CN110035883A - 模制或与模制相关的改进 - Google Patents
模制或与模制相关的改进 Download PDFInfo
- Publication number
- CN110035883A CN110035883A CN201780074242.7A CN201780074242A CN110035883A CN 110035883 A CN110035883 A CN 110035883A CN 201780074242 A CN201780074242 A CN 201780074242A CN 110035883 A CN110035883 A CN 110035883A
- Authority
- CN
- China
- Prior art keywords
- molding
- mold
- molding material
- prefabricated component
- edge
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000465 moulding Methods 0.000 title claims abstract description 31
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- 239000011347 resin Substances 0.000 claims description 35
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- 229920001187 thermosetting polymer Polymers 0.000 claims description 16
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- 239000012790 adhesive layer Substances 0.000 claims description 9
- 238000007711 solidification Methods 0.000 claims description 9
- 230000008023 solidification Effects 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 8
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- 230000014759 maintenance of location Effects 0.000 description 6
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- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 4
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 4
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 4
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
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- 125000003118 aryl group Chemical group 0.000 description 3
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- 125000003055 glycidyl group Chemical group C(C1CO1)* 0.000 description 3
- 230000000717 retained effect Effects 0.000 description 3
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- QTWJRLJHJPIABL-UHFFFAOYSA-N 2-methylphenol;3-methylphenol;4-methylphenol Chemical compound CC1=CC=C(O)C=C1.CC1=CC=CC(O)=C1.CC1=CC=CC=C1O QTWJRLJHJPIABL-UHFFFAOYSA-N 0.000 description 2
- YBRVSVVVWCFQMG-UHFFFAOYSA-N 4,4'-diaminodiphenylmethane Chemical compound C1=CC(N)=CC=C1CC1=CC=C(N)C=C1 YBRVSVVVWCFQMG-UHFFFAOYSA-N 0.000 description 2
