CN111231456A - 一种纤维-金属混杂复合层板及其制备方法 - Google Patents

一种纤维-金属混杂复合层板及其制备方法 Download PDF

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CN111231456A
CN111231456A CN201811432899.9A CN201811432899A CN111231456A CN 111231456 A CN111231456 A CN 111231456A CN 201811432899 A CN201811432899 A CN 201811432899A CN 111231456 A CN111231456 A CN 111231456A
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composite laminate
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姚友强
祝颖丹
涂丽艳
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Ningbo Institute of Material Technology and Engineering of CAS
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Abstract

本发明公开了一种纤维‑金属混杂复合层板，它包括金属基层、树脂基复合材料层，以及位于所述金属基层与树脂基复合材料层之间的胶层；所述胶层主要由M层胶层基材和N层胶膜组成，其中M，N为整数，N≥1，N＞M≥0；本发明纤维‑金属混杂复合层板可用于汽车材料领域，可在模压成型过程中共固化成型，生产效率高；通过控制所添加纤维网格布及胶膜的层数即可控制纤维‑金属混杂层板的胶层厚度，从而优化纤维‑金属混杂复合材料的性能。

Description

一种纤维-金属混杂复合层板及其制备方法
技术领域
本发明属于复合材料结构件生产领域，更具体地涉及一种纤维-金属混杂复合层板及其制备方法。
背景技术
混杂复合材料综合了传统纤维复合材料和金属材料的特点，具有高的比刚度和比强度，优良的疲劳性能以及高的损伤容限，较金属材料可实现显著的减重效果，是航空航天及汽车结构轻量化的重要发展方向。
混杂复合材料在汽车中的应用与其在飞机中具有不同的要求，其中一个主要方面就是制造成本，汽车结构件的制造成本要比飞机低得多。因此，汽车用纤维-金属混杂复合材料结构要相对简单，包含一层金属基板，一层整体或局部增强的树脂基复合材料以及可选的中间隔层。树脂基复合材料的成型工艺是混杂复合材料制造过程的关键步骤。为了探索短时间、低能耗的固化工艺，已有多个复合材料制造商开发了快速固化的复合材料预浸料，这种快速固化预浸料可通过模压成型工艺在几分钟内热压固化。而结合模压成型与胶接工艺，在快速固化预浸料模压成型的同时实现其与金属的胶接，即共固化成型工艺，可极大程度上缩短生产周期，降低汽车结构件的生产成本。
由于预浸料成型必须要有一定的压力，胶层在固化过程中被挤出，当前共固化成型工艺技术存在胶层厚度无法控制的问题。然而，胶层厚度对金属与树脂基复合材料间的界面结合强度具有重要影响，进而影响到纤维-金属混杂复合材料性能的发挥。为此，提供一种在保持共固化成型工艺简便、生产效率高的同时实现胶层厚度可控的制备方法具有重要意义。
发明内容
本发明所要解决的技术问题是，克服以上现有技术的缺点：提供一种制备工艺简便、生产效率高、胶层厚度可控的纤维-金属混杂复合层板及其制备方法。
本发明的技术解决方案如下：一种纤维-金属混杂复合层板，它包括金属基层、树脂基复合材料层，以及位于所述金属基层与树脂基复合材料层之间的胶层。
作为优选，所述金属基层为铝合金板或合金钢板。
作为优选，所述树脂基复合材料层为单层或多层纤维预浸料层。
作为进一步优选，所述纤维预浸料层中的纤维增强体为玻璃纤维或碳纤维，基体树脂为环氧树脂。
所述胶层主要由M层胶层基材和N层胶膜组成，其中M，N为整数，N≥1，N＞M≥0。
作为优选，当M＞0时，所述胶层的组成结构为每层所述胶层基材夹在所述胶膜之间。
作为优选，N≥2，M=（N-1），所述胶层的组成结构为每层所述胶层基材夹在所述胶膜之间，由M层胶层基材和N层胶膜交替层叠而成。
作为优选，所述胶层基材为纤维网格布。
作为最优选，所述纤维网格布为尼龙纤维网格布。
本发明提供一种所述纤维-金属混杂复合层板的制备方法，包括以下步骤：
1）根据所需胶层厚度以及胶层基材、胶膜的厚度确定胶层基材层数M和胶膜层数N，其中M，N为整数，N≥1，N＞M≥0；
2）在金属基层上由底层至顶层按照一层胶膜一层胶层基材的先后铺贴顺序铺贴完所有胶层基材和胶膜，最后再铺贴树脂基复合材料层； 通过模压、加热固化制得所述纤维-金属混杂复合层板。
作为优化，胶膜的材料与所述树脂基复合材料层的树脂基材料相同。
本发明的有益效果是：本发明纤维-金属混杂复合层板可用于汽车材料领域，可在模压成型过程中共固化成型，生产效率高；选用纤维网格布作为胶层基材，使胶膜在热压成型过程中能够填充于纤维网格布的网格中，尽可能的降低了对胶层性能的影响，通过控制所添加纤维网格布及胶膜的层数即可控制纤维-金属混杂层板的胶层厚度，从而优化纤维-金属混杂复合材料的性能。同时，一定厚度的胶层可隔断碳纤维增强体与金属层之间的接触，从而避免碳纤维与金属层之间由于电位差的存在而导致的电化学腐蚀问题。本发明铺层之后放入模具中，利用模压成型工艺使胶膜与预浸料共固化即可得到胶层厚度一定的纤维-金属混杂复合层板，工艺简单高效，适合推广使用。
附图说明
图1为本发明纤维-金属混杂复合层板的结构示意图。
图中：1、上模，2、下模，3、树脂基复合材料层，4、金属基层，5、胶膜，6、胶膜基材。
具体实施方式
下面用具体实施例对本发明做进一步详细说明，但本发明不仅局限于以下具体实施例。
实施例
如图1所示，所述的纤维-金属混杂复合层板包括一层1.5mm厚的钢板，一层厚度为1.5mm左右的碳纤维复合材料，以及中间的胶层，并在胶层中引入一定层数的尼龙纤维网格布作为胶层基材。铺贴顺序为钢板-胶膜-胶层基材-胶膜-胶层基材-胶膜-碳纤维预浸料，胶层基材与胶膜交替铺层，以实现对胶层厚度的控制。铺层之后放入模具中，利用模压成型工艺使胶膜与预浸料共固化即可得到一定胶层厚度的碳纤维-钢混杂复合层板。具体制备方法如下:
a）对钢板表面进行溶剂擦洗去脂、喷砂、硅烷化处理；
去脂处理采用的有机溶剂为丙酮或异丙醇。喷砂处理采用的喷砂磨料选用石英砂料，规格（磨料平均直径大小）为0.25mm，喷砂时的空气压力分别为0.4MPa，喷砂时喷枪与构件材料表面成75度，喷枪移动速度为500mm/min，喷射距离为100mm，喷口直径5mm。硅烷化处理是经脱脂、水洗后，在浓度为3%、pH为7.5-8的硅烷溶液中浸泡10s，然后180℃高温烘干。
b）所用碳纤维预浸料可在150℃下10min固化，碳纤维为平纹织物，树脂含量43%，厚度0.25mm；所用胶膜为碳纤维预浸料基体所对应的环氧树脂胶膜；
c）在经过表面处理后的钢板表面铺上一层环氧树脂胶膜；然后将胶层基材与胶膜重复交替铺层，达到一定胶层厚度后，继续铺贴6层碳纤维预浸料；
d）将铺层好的材料置入模具中，进行模压固化成形。固化温度为150℃，压力4-5MPa，固化时间10min。冷却后脱模即得到碳纤维-钢混杂复合层板。
以上仅是本发明的特征实施范例，对本发明保护范围不构成任何限制。凡采用同等交换或者等效替换而形成的技术方案，均落在本发明权利保护范围之内。

