CN109537161A - 一种热塑碳纤维复合板材及生产方法 - Google Patents

一种热塑碳纤维复合板材及生产方法 Download PDF

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CN109537161A
CN109537161A CN201811375441.4A CN201811375441A CN109537161A CN 109537161 A CN109537161 A CN 109537161A CN 201811375441 A CN201811375441 A CN 201811375441A CN 109537161 A CN109537161 A CN 109537161A
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潘国立
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Yangzhou Chaofeng Automobile Interior Decoration Co Ltd
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Abstract

本发明公开了复合板材技术领域的一种热塑碳纤维复合板材及生产方法。一种热塑碳纤维复合板材，包括以下重量份的的各组分：碳纤维长纤20～50份、热塑材料40～70份、界面增强材料10份。一种热塑碳纤维复合板材的生产方法，包括如下步骤：(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；(2)梳理；(3)铺网；(4)预针刺；(5)二次针刺；(6)形成碳纤维热塑复合板材毡材。(7)通过热压机压型以后形成碳纤维热塑复合板材。本发明的优点是简化工艺，将碳纤维长纤和热塑材料之间柔性缠结，制成杂乱的空间结构，提高强度。

Description

一种热塑碳纤维复合板材及生产方法
技术领域
本发明涉及复合板材技术领域，特别涉及一种热塑碳纤维复合板材及生产方法。
背景技术
复合板材在各种工业行业都有广泛应用，如航空、高铁、风电等工业领域。随着汽车工业的飞速发展，高性能的复合板材必将在汽车上得到更广泛的应用。然而，由于传统金属部件加工成型工艺技术非常成熟，复合板材成型工艺复杂，加工周期长，热固性复合板材在生产过程中不环保，且该复合板材又难以回收重复利用，在一定程度上增加了自然环境的负担。
现有技术中公开了一种发明，申请号为CN201110358792.6，授权公告号为CN102492289B，授权公告日为20130828，名称为一种碳纤维增强复合板材及其制备工艺，采用模压成型方法，模具分上下模，外包裹加热套实现加热，用热电偶控温，变压器调整升温速度，成型时将碳纤维编织物放入预先清理好的成型模具中并紧贴下模腔，将碳纤维编织物放在可调控张拉机构中预张紧，张拉过程中要保证纤维连续且张紧度一致，通过调节碳纤维编织物的张紧力，使碳纤维编织物在进入成型模具前始终处于有张紧力的状态，然后通过定位装置固定在模具上，铺上所需厚度的热固性树脂粉末，然后调整整个张拉机构至所需高度，重复上述工艺逐层地将碳纤维编织物和所需厚度的热固性树脂粉末铺在模具上，根据制成后碳纤维增强复合板材所应达到的力学性能指标及碳纤维增强复合板材的宽度与厚度确定板材内部所需铺设碳纤维编织物的规格及数量，由成型模具及碳纤维编织物定位装置确定碳纤维编织物在碳纤维增强复合板材中的基体位置及布置形式，直至达到所设计的层数和厚度，然后盖上上模，加热升温，压制成型。现有技术，通过逐层地将碳纤维编织物和所需厚度的热固性树脂粉末铺在模具上压制成型，工艺复杂，同时，碳纤维编织物和热固树脂是有序的逐层复合形成的，热固树脂无法完全渗透入碳纤维编织物中，而是在碳纤维编织物接触的表面固化，形成的碳纤维复合板材的强度有待提高，为了提高强度，需要铺设多层，增加了工艺复杂程度。
发明内容
本发明的目的是提供一种简化工艺、提高强度的热塑碳纤维复合板材及生产方法。
为了实现上述发明目的，本发明热塑碳纤维复合板材及生产方法采用的如下技术方案：
一种热塑碳纤维复合板材，包括以下重量份的的各组分：碳纤维长纤20～50份、热塑材料40～70份、界面增强材料10份。
优选的，所述碳纤维长纤的长度为80mm～100mm。
优选的，所述的界面增强材料是纳米胶粘剂。
一种热塑碳纤维复合板材的生产方法，包括如下步骤：
(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；通过开松机开松，使得碳纤维长纤、热塑材料和界面增强材料之间分离并充分混合；
(2)梳理：将步骤(1)中分离的混合物料置于梳理机中进行梳理成网，构成单层网，单层网的克重为20～50克；将开松后的混合物料经梳理机梳理，形成的单层网中碳纤维长纤和热塑材料混合分布；
(3)铺网：将步骤(2)中梳理后的单层网叠加铺设多层，构成多层网，多层网的克重为300g/m2～5000g/m2；将单层网铺设多层，通过控制多层网的克重，达到较高的强度；
