CN110563977A - 复合纤维布及其制备方法和复合材料 - Google Patents

复合纤维布及其制备方法和复合材料 Download PDF

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Publication number
CN110563977A
CN110563977A CN201910725554.0A CN201910725554A CN110563977A CN 110563977 A CN110563977 A CN 110563977A CN 201910725554 A CN201910725554 A CN 201910725554A CN 110563977 A CN110563977 A CN 110563977A
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China
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treatment
fiber
fiber cloth
composite
composite fiber
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朱才镇
徐中国
刘会超
陈红辉
杨敬龙
杨光
徐坚
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Shenzhen University
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Shenzhen University
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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
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    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B29C70/14—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat oriented
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  • Manufacturing & Machinery (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

本发明提供了一种复合纤维布的制备方法，其特征在于，包括如下步骤:将树脂于纤维上进行负载处理，得到纤维预浸料，其中纤维的体积分数为40％～70％，树脂基体体积分数为30％～60％；对所述纤维预浸料进行塑形处理，得到特定形状的纤维预浸料；对所述特定形状的纤维预浸料进行取向处理；将所述取向化的纤维预浸料后处理成型，得到所述复合纤维布，将多层纤维布进一步后处理可以得到复合材料。本发明所述的制备方法工艺，可以降低传统单向纤维预浸料的取向度，提高了纤维布横向和纵向的均一性，而且将多层纤维布进一步后处理得到的复合材料也更均匀且有利于复合材料成型，适合大规模推广应用。

Description

复合纤维布及其制备方法和复合材料
技术领域
本发明属于复合材料领域，具体涉及一种复合纤维布及其制备方法和复合材料。
背景技术
纤维增强复合材料是指由纤维材料和树脂基体按一定比例混合后形成的高性能复合材料。由于轻质、高比刚度、高比强度、耐高低温性能好、热膨胀系数和摩擦系数低以及良好的抗疲劳性等一系列优异的性能，纤维增强复合材料成为重要的航空航天、军事等领域中重要的战略资源材料，在轨道交通、汽车、船舶、能源等诸多领域也有非常广阔的应用前景。典型的代表为碳纤维复合材料。
