金属玻璃选自：以铁为基的金属玻璃，以镍为基的金属玻璃，以钛为基的金属玻璃，以铝为基的金属玻璃，以镁为基的金属玻璃，及以钴为基的金属玻璃。
3.如权利要求1所述的制造方法，其特征在于，该合金或该金属玻璃作为一靶材，以应用于卷轮对卷轮溅镀制程中，将合金膜或金属玻璃膜溅镀于碳纤维芯材上。
4.如权利要求3所述的制造方法，其特征在于，该溅镀制程通过一卷轮对卷轮溅镀装置加以制作，该卷轮对卷轮溅镀装置包括：一上靶材置于一上溅镀器；一下靶材置于一下溅镀器；一第一卷轮其上绕以碳纤维芯材，并置于该溅镀装置的进料端；以及一第二卷轮设于该溅镀装置的接收端，以接收通经该上、下靶材且被溅镀而形成的碳纤维合金膜包覆线。
5.如权利要求4所述的制造方法，其特征在于，自该第一卷轮释出的碳纤维芯材作为一基材，于通经该溅镀装置的上、下靶材之间时被溅镀，该溅镀装置置于一真空室中。
6.如权利要求1所述的制造方法，其特征在于，该碳纤维合金包覆线片材相互堆栈，且夹压于上、下半模之间，该热压机置于一真空室中。
7.如权利要求1所述的制造方法，其特征在于，该加热器用来加热该片材至该高熵合金及液态金属合金或金属玻璃的玻璃转换温度。
8.如权利要求1所述的制造方法，其特征在于，该振动器用来振动介于该上、下半模间的片材，以摩擦加热熔融该合金或金属玻璃，而于停止该振动器后，迅速降温，于加压下维持该等碳纤维合金膜包覆线的片材在非晶形状态下。
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