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- -1 alcohol amine Chemical class 0.000 description 2
- 230000001588 bifunctional effect Effects 0.000 description 2
- 229940106691 bisphenol a Drugs 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
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- 230000006835 compression Effects 0.000 description 2
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- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 description 1
- CWLKGDAVCFYWJK-UHFFFAOYSA-N 3-aminophenol Chemical compound NC1=CC=CC(O)=C1 CWLKGDAVCFYWJK-UHFFFAOYSA-N 0.000 description 1
- VTEBEHXYQSENAU-UHFFFAOYSA-N C(C1CO1)C(C(C(O)CC1CO1)O)O.C(COCCO)O Chemical compound C(C1CO1)C(C(C(O)CC1CO1)O)O.C(COCCO)O VTEBEHXYQSENAU-UHFFFAOYSA-N 0.000 description 1
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- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- AFEQENGXSMURHA-UHFFFAOYSA-N oxiran-2-ylmethanamine Chemical compound NCC1CO1 AFEQENGXSMURHA-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
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- 238000007725 thermal activation Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- 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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29B11/00—Making preforms
- B29B11/06—Making preforms by moulding the material
- B29B11/12—Compression moulding
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C33/10—Moulds or cores; Details thereof or accessories therefor with incorporated venting means
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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
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- B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
- B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
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- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- 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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