然而，纤维增强复合材料的成本，尤其是制造成本非常高，同时高纤维体积分数的复合材料的成型工艺复杂，无法实现大规模工业化生产，因此极大的限制了纤维增强复合材料在各个领域的应用。
因此开发一种新的纤维增强复合材料制备方法来节约成本十分有必要。
发明内容
本发明的目的是提供一种复合纤维布及其制备方法，以解决现有复合纤维布制备成本过高的技术问题。
本发明另一目的是提供一种复合材料，以解决现有的复合材料器械强度不够，性能不够优异的技术问题。
本发明的一方面提供了一种复合纤维布的制备方法，其特征在于，包括如下步骤：
将树脂于纤维上进行负载处理，得到纤维预浸料，其中纤维的体积分数为40％～70％，树脂基体体积分数为30％～60％；
对所述纤维预浸料进行塑形处理，得到特定形状的纤维预浸料；
对所述特定形状的纤维预浸料进行取向处理；
将所述取向处理的纤维预浸料经光照处理、微波处理、超声处理、热处理、加压处理方式中的至少一种处理成型，得到所述复合纤维布。
优选地，所述纤维包括碳纤维、芳纶纤维、玻璃纤维、聚烯烃纤维、聚酰胺纤维、聚酰亚胺纤维、聚酯纤维、无机陶瓷纤维、聚苯并噁唑纤维、聚四氟乙烯纤维中的至少一种。
优选地，所述树脂基体包括聚烯烃、聚酰胺、聚芳醚酮、聚醚醚酮、聚砜、聚醚砜、聚亚苯基砜、聚醚酮酮、聚碳酸酯、聚乳酸、聚氯乙烯、聚苯硫醚、聚酯、聚酰亚胺树脂、聚酰胺、环氧树脂、酚醛树脂中的至少一种。
优选地，还包括对纤维的展宽处理。
进一步优选地，所述展宽处理后的纤维厚度≤120μm。
优选地，所述负载处理包括挤出、喷射、涂覆、吸附和浸渍中的至少一种；
优选地，所述形状处理的方式包括牵引、收卷或裁剪中的至少一种；
所述取向化处理包括机械臂处理、风力处理、液流处理、重力处理、振动处理、涡流处理中的至少一种。
优选地，所述热压成型温度为80～400℃；
优选地，所述热压成型的压强为1～200MPa；
优选地，所述热压成型的保压时间为5～600min。
优选地，所述成型的光照波长为200～800nm；
优选地，所述成型的微波波长为0.1mm～1m；
优选地，所述成型的超声频率为20-140kHz。
本发明另一方面提供了一种复合纤维布，由所述复合纤维布的制备方法制得。
优选地，所述的复合纤维布的厚度≤200μm。
本发明还一方面提供了一种复合材料，由两层以上的所述的复合纤维布叠合加工处理得到。
优选地，所述加工处理包括光照处理、微波处理、超声处理、热处理和加压处理中的至少一种。
优选地所述热压成型温度为80～400℃；
所述热压成型的压强为1～200MPa；
所述热压成型的保压时间为5～600min。
优选地，所述成型的光照波长为200～800nm。
所述成型的微波波长为0.1mm～1m。
所述成型的超声频率为20-140kHz。
与现有技术相比，本发明的制备工艺采用先负载，再塑形，然后取向化处理，通过分解步骤不仅能达到理想的材料效果即多种技术效果的结合，而且通过步骤的分解使得制备工艺门槛下降，变得更容易施行和控制，降低了反应条件和操作门槛。
本发明的复合纤维布对较短的纤维进行统一取向处理，加强短纤维的机械性能，然后对长的纤维进行随机取向处理，得到的纤维布在二维平面内的纤维分布是随机的，因此各个朝向的性质均一，不会出现局部的应力不均导致的撕裂。
与现有技术相比，本发明的复合材料由所述复合纤维布经过叠合加工处理得到，使得所述复合材料具备与叠合方向垂直的平面内的各向同性性能。由于是多层叠合，不会改变与叠合方向垂直的平面内的性能，但会增强其他方向的性能，使之各个方向的性能都很强。
附图说明
图1为本发明一实施例所述复合纤维布的拉应力测试图；
图2为本发明一实施例所述复合材料的制备流程示意图。
具体实施方式
为了使本发明要解决的技术问题、技术方案及有益效果更加清楚明白，以下结合实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