Claims (10)

1.一种纤维-金属混杂复合层板，其特征在于：它包括金属基层、树脂基复合材料层，以及位于所述金属基层与树脂基复合材料层之间的胶层。
2.根据权利要求1所述的纤维-金属混杂复合层板，其特征在于：所述金属基层为铝合金板或合金钢板。
3.根据权利要求2所述的纤维-金属混杂复合层板，其特征在于：所述树脂基复合材料层为单层或多层纤维预浸料层。
4.根据权利要求3所述的纤维-金属混杂复合层板，其特征在于：所述纤维预浸料层中的纤维增强体为玻璃纤维或碳纤维，基体树脂为环氧树脂。
5.根据权利要求1所述的纤维-金属混杂复合层板，其特征在于：所述胶层主要由M层胶层基材和N层胶膜组成，其中M，N为整数，N≥1，N＞M≥0。
6.根据权利要求5所述的纤维-金属混杂复合层板，其特征在于：当M＞0时，所述胶层的组成结构为每层所述胶层基材夹在所述胶膜之间。
7.根据权利要求6所述的纤维-金属混杂复合层板，其特征在于：N≥2，M=（N-1），所述胶层的组成结构为每层所述胶层基材夹在所述胶膜之间，由M层胶层基材和N层胶膜交替层叠而成。
8.根据权利要求7所述的纤维-金属混杂复合层板，其特征在于：所述胶层基材为纤维网格布。
9.根据权利要求8所述的纤维-金属混杂复合层板，其特征在于：所述纤维网格布为尼龙纤维网格布。
10.一种权利要求5-9中任一项所述纤维-金属混杂复合层板的制备方法，其特征在于，包括以下步骤：
1）根据所需胶层厚度以及胶层基材、胶膜的厚度确定胶层基材层数M和胶膜层数N，其中M，N为整数，N≥1，N＞M≥0；
2）在金属基层上由底层至顶层按照一层胶膜一层胶层基材的先后铺贴顺序铺贴完所有胶层基材和胶膜，最后再铺贴树脂基复合材料层； 通过模压、加热固化制得所述纤维-金属混杂复合层板。
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CN112157966A (zh) * 2020-09-29 2021-01-01 首钢集团有限公司 一种纤维增强的金属材料复合板
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CN113561497A (zh) * 2021-06-28 2021-10-29 哈尔滨工业大学（威海） 一种表面编织的金属材料与frp复合材料一体化连接方法
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CN112537103A (zh) * 2020-04-13 2021-03-23 廊坊市飞泽复合材料科技有限公司 一种汽车覆盖件复合材料结构及其成型方法
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CN113561497A (zh) * 2021-06-28 2021-10-29 哈尔滨工业大学（威海） 一种表面编织的金属材料与frp复合材料一体化连接方法
CN113715369A (zh) * 2021-07-19 2021-11-30 航天特种材料及工艺技术研究所 一种磁性吸波胶膜与金属表面固化成型的金属基吸波材料制备方法
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