(4)预针刺：对步骤(3)中铺网后的多层网置于针刺机中进行针刺加工，预针刺密度为55～65针/cm3，针刺深度在50～80毫米，制得第一预制品；将铺设好的多层网进行预针刺加工，使得多层网之间柔性缠结，碳纤维板材和热塑材料之间交缠，具有较好的稳定性和弹性；
(5)二次针刺：对步骤(4)中制得的预制品置于针刺机中进行二次针刺加工，二次针刺密度为45～55针/cm3，针刺深度在20～50毫米，制得碳纤维热塑复合毡材。通过对第一预制品进行二次针刺，提高多层网之间的柔性缠接，具有更高的稳定性和弹性，达到较高的强度；
(6)热压成型：将步骤(5)中制得的碳纤维热塑复合毡材置于热压机的加热板上预热，上下预热温度控制在200～250℃、预热时间60～100秒，启动热压成型设备，压力15～20MPa，成型时间35～55秒，得到所述热塑碳纤维复合板材。将碳纤维热塑复合毡材置于热压成型设备中热压成型，一次性成型，较现有技术中的多次成型工艺相比，简化工艺，操作简单。
与现有技术相比，本发明的有益效果在于：
本发明通过将碳纤维长纤和热塑材料复合，通过严格的配比，展现出较高的强度，并通过针刺机多次针刺，将碳纤维长纤和热塑材料之间相互交缠得到杂乱的空间结构，使得碳纤维长纤与热塑材料之间相互柔性缠结，通过采用80mm～100mm碳纤维长纤，使得碳纤维长纤与热塑材料之间缠结的更加紧密，结合度更好，进一步提高本发明碳纤维复合板材的强度，较现有技术中的热固成型工艺相比，通过热压一次成型，简化工艺步骤，提高生产效率。
具体实施方式
下面结合具体实施方式，进一步阐明本发明，应理解这些实施方式仅用于说明本发明而不用于限制本发明的范围，在阅读了本发明之后，本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定的范围。
实施例1：
一种热塑碳纤维复合板材，包括以下重量份的的各组分：碳纤维长纤20份、热塑材料40份、界面增强材料10份。碳纤维长纤的长度为80mm。界面增强材料是纳米胶粘剂。
一种热塑碳纤维复合板材的生产方法，包括如下步骤：
(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；
(2)梳理：将步骤(1)中分离的混合物料置于梳理机中进行梳理成网，构成单层网，单层网的克重为20克；
(3)铺网：将步骤(2)中梳理后的单层网叠加铺设多层，构成多层网，多层网的克重为的300g/m2；
(4)预针刺：对步骤(3)中铺网后的多层网置于针刺机中进行针刺加工，预针刺密度为55针/cm3，针刺深度在50毫米，制得第一预制品；
(5)二次针刺：对步骤(4)中制得的预制品置于针刺机中进行二次针刺加工，二次针刺密度为45针/cm3，针刺深度在20毫米，制得碳纤维热塑复合毡材；
(6)热压成型：将步骤(5)中制得的碳纤维热塑复合毡材置于热压机的加热板上预热，上下预热温度控制在200℃、预热时间60秒，启动热压成型设备，压力15MPa，成型时间35秒，得到热塑碳纤维复合板材。
实施例2：
一种热塑碳纤维复合板材，包括以下重量份的的各组分：碳纤维长纤30份、热塑材料50份、界面增强材料10份。碳纤维长纤的长度为90mm。界面增强材料是纳米胶粘剂。
一种热塑碳纤维复合板材的生产方法，包括如下步骤：
(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；
(2)梳理：将步骤(1)中分离的混合物料置于梳理机中进行梳理成网，构成单层网，单层网的克重为30克；
(3)铺网：将步骤(2)中梳理后的单层网叠加铺设多层，构成多层网，多层网的克重为的2000g/m2；
(4)预针刺：对步骤(3)中铺网后的多层网置于针刺机中进行针刺加工，预针刺密度为60针/cm3，针刺深度在60毫米，制得第一预制品；
(5)二次针刺：对步骤(4)中制得的预制品置于针刺机中进行二次针刺加工，二次针刺密度为50针/cm3，针刺深度在40毫米，制得碳纤维热塑复合毡材；
(6)热压成型：将步骤(5)中制得的碳纤维热塑复合毡材置于热压机的加热板上预热，上下预热温度控制在220℃、预热时间80秒，启动热压成型设备，压力18MPa，成型时间40秒，得到热塑碳纤维复合板材。
实施例3：
一种热塑碳纤维复合板材，包括以下重量份的的各组分：碳纤维长纤50份、热塑材料70份、界面增强材料10份。碳纤维长纤的长度为100mm。界面增强材料是纳米胶粘剂。
一种热塑碳纤维复合板材的生产方法，其特征在于，包括如下步骤：
(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；
(2)梳理：将步骤(1)中分离的混合物料置于梳理机中进行梳理成网，构成单层网，单层网的克重为50克；
(3)铺网：将步骤(2)中梳理后的单层网叠加铺设多层，构成多层网，多层网的克重为的5000g/m2；
(4)预针刺：对步骤(3)中铺网后的多层网置于针刺机中进行针刺加工，预针刺密度为65针/cm3，针刺深度在80毫米，制得第一预制品；
(5)二次针刺：对步骤(4)中制得的预制品置于针刺机中进行二次针刺加工，二次针刺密度为55针/cm3，针刺深度在50毫米，制得碳纤维热塑复合毡材；
(6)热压成型：将步骤(5)中制得的碳纤维热塑复合毡材置于热压机的加热板上预热，上下预热温度控制在250℃、预热时间100秒，启动热压成型设备，压力20MPa，成型时间55秒，得到热塑碳纤维复合板材。