本发明实施例一方面提供了一种复合纤维布的制备方法，包括如下步骤：
S01：将树脂于纤维上进行负载处理，得到纤维预浸料，其中纤维的体积分数为40％～70％，树脂基体体积分数为30％～60％；
S02：对所述纤维预浸料进行塑形处理，得到特定形状的纤维预浸料；
S03：对所述特定形状的纤维预浸料进行取向处理；
S04：将所述取向处理的纤维预浸料经光照处理、微波处理、超声处理、热处理、加压处理方式中的至少一种处理成型，得到所述复合纤维布。
步骤S01中的基体材料采用的是树脂，掺杂改性材料是纤维，通过预先的负载处理可以使得所述树脂直接渗透入所述纤维的缝隙里面，使之交融性更好，质地更均一，直接导致所述复合纤维布的机械性能和质地的提升。
具体的步骤S01中还包括对所述纤维的展宽预处理。在负载处理之前还可以将纤维进行预处理，相比一维丝状的纤维，将纤维处理为极薄的二维形态可以极大地增加负载面积。
更具体的在步骤S01中，所述纤维的厚度≤120μm。控制展宽的厚度在一个较低值可以使得所述纤维的表面积具备一个下限，负载量可以增加。
更具体的在步骤S01中，所述纤维包括碳纤维、芳纶纤维、玻璃纤维、聚烯烃纤维、聚酰胺纤维、聚酰亚胺纤维、聚酯纤维、无机陶瓷纤维、聚苯并噁唑纤维、聚四氟乙烯纤维中的至少一种。不同的纤维掺杂可以明显的改变复合纤维布的性质。加入碳纤维可以明显降低密度，增加耐磨性能和机械性能。加入玻璃纤维可以改变电学性能，和热力学性能，如使之绝缘性更好，绝热性能更佳等。加入其它聚合物可以改善其抗腐蚀、柔韧性、刚性等性能。根据不同的应用场景可以选取不同的掺杂材料。
更具体的在步骤S01中，所述树脂基体包括聚烯烃、聚酰胺、聚芳醚酮、聚醚醚酮、聚砜、聚醚砜、聚亚苯基砜、聚醚酮酮、聚碳酸酯、聚乳酸、聚氯乙烯、聚苯硫醚、聚酯、聚酰亚胺树脂、聚酰胺、环氧树脂、酚醛树脂中的至少一种。
聚合物基体具备不同的性能同样的根据需要可以通过选取不同的基体材料。
更具体的在步骤S01中，所述负载处理包括挤出、喷射、涂覆、吸附和浸渍中的至少一种；通过这些处理手段可以使得所述聚合物能渗透入纤维的缝隙里面，也可以通过机器给予的初始速度减少界面间隙。还可以通过挤压等手段直接结合。
更具体的在步骤S02中，所述形状处理的方式包括牵引、收卷或裁剪中的至少一种；预先的形状处理可以使得所述复合纤维的前驱体形成统一的制式规格，方便进一步的加工。
具体的在步骤S03中，对较短的纤维进行统一取向处理，加强短纤维的机械性能，然后对长的纤维进行随机取向处理，得到的纤维布在二维平面内的纤维分布是随机的，因此各个朝向的性质均一，不会出现局部的应力不均导致的撕裂。
更具体的在步骤S03中，所述取向化处理包括机械臂处理、风力处理、液流处理、重力处理、振动处理、涡流处理中的至少一种。
取向化处理可以方便对所述复合纤维布进一步加工，同样的取向可以进一步的加强所述复合纤维布的机械性能和均一性。
更具体的在步骤S04中，所述热压成型温度为80～400℃更具体的在步骤S04中，所述成型的光照波长为200～800nm；更具体的在步骤S04中，所述成型的微波波长为0.1mm～1m；更具体的在步骤S04中，所述成型的超声频率为20-140kHz。。根据不同的原料、不同的配比选取参数范围。
更具体的在步骤S04中，所述热压成型的压强为1～200MPa；有些情况下需要加大压强保证融合，如无机填料和聚合物掺杂，有些时候两种聚合物掺杂仅在较低压力下即可融合。
更具体的在步骤S04中，所述热压成型的保压时间为5～600min。根据相容性优选热压成型时间，保证融合完毕。
本发明另一方面提供了一种复合纤维布，由复合纤维布的制备方法制得。通过对短纤维的统一取向使其机械性能加强，然后对长纤维和加强后的短纤维进行随机取向处理，然后制备出纤维布，所得的复合纤维布。因此所得的复合纤维布具备各向同性。机械性能均一，不会因为分布不均一导致局部应力过大而引起撕裂。因此更结实耐用。在优选实施例中所述复合纤维布的厚度≤200μm。由于本发明的复合纤维布具备很强的机械性能，因此很薄的情况下就能产生相同的技术效果，而较薄的复合纤维布具备更广阔的应用场景，因此优选此厚度范围。