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- 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
- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
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- B32B2260/02—Composition of the impregnated, bonded or embedded layer
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- B32—LAYERED PRODUCTS
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/14—Mixture of at least two fibres made of different materials
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Reinforced Plastic Materials (AREA)
- Moulding By Coating Moulds (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
一种用于模制材料的模具,所述模具包括至少两个可朝向和背离彼此而相对于彼此移动的相应的模具元件(14,16,18,20),朝向移动在位于所述模具内形成的型腔内的模制材料上施加压力,其中在所述模具元件接触时,所述模具型腔包括凹部(120),所述凹部(120)位于模制件的边缘之外,以允许在模制期间气体(12)逸出。
Description
本发明涉及模制或与模制有关的改进,并且具体地涉及压缩模制的改进。
压缩模制是已知的并被广泛使用多年,并且用于生产宽范围的制品。理想的是模制件尽可能均匀并且跨过模制件的整个横截面具有所需的物理性能。然而,为了生产模制件,首先必须将材料置于模具内,并且然后将模具的元件合在一起以在模制材料上施加压力并迫使材料至模具的末端。当将模具的模具元件合在一起时,这些元件之间的气体(空气或其他流体)将被挤出朝向模具的侧面。在特别是生产复杂形状的模制件的某些情况下,这些流体不能逸出,并且它们可能与模制材料的边缘混合,导致所生产的模制件边缘的不规则性和缺陷,从而造成模制件的性能降低。在由纤维增强的热固性树脂生产模制件时,这个问题可能尤其严重,所述纤维增强的热固性树脂通常被模制成纤维增强的热固性树脂层的堆叠体,并且如果模制件具有复杂的结构则更是如此。
本发明通过提供改进的模具并提供模制工艺来提供这些问题的解决方案。
根据本发明,提供了所附权利要求中任一项所限定的系统、模具和预制件。
在一个实施方式中,提供了一种模制系统,所述模制系统包括模具型腔,所述模具型腔容纳有待在压力下模制的模制材料,凹部设置在所述模制材料的边缘处,以允许在压力下模制所述模制材料期间截留气体从所述模具型腔内逸出。
模制系统可包括模具,所述模具包括至少两个可朝向和背离彼此而相对于彼此移动的相应的模具元件,朝向移动在位于所述模具内形成的型腔内的模制材料上施加压力,其中在所述模具元件接触时,所述模具型腔包括凹部,所述凹部位于所述模制材料的边缘之外,以允许在模制期间气体逸出。
用于如上所述的系统中的模制材料包括预制的热固性材料,例如预浸料,其中所述预制件成形以在其边缘处提供一个或多个通道来提供凹部,以允许在模制期间空气逸出到所述预制件的末端之外。
这些通道呈波状边缘或锯齿或波纹形式。在优选的实施方式中,预制件包括多个层,并且在预制件的一个或多个层中提供波状边缘或锯齿或波纹。优选地,波状边缘或锯齿或波纹设置在粘合层中,并且更优选仅设置在粘合层中。
预制件优选包括粘合层,所述粘合层包含用于将预制件粘合到基底上的粘合剂。粘合层
预制件可包括嵌入含有树脂固化剂的热固性树脂如环氧树脂或聚酯树脂的基质中的纤维材料(例如碳纤维、玻璃纤维或芳族聚酰胺纤维)。
在本发明的一个实施方式中,模制材料包括预制件,所述预制件包括在其边缘处延伸超出所述预制件末端的波纹,以允许在模制期间气体流入由波纹和型腔形成的凹部中。
模制材料包括不同材料的层。在一个实施方式中,模制材料包括用于将所述模制材料粘合到金属层上的层。
在另外的实施方式中,模制材料包括多个部分或完全固化的纤维增强片材层。
在另一个实施方式中,所述模具能够被加热,以便它可以软化热塑性材料或固化热固性材料。
在另外的实施方式中,提供了一种预制件,其包含可固化的热固性树脂,所述预制件具有波纹状边缘。预制件可包括嵌入可热固化树脂的基质中的纤维材料,例如通常称为预浸料的材料。
在一个实施方式中,预制件包括预浸料和设置在预浸料的一个或两个表面上的粘合剂层,所述粘合剂层具有波纹状边缘。粘合剂层适于将预制件粘合到金属上。