Claims (4)

1.一种热塑碳纤维复合板材，其特征在于，包括以下重量份的的各组分：碳纤维长纤20～50份、热塑材料40～70份、界面增强材料10份。
2.根据权利要求1所述的热塑碳纤维复合板材，其特征在于，所述碳纤维长纤的长度为80mm～100mm。
3.根据权利要求1所述的热塑碳纤维复合板材，其特征在于：所述的界面增强材料是纳米胶粘剂。
4.根据权利要求1所述的热塑碳纤维复合板材的生产方法，其特征在于，包括如下步骤：
(1)混合：按照配方量称取碳纤维长纤，热塑材料，界面增强材料混合，然后置于开松机中开松形成分离的混合物料；
(2)梳理：将步骤(1)中分离的混合物料置于梳理机中进行梳理成网，构成单层网，单层网的克重为20～50克；
(3)铺网：将步骤(2)中梳理后的单层网叠加铺设多层，构成多层网，多层网的克重为300g/m2～5000g/m2；
(4)预针刺：对步骤(3)中铺网后的多层网置于针刺机中进行针刺加工，预针刺密度为55～65针/cm3，针刺深度在50～80毫米，制得第一预制品；
(5)二次针刺：对步骤(4)中制得的预制品置于针刺机中进行二次针刺加工，二次刺密度为45～55针/cm3，针刺深度在20～50毫米，制得碳纤维热塑复合毡材；
(6)热压成型：将步骤(5)中制得的碳纤维热塑复合毡材置于热压机的加热板上预热，上下预热温度控制在200～250℃、预热时间60～100秒，启动热压成型设备，压力15～20MPa，成型时间35～55秒，得到所述热塑碳纤维复合板材。
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