本发明实施例还一方面提供了一种复合材料，由两层以上的所述的复合纤维布叠合加工处理得到。
具体的在一实施例中，所述加工处理包括光照处理、微波处理、超声处理、热处理和加压处理中的至少一种。叠合之后需要使得层与层之间融合，因此需要经过处理得到。
进一步优选实施例中，所述热压成型温度为80～400℃；所述热压成型的压强为1～200MPa；所述热压成型的保压时间为5～600min。可以根据不同需求调整参数。
进一步优选实施例中，所述成型的光照波长为200～800nm。所述成型的微波波长为0.1mm～1m。所述成型的超声频率为20-140kHz。同样的根据不同的应用场景调整参数。
如图2所示，为本发明实施例所述的复合材料由纤维片经过取向处理，成型处理得到复合纤维布，然后复合纤维布经过叠合加工处理得到复合材料。
以下结合附图和具体实施例对所述技术方案进行进一步说明。
实施例1
本实施例提供了一种复合纤维布：
由体积分数聚芳醚酮、聚醚醚酮和聚酰胺以及体积分数为60％的碳纤维组成。
本实施例的复合纤维布的制备方法如下：
按照上述体积分数将聚酰胺负载于碳纤维上得到纤维预浸料；
将纤维预浸料经过牵引、收卷和裁剪得到纤维预浸料；
对长度≤15mm的纤维预浸料进行统一取向处理，对长度＞40mm进行随机取向处理；
将所述统一取向的纤维预浸料热压成型，参数条件为热压压强是10MPa，热压温度为370℃，保压10min，得到复合纤维布。
将10层所述复合纤维布进行热压成型处理得到复合材料，热压处理温度为300℃，压强为20MPa，处理时间为100min。
对所述复合纤维布进行抗拉强度测试，性能如图1所示，其各个方向的拉伸强度约为460Mpa，具备各向同性。
实施例2
本实施例提供了一种复合纤维布：
由体积分数45％的环氧树脂、聚醚砜和聚亚苯基砜不饱和聚酯树脂以及体积分数为55％的玻璃纤维和超高分子量聚乙烯纤维组成。
本实施例的复合纤维布的制备方法如下：
按照上述体积分数将聚酰胺负载于碳纤维上得到纤维预浸料；
将纤维预浸料经过牵引、收卷和裁剪得到纤维预浸料；
对长度≤15mm的纤维预浸料进行统一取向处理，对长度＞40mm进行随机取向处理；；
将所述统一取向的纤维预浸料热压成型，参数条件为热压压强是10MPa，热压温度为170℃，保压10min，得到复合纤维布。
将3层所述复合纤维布进行热压成型处理和微波处理得到复合材料，热压处理温度为200℃，压强为10MPa，处理时间为50min；所述成型的微波波长为0.5mm。
实施例3
本实施例提供了一种复合纤维布：
由体积分数55％的醚酮酮、聚碳酸酯、聚乳酸、聚乙烯和聚丙烯以及体积分数为45％的玻璃纤维、超高分子量聚乙烯纤维和碳纤维组成。
本实施例的复合纤维布的制备方法如下：
按照上述体积分数将聚酰胺负载于碳纤维上得到纤维预浸料；
将纤维预浸料经过牵引、收卷和裁剪得到纤维预浸料；
对长度≤15mm的纤维预浸料进行统一取向处理，对长度＞40mm进行随机取向处理；将所述统一取向的纤维预浸料热压成型，参数条件为热压压强是40MPa，热压温度为1500℃，保压100min，得到复合纤维布。
将20层所述复合纤维布进行热压成型处理和超声处理得到复合材料，热压处理温度为300℃，压强为10MPa，处理时间为50min；所述超声频率为80kHz。
实施例4
本实施例提供了一种复合纤维布：
由体积分数65％的聚氯乙烯、聚苯硫醚、聚酯、聚酰亚胺树脂和聚酰胺以及体积分数为35％的碳纤维和玻璃纤维组成。。
本实施例的复合纤维布的制备方法如下：
按照上述体积分数将聚酰胺负载于碳纤维上得到纤维预浸料；
将纤维预浸料经过牵引、收卷和裁剪得到纤维预浸料；
对长度≤15mm的纤维预浸料进行统一取向处理，对长度＞40mm进行随机取向处理；
将所述统一取向的纤维预浸料热压成型，参数条件为热压压强是100MPa，热压温度为400℃，保压600min，得到复合纤维布。