预制件可包括树脂浸渍的纤维增强层,粘合剂层和金属层。
预制件可以在本申请所述的任何实施方式中用作模制材料。
因此,本发明提供了一种用于模制可流动材料的模具,所述可流动材料随后在模具内固化,所述模具包括至少两个可朝向和背离彼此而相对于彼此移动的模具元件,朝向移动一起在位于所述模具内的模制材料上施加压力,其中所述元件中的至少一个在其末端处设置有凹部,所述凹部在模制件边缘之外,以便当元件在模具内的模制材料上施加压力时允许空气逸出。
模具能够被加热。
在一个替代性实施方式中,提供了一种方法,所述方法包括模制预制的热固性材料,例如预浸料,包括纤维材料(例如碳纤维、玻璃纤维或芳族聚酰胺纤维),所述预制的热固性材料嵌入热固性树脂如环氧树脂或聚酯树脂的基质中,所述热固性树脂通常含有用于树脂的热活化硬化剂(固化剂),所述预制的热固性材料成形为使得在其边缘处提供一个或多个通道,以允许在模制期间气体逸出到预制件的末端之外。在该实施方式中,本发明还提供一种包含可固化热固性树脂的预制件,所述预制件具有波纹状边缘。
优选的是,预制件是嵌入可热固化树脂的基质中的纤维材料,例如通常称为预浸料的材料。预制件还可包括未浸渍的纤维增强材料(干纤维增强材料)。预制件还可包括预浸料和干燥纤维增强材料的组合。
在包括模制预制件的另一替代性方法中,在模具内的预制件的至少一侧上提供另一层,并且所述另一层设置有波纹,所述波纹优选地在其边缘处延伸超出预制件的末端以允许在模制过程中空气流入由波纹形成的空间内。
在本发明的这些实施方式中,在模具型腔内提供空间,以允许由模制过程截留的气体逸出超过模制件的边界。所需的空间将取决于模制件的尺寸和形状以及纤维材料和可固化树脂基质的性质。例如,纤维材料可以是可紧密或松散织造的织造材料,松散织造的材料可容纳更多的气体,并且因此可能需要更大的空间来排空任何截留气体。在许多情况下,预制件例如预浸料堆叠在模具中,然后模制和固化,并且堆叠体越大,截留的气体的可能性越大并且可能需要更大的空间以使其能够被排空。
根据本发明,截留气体的量和除去截留气体的能力还取决于所生产的部件的形状的复杂性和所需模具的复杂性。
通常,部件的形状越复杂,越难以除去截留气体例如空气,并且在更复杂形状的模制件的情况下,优选使用本发明的替代性实施方式,即叠加的粘合剂膜层。
本发明还可用于由不同材料的层形成模制件。例如,本发明可以用于借助于粘合剂层将金属层粘合到预浸料上,特别是生产可用作汽车和航空航天部件的材料。在一个实施方式中,预制件包括粘合剂层,所述粘合剂层可以在其边缘处设置有波纹,所述波纹提供用于排空截留气体的空间。
在本领域中已知纤维增强复合材料中的弯曲纤维,线性变形、皱折或隆起的纤维大大降低了机械性能,特别是复合材料的强度和弹性模量。因此非常希望制造具有高度对齐的纤维的复合材料。特别是在含有干纤维层的VARTM铺叠中,在铺叠和加工两者期间中保持纤维对齐是一个问题。本发明通过降低对齐被纤维之间截留的气体扰乱的可能性而有助于保持纤维对齐。
具有纬纱和经纱纤维的固化或部分固化的织造或非织造纤维增强片材有时用作预制件中的中间层,中间层的形式为一种或多种预浸料的堆叠体,特别是如果预浸料包含单向纤维。层压部件可以由一层或多层的预浸料、干纤维材料和纤维增强片材的任何组合形成。每层可容纳可通过本发明技术排空的气体。
在本发明的一个实施方式中,模具内的叠层包含多个部分或完全固化的纤维增强片材层。在一个优选的实施方式中,这些层铺叠有包含纬纱和经纱纤维的材料的中间层,这确保了保持堆叠体中的预浸料内的纤维的对齐。本发明能够使气体从堆叠体中排空。
使用部分或完全固化的纤维增强片材允许从片材中具有高度对齐纤维的材料的大堆叠体生产具有非常高纤维含量的制品。此外,片材形状与固化状态的组合有利于将片材调整为模具的形状,而不损害在形成复合构件或部件的叠层中的纤维的对齐、或者换句话说平直度。这对于复杂形状诸如风力涡轮机叶片的翼型是特别重要的,其中希望的纤维分布是复杂的三维形状。已发现使用本发明改善这些材料性能的均匀性。
结构纤维可以包括断裂(即拉断)、选择性不连续或连续的纤维。结构纤维可由多种材料制成,例如碳、石墨、玻璃、金属化聚合物、芳族聚酰胺及其混合物。优选玻璃纤维和碳纤维,对于长度超过40米,例如50至60米的风力涡轮机壳优选碳纤维。结构纤维可以是由多根单独纤维制成的单个丝束,并且它们可以是织造织物或非织造织物。根据最终层压件所需的性能,纤维可以是单向、双向或多向的。通常,纤维将具有圆形或者几乎圆形的横截面,直径为3至20μm,优选5至12μm。
示例性的单向结构纤维层由可从Hexcel Corporation获得的碳纤维制成。用于制造单向纤维层的合适的碳纤维包括:IM7碳纤维,其可作为含有6,000或12,000根长丝并且重量分别为0.223g/m和0.446g/m的纤维获得;IM8-IM10碳纤维,其可作为含有12,000根长丝并且重量为0.446g/m至0.324g/m的纤维获得;以及AS7碳纤维,其可作为含有12,000根长丝并且重量为0.800g/m的纤维获得。
