CN110951217A - 一种芳纶纤维增强碳纤维树脂预浸料及其制备方法 - Google Patents

一种芳纶纤维增强碳纤维树脂预浸料及其制备方法 Download PDF

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CN110951217A
CN110951217A CN201911245174.3A CN201911245174A CN110951217A CN 110951217 A CN110951217 A CN 110951217A CN 201911245174 A CN201911245174 A CN 201911245174A CN 110951217 A CN110951217 A CN 110951217A
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胡晓智
谭波
孙兴祥
夏建明
杨小兵
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Zhejiang Baojing Carbon Material Co ltd
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Abstract

本发明涉及一种芳纶纤维增强碳纤维树脂预浸料及其制备方法。该产品主要成分为碳纤维、环氧树脂、芳纶纤维,首先以丙酮作为有机溶剂,将芳纶纤维均匀分散在环氧树脂中,再利用预浸料机将添加了芳纶纤维的环氧树脂与碳纤维结合,通过辊压成型的工艺制备芳纶纤维增强碳纤维树脂预浸料。本申请相对于普通碳纤维预浸料来说,产品层压固化后所形成的碳纤维增强树脂基复合材料(CFRP)制品的强度、模量等多项力学性能都得到了大幅度提高,同时还能够增强CFRP的结构稳定性和抗冲击性能,对改善CFRP材料层间树脂脆性大、易发生分层断裂破坏的缺点有重要意义。