将100层所述复合纤维布进行热压成型处理和光照处理得到复合材料，热压处理温度为400℃，压强为200MPa，处理时间为200min；所述光照波长为365nm。
实施例5
本实施例提供了一种复合纤维布：
由体积分数70％的聚醚酮酮、环氧树脂和聚酰胺以及体积分数为30％的聚四氟乙烯纤维组成。
本实施例的复合纤维布的制备方法如下：
按照上述体积分数将聚酰胺负载于碳纤维上得到纤维预浸料；
将纤维预浸料经过牵引、收卷和裁剪得到纤维预浸料；
对长度≤15mm的纤维预浸料进行统一取向处理，对长度＞40mm进行随机取向处理；
将所述统一取向的纤维预浸料热压成型，参数条件为热压压强是30MPa，热压温度为80℃，保压30min，得到复合纤维布。
将60层所述复合纤维布进行热压成型处理、微波处理和光照处理得到复合材料，热压处理温度为300℃，压强为5MPa，处理时间为100min；所述光照波长为650nm；所述微波波长为0.1m。

Claims (14)

1.一种复合纤维布的制备方法，其特征在于，包括如下步骤：
将树脂于纤维上进行负载处理，得到纤维预浸料，其中纤维的体积分数为40％～70％，树脂基体体积分数为30％～60％；
对所述纤维预浸料进行塑形处理，得到特定形状的纤维预浸料；
对所述特定形状的纤维预浸料进行取向处理；
将所述取向处理的纤维预浸料经光照处理、微波处理、超声处理、热处理、加压处理方式中的至少一种处理成型，得到所述复合纤维布。
2.如权利要求1所述的复合纤维布的制备方法，其特征在于：所述纤维包括碳纤维、芳纶纤维、玻璃纤维、聚烯烃纤维、聚酰胺纤维、聚酰亚胺纤维、聚酯纤维、无机陶瓷纤维、聚苯并噁唑纤维、聚四氟乙烯纤维中的至少一种。
3.如权利要求1所述的复合纤维布的制备方法，其特征在于：所述树脂基体包括聚烯烃、聚酰胺、聚芳醚酮、聚醚醚酮、聚砜、聚醚砜、聚亚苯基砜、聚醚酮酮、聚碳酸酯、聚乳酸、聚氯乙烯、聚苯硫醚、聚酯、聚酰亚胺树脂、聚酰胺、环氧树脂、酚醛树脂中的至少一种。
4.如权利要求1所述的复合纤维布的制备方法，其特征在于：
还包括对纤维的展宽处理。
5.如权利要求4所述的复合纤维布的制备方法，其特征在于：
所述展宽处理后的纤维厚度≤120μm。
6.如权利要求1所述的复合纤维布的制备方法，其特征在于：
所述负载处理包括挤出、喷射、涂覆、吸附和浸渍中的至少一种；
所述形状处理的方式包括牵引、收卷或裁剪中的至少一种；
所述取向化处理包括机械臂处理、风力处理、液流处理、重力处理、振动处理、涡流处理中的至少一种。
7.如权利要求1所述的复合纤维布的制备方法，其特征在于：
所述热压成型温度为80～400℃。
8.如权利要求1所述的复合纤维布的制备方法，其特征在于：
所述热压成型的压强为1～200MPa；
所述热压成型的保压时间为5～600min；
所述成型的光照波长为200～800nm；
所述成型的微波波长为0.1mm～1m；
所述成型的超声频率为20-140kHz。
9.一种复合纤维布，其特征在于：由权利要求1-8任一所述复合纤维布的制备方法制得。
10.如权利要求9所述的复合纤维布，其特征在于：所述复合纤维布的厚度≤200μm。
11.一种复合材料，其特征在于：由两层以上的权利要求9或10所述的复合纤维布叠合加工处理得到。
12.如权利要求11所述的复合材料，其特征在于所述加工处理包括光照处理、微波处理、超声处理、热处理和加压处理中的至少一种。
13.如权利要求12所述的复合材料，其特征在于：
所述热压成型温度为80～400℃；
所述热压成型的压强为1～200MPa；
所述热压成型的保压时间为5～600min。
14.如权利要求12所述的复合材料，其特征在于：
所述成型的光照波长为200～800nm；
所述成型的微波波长为0.1mm～1m；
所述成型的超声频率为20-140kHz。
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