热固性材料可包含树脂组合物。树脂组合物包含与固化剂组合的一种或多种树脂组分。优选地,树脂组分包含环氧树脂。
环氧树脂的反应性由其环氧当量(EEW)指示,EEW越低,反应性越高。环氧当量可以计算如下:(环氧树脂分子量)/(每分子中的环氧基团的数目)。另一种方法是用环氧值计算,环氧值可以定义如下:环氧值=100/环氧当量,然后计算每分子的环氧基团:(环氧值×分子量)/100。然后计算分子量:(100×每分子的环氧基团)/环氧值。然后计算分子量:环氧当量×每分子的环氧基团。
环氧树脂具有在150至1500范围内的如EEW所指示的高反应性,优选高反应性,例如在200至500范围内的EEW,并且树脂组合物包含树脂和促进剂或固化剂。合适的环氧树脂可包含两种或更多种选自单官能、双官能、三官能和/或四官能环氧树脂的环氧树脂的共混物。
举例来说,合适的双官能环氧树脂包括基于以下的那些:双酚F的二缩水甘油醚、双酚A的二缩水甘油醚(任选地溴化的)、苯酚和甲酚酚醛环氧树脂、苯酚-甲醛加合物的缩水甘油醚、脂族二醇的缩水甘油醚、二缩水甘油醚、二乙二醇二缩水甘油醚、芳族环氧树脂、脂族聚缩水甘油醚、环氧化烯烃、溴化树脂、芳族缩水甘油胺、杂环缩水甘油酰亚胺和酰胺(glycidyl imidines and amides)、缩水甘油醚、氟化环氧树脂、缩水甘油酯或其任何组合。
双官能环氧树脂可选自双酚F的二缩水甘油醚、双酚A的二缩水甘油醚、二缩水甘油基二羟基萘、或其任何组合。
举例来说,合适的三官能环氧树脂可以包括基于以下的那些:苯酚和甲酚酚醛环氧树脂、苯酚-甲醛加合物的缩水甘油醚、芳族环氧树脂、脂族三缩水甘油醚、二脂族三缩水甘油醚、脂族聚缩水甘油胺、杂环缩水甘油酰亚胺和酰胺、缩水甘油醚、氟化环氧树脂、或其任何组合。合适的三官能环氧树脂可从Huntsman Advanced Materials(瑞士蒙泰)以商品名MY0500和MY0510(三缩水甘油基对氨基苯酚)以及MY0600和MY0610(三缩水甘油基间氨基苯酚)获得。三缩水甘油基间氨基苯酚也可从Sumitomo Chemical Co.(日本大阪)以商品名ELM-120获得。合适的四官能环氧树脂包括N,N,N',N'-四缩水甘油基-间二甲苯二胺(从Mitsubishi Gas Chemical Company以名称Tetrad-X可商购,和从CVC Chemicals以名称Erisys GA-240可商购)、和N,N,N',N'-四缩水甘油基亚甲基二苯胺(例如MY0720和MY0721,来自Huntsman Advanced Materials)。其他合适的多官能环氧树脂包括DEN438(来自DowChemicals,密歇根州米德兰)、DEN439(来自DowChemicals)、Araldite ECN 1273(来自Huntsman Advanced Materials)、和Araldite ECN 1299(来自Huntsman AdvancedMaterials)。
如上所述,本发明中使用的层可以形成预浸料堆叠体,所述堆叠体在模具中固化以生产成品。预浸料是用于描述浸渍的纤维和织物或与未固化状态并准备固化的树脂组合的术语。纤维可以呈丝束或织物的形式,并且丝束通常包括多根称为长丝的细纤维。预浸料中使用的纤维材料和树脂将取决于固化的纤维增强材料的所需性能以及固化层压件的用途。纤维材料在本申请中被描述为结构纤维。树脂可以以各种方式与纤维或织物组合。树脂可以粘着于纤维材料的表面上。树脂可以部分或完全浸渍纤维材料。树脂可以浸渍纤维材料,以便在预浸料材料的加工过程中提供便于除去气体诸如空气的途径。
预浸料中的纤维可以是平行于固化的纤维增强片材的长度取向的单向纤维。这在固化的纤维增强片材的长度上提供了非常高的强度和刚度。在一些应用中,其他取向或取向组合可能是合适的。其他合适取向的实例是相对于片材长度在+-45°、+-30°、或0-90°处取向的双轴纤维;和在+-45°处并在片材的长度上取向的三轴纤维。此种取向增加了复合材料的沿边和/或扭曲强度和刚度。
从经济的观点来看,希望模制周期时间尽可能短。除了需要热量以增强树脂的固化之外,固化反应本身是放热的,并且在时间/温度固化周期中需要考虑这一点,特别是对于大且厚的预浸料堆叠体的固化,如生产用于工业应用的层压件越来越多地是这种情况,其中使用大量的环氧树脂,并且由于树脂固化反应的放热,在堆叠体内可能产生高温。应避免过高的温度,因为它们可能损坏模具增强件或导致树脂的一定分解。过高的温度还可能导致失去对树脂固化的控制,导致失控固化。
通过参考附图来说明本发明,其中
图1示出了第一模制方法的示意图,并且
图2示出了根据本发明的一个实施方式的模制方法的示意图。
图3示出了根据本发明实施方式的不含锯齿的固化预制件(a)和包含锯齿的预制件(b)。