Description

一种芳纶纤维增强碳纤维树脂预浸料及其制备方法
技术领域
本发明涉及碳纤维复合技术领域,具体的说,是一种芳纶纤维增强碳纤维树脂预浸料及其制备方法。
背景技术
碳纤维增强树脂基复合材料(CFRP)是以碳纤维或碳纤维织物为增强体,以热固性或热塑性树脂为基体,经过合适的成型工艺所制备的层状复合材料。其兼并了碳纤维的高强度和树脂的低比重,从而表现出了优异的综合性能,是目前世界上最先进的复合材料之一。
相同质量条件下,CFRP的强度是钢的10倍,但密度比钢要低50%,比铝低30%,因而其轻量化效果十分明显。此外,与传统的金属材料相比,CFRP复合材料还具有耐疲劳性好、热膨胀系数小、耐腐蚀性能好、可设计性强、成型性好等优点,因而被广泛应用于航空航天;导弹、隐形飞机等国防科技领域;大型客机等民用航空领域;高速轨道交通、船泊、新型汽车等民用交通领域;以及体育用品、化工机械、电力设施、纺织机械和医疗器械等日常生活及工业生产领域。
碳纤维树脂预浸料是在高温高压条件下,将环氧树脂浸渍在连续碳纤维或织物上,制成的树脂基体与碳纤维的组合物。它是由碳纤维、环氧树脂等材料组成,经过涂膜、热压、冷却、覆膜、卷曲等工艺加工而成的。碳纤维树脂预浸料是制造CFRP材料及其制件的中间材料,构成了CFRP材料的基本单元。将预浸料按照特定的设计方案堆叠层压,在对应环氧树脂固化条件下热压成型,即可制备得到CFRP材料。
碳纤维树脂预浸料质量的均匀性和稳定性,是保证CFRP材料及其制件质量和可靠性的重要环节。由于CFRP材料是经过多层预浸料通过热压工艺制备成型的,其结构内存在着脆性较大的纯环氧树脂连接层,致使CFRP结构表现出层间结合强度较低、易发生分层破坏等缺点,严重影响了整体结构的稳定性和安全性。图1展示了CFRP结构遭受冲击而发生分层破坏的照片,破坏裂纹易沿着碳纤维层间扩展,发生明显的分层破坏行为。
发明内容
本发明的目的在于克服现有技术的不足,提供一种芳纶纤维增强碳纤维树脂预浸料及其制备方法。该产品主要成分为碳纤维、环氧树脂、芳纶纤维,首先以丙酮作为有机溶剂,将芳纶纤维均匀分散在环氧树脂中,再利用预浸料机将添加了芳纶纤维的环氧树脂与碳纤维结合,通过辊压成型的工艺制备芳纶纤维增强碳纤维树脂预浸料。
本发明的目的是通过以下技术方案来实现的:
一种芳纶纤维增强碳纤维树脂预浸料,其原料组份的质量比为:
芳纶纤维:0.5~2份;
环氧树脂:100份;
碳纤维:67~400份。
碳纤维为单向碳纤维丝或碳纤维编织布;
芳纶纤维为短切纤维或浆粕,芳纶短切纤维长度为1~12mm,芳纶浆粕纤维长度为<1mm。
一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其具体工艺为:
其生产设备为普通预浸料机,经过涂膜、热压、冷却、覆膜、卷曲等工艺加工而成,无需对加工设备进行额外改造。
一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其具体步骤为:
(1)将芳纶纤维置于鼓风干燥箱中充分烘干,去除内部吸附的水分;
所述的具体烘干温度为90℃,时间为24h;
(2)将10wt%的环氧树脂A组份与等量的丙酮混合,搅拌至完全溶解;
所述的环氧树脂分为两部分:A组份为树脂部分,B组份为固化剂部分,此处仅使用A组份;
所用的丙酮按质量比1:1的比例加入到环氧树脂A组份中;
(3)将环氧树脂A组份/丙酮混合物倒入芳纶纤维中,充分搅拌均匀,使得环氧树脂充分润湿芳纶短纤维;
因丙酮具有良好的渗透性,溶解环氧树脂A组份后能够带其渗透进芳纶纤维交错的孔隙结构中,使得环氧树脂充分润湿并包裹芳纶纤维。
(4)将混合物置于鼓风干燥箱中,在90℃条件下热处理,直至丙酮完全挥发;
所述热处理具体方法为:每隔30min取出手动搅拌一次,称量并记录混合物重量,直至重量不再下降,此时丙酮完全挥发。
(5)将另外90wt%的环氧树脂A组份分多次加入上述混合物中,同时持续搅拌12h以上,直至芳纶短纤维完全分散在环氧树脂A组份中;
所述搅拌的处理时候,可通过加热降低树脂的粘度。
(6)按照比例添加环氧树脂B组份(固化剂),并利用三辊研磨机混合均化。
(7)在涂胶机上通过涂膜、热压、冷却制成芳纶短纤维复合环氧树脂膜。
(8)利用预浸料机,将预制的芳纶纤维复合环氧树脂膜结合碳纤维,经过覆膜、卷曲工艺制备得到芳纶纤维增强碳纤维树脂预浸料。
与现有技术相比,本发明的积极效果是:
本申请产品制备方法简单,无需对现有的预浸料机等生产设备进行大幅度改造,且芳纶纤维添加量少,改进成本低廉。
本申请将高强度高韧性的芳纶纤维作为增强纤维引入碳纤维树脂预浸料,在经层叠热压固化成型后,芳纶纤维将均匀分布于CFRP材料结构内部层间,通过纤维桥连作用提高层间树脂的韧性,提升CFRP材料的强度、模量和韧性等力学性能,从而有效改善CFRP材料层间树脂脆性大,结构易发生分层断裂的问题。
附图说明
图1CFRP结构碳纤维层间的破坏与分离照片;
图2CFRP材料剖面光学显微照片,a碳纤维层,b芳纶纤维增强层间环氧树脂层;
图3为普通碳纤维树脂预浸料样品与芳纶纤维增强碳纤维树脂预浸料对比照片;a普通样品对比照片,b为芳纶纤维增强碳纤维预浸料照片;
图4为未添加芳纶纤维的CFRP试样与添加芳纶纤维的CFRP试样部分力学性能对比。a为90°纤维方向力学性能测试结果,b为0°纤维方向力学性能测试结果。
具体实施方式
以下提供本发明一种芳纶纤维增强碳纤维树脂预浸料及其制备方法的具体实施方式。
实施例1
芳纶浆粕增强单向碳纤维树脂预浸料的制备。
原料:所用碳纤维为日本东丽公司(Toray)生产的12K T700工业级单向碳纤维丝,碳纤维铺展宽度为1m,纤维分布面密度为150g/m2;所用环氧树脂为精功(绍兴)复合材料有限公司生产的MT3型环氧树脂,固化温度为130℃,设计树脂分布面密度约为80g/m2;所用的芳纶纤维为美国杜邦公司(Dupont)生产的凯夫拉(Kevlar)芳纶浆粕,纤维长度≤1mm,纤维直径为≤1μm;设计预浸料各组分质量比为:芳纶纤维:1.25份;环氧树脂:100份;碳纤维:200份。
制备方法:取10wt%的环氧树脂A组份,混合等量的丙酮搅拌均匀直至树脂完全溶解,然后将溶液倒入干燥的芳纶浆粕中并搅拌均匀。将混合物置于鼓风干燥箱中,在60℃下热处理并间歇性搅拌,至混合物质量不再下降,此时丙酮完全挥发。将剩余的环氧树脂A组份分多次加入混合物中,并不断加热搅拌12h,直至芳纶纤维在环氧树脂中分散均匀。按比例混入环氧树脂B组份(固化剂),并研磨均化。
最后利用预浸料机,通过涂膜、热压、冷却、覆膜、卷曲等工艺制备得到芳纶纤维增强碳纤维树脂预浸料。
所制备的芳纶纤维增强碳纤维预浸料样品照片如图3所示。未添加芳纶纤维的碳纤维预浸料表面光亮,添加了芳纶纤维的碳纤维预浸料能在明显观察到芳纶纤维的痕迹,芳纶纤维分布均匀,且无大块团聚产生。
将以上两种预浸料,在相同条件下热压成型制备CFRP层合板试样(成型方法:模压成型;成型压力:1MPa;固化升温制度:85℃-30min,130℃-2h),并测试0°和90°力学性能,测试结果如图4所示。测试表明,芳纶纤维的加入,能够明显提升CFRP材料的各项力学性能,其中0°拉伸强度提升率达11.95%;0°压缩强度提升率达12.96%;0°弯曲强度提升率达2.69%。90°拉伸强度提升率达7.04%;90°压缩强度提升率达6.91%;90°弯曲强度提升率达17.69%。这说明,得益于芳纶纤维的层间桥连作用,大大增强CFRP材料层间树脂的强度和韧性,阻碍裂纹的产生于扩展,提升CFRP的多项力学性能,使得CFRP材料的结构稳定性和安全性大大增强。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员,在不脱离本发明构思的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围内。