图1示出了常规模制系统(10)的一部分,其包括由模具元件(14,16,18,20)形成的模具型腔,所述模具型腔容纳在压力下模制的模制材料(碳纤维增强塑料,CFRP)。模具元件(18)是金属层。当模具闭合并且所有元件(14,16,18,20)朝向彼此移动时,型腔被封闭,使得在施加压力和热量时,造成模制材料中的树脂流动和固化,用树脂填充模具型腔中的任何型腔,和空气形式的气体(12)被截留在固化的模制材料中(图1和图3(a))。这降低了固化的模制材料的机械性能(拉伸强度和层间剪切强度)。
图2示出了根据本发明的模制系统(100)的一部分,其包括模具型腔,所述模具型腔容纳在压力下模制的模制材料(CFRP),凹部设置在模制材料(CFRP)的边缘处以允许截留气体从模具型腔内逃逸。以这种方式,截留气体以此形式可以从封闭型腔中逸出。
图2中的模具包括可朝向和背离彼此而相对于彼此移动的相应的模具元件(140,160,180,200),朝向移动在位于所述模具内形成的型腔内的模制材料(CFRP)上施加压力,其中在所述模具元件(140,160,180,200)接触时,所述模具型腔包括凹部(120),所述凹部(120)位于模制件的边缘之外,以允许在模制期间气体逸出。
图3(a)示出了具有直边的常规模制材料。该材料用于如图1所示的模制系统中。图3(b)示出了根据本发明的模制材料。所述模制材料包括预制的热固性材料的预制件,其中所述预制件成形以在其边缘处提供一个或多个通道来提供一个或多个凹部,以允许在模制期间气体逸出到所述预制件的末端之外。通道呈锯齿形式。
Claims (16)
1.一种模制系统,包括模具型腔,所述模具型腔容纳有待在压力下模制的模制材料,凹部设置在所述模制材料的边缘处,以允许在压力下模制所述模制材料期间截留气体从所述模具型腔内逸出。
2.权利要求1所述的模制系统,其中,所述模制材料包括增强部分和用于将所述增强部分粘合到基底、优选金属基底上的粘合部分,所述凹部设置在所述粘合部分的边缘处,以防止截留空气在所述增强部分内或所述增强部分表面上。
3.权利要求2所述的模制系统,其中,所述凹部仅设置在所述粘合部分的边缘之外。
4.权利要求2或3所述的模制系统,其中,所述增强部分包括一层或多层纤维增强材料,所述纤维增强材料浸渍有增强树脂材料。
5.权利要求4所述的模制系统,其中,所述模制材料包括用于将所述模制材料粘合到金属层上的层。
6.前述权利要求中任一项所述的模制系统,其中,所述模制材料包括预制件,所述预制件包括在其边缘处延伸超出所述预制件末端的锯齿或波状唇缘,以允许在模制期间空气流入由所述锯齿或波状唇缘和所述型腔形成的凹部中。
7.前述权利要求中任一项所述的模制系统,其中,所述模制材料被容纳在由模具元件和金属层形成的型腔内。
8.前述权利要求中任一项所述的模制系统,其中,所述模具能够被加热,使得所述模具可以软化热塑性材料或固化热固性材料。
9.一种用于模制材料的模具,用于前述权利要求中任一项所述的系统中,所述模具包括:至少两个可朝向和背离彼此而相对于彼此移动的相应的模具元件,朝向移动在位于所述模具内形成的型腔内的模制材料上施加压力,其中在所述模具元件接触时,所述模具型腔包括凹部,所述凹部位于所述模制材料的边缘之外,以允许在模制期间气体逸出。
10.一种用于权利要求1至8所述的系统中的模制材料,用于权利要求9所述的模具中,其中,所述模制材料包括预制的热固性材料,例如预浸料,其中所述预制件成形以在其边缘处提供一个或多个通道来提供一个或多个凹部,以允许在模制期间空气逸出到所述预制件的末端之外。
11.一种预制件,包括可固化的热固性树脂,所述预制件具有锯齿状边缘或波状唇缘或波纹状边缘。
12.权利要求11所述的预制件,包括嵌入可热固化树脂的基质中的纤维材料,例如通常称为预浸料的材料。
13.权利要求11或12中任一项所述的预制件,包括预浸料和设置在所述预浸料的一个或两个表面上的粘合剂层,所述粘合剂层具有锯齿或波状唇缘或波纹状边缘。
14.权利要求13所述的预制件,其中,所述粘合剂层适于将所述预制件粘合到金属上。
15.权利要求11至14中任一项所述的预制件,其中,所述预制件包括树脂浸渍的纤维增强层、粘合剂层和金属层。
16.一种用于模制材料的模具,所述模具包括至少两个可朝向和背离彼此而相对于彼此移动的相应的模具元件,朝向移动在位于所述模具内形成的型腔内的模制材料上施加压力,其中在所述模具元件接触时,所述模具型腔包括凹部,所述凹部位于所述模制材料的边缘之外,以允许在模制期间气体逸出。
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CN105729818A (zh) * | 2014-12-24 | 2016-07-06 | 赫克赛尔控股有限责任公司 | 模制材料的改善或有关模制材料的改善 |
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