Claims (7)

1.一种芳纶纤维增强碳纤维树脂预浸料,其特征在于,其原料组份的质量比为:
芳纶纤维:0.5~2份;
环氧树脂:100份;
碳纤维:67~400份。
2.如权利要求1所述的一种芳纶纤维增强碳纤维树脂预浸料,其特征在于,碳纤维为单向碳纤维丝或碳纤维编织布。
3.如权利要求1所述的一种芳纶纤维增强碳纤维树脂预浸料,其特征在于,芳纶纤维为短切纤维或浆粕,芳纶短切纤维长度为1~12mm,芳纶浆粕纤维长度为<1mm。
4.一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其特征在于,其具体步骤为:
(1)将芳纶纤维置于鼓风干燥箱中充分烘干,去除内部吸附的水分;
(2)将10wt%的环氧树脂A组份与等量的丙酮混合,搅拌至完全溶解;
所述的环氧树脂分为两部分:A组份为树脂部分,B组份为固化剂部分,此处仅使用A组份;
(3)将环氧树脂A组份/丙酮混合物倒入芳纶纤维中,充分搅拌均匀,使得环氧树脂充分润湿芳纶短纤维;
(4)将混合物置于鼓风干燥箱中,在90℃条件下热处理,直至丙酮完全挥发;
(5)将另外90wt%的环氧树脂A组份分多次加入上述混合物中,同时持续搅拌12h以上,直至芳纶短纤维完全分散在环氧树脂A组份中;
(6)按照比例添加环氧树脂B组份,并利用三辊研磨机混合均化;
(7)在涂胶机上通过涂膜、热压、冷却制成芳纶短纤维复合环氧树脂膜;
(8)利用预浸料机,将预制的芳纶纤维复合环氧树脂膜结合碳纤维,经过覆膜、卷曲工艺制备得到芳纶纤维增强碳纤维树脂预浸料。
5.如权利要求1所述的一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其特征在于,所述的原料具体烘干温度为90℃,时间为24h。
6.如权利要求1所述的一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其特征在于,所用的丙酮按质量比1:1的比例加入到环氧树脂A组份中。
7.如权利要求1所述的一种芳纶纤维增强碳纤维树脂预浸料的制备方法,其特征在于,所述热处理具体方法为:每隔30min取出手动搅拌一次,称量并记录混合物重量,直至重量不再下降,此时丙酮完全挥发。
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