CN111331953B - 一种层内阵列熔融渗透热塑性预浸织物制备方法及其应用 - Google Patents
一种层内阵列熔融渗透热塑性预浸织物制备方法及其应用 Download PDFInfo
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Abstract
本发明属于热塑性预浸织物技术领域;尤其涉及一种层内阵列熔融渗透热塑性预浸织物制备方法及其应用。包括:按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层、阵列熔渗树脂层、中心纤维织物层、阵列熔渗树脂层、热熔树脂膜层;阵列熔渗树脂层为热塑性纤维编织的网格结构;中心纤维织物层由展纱纤维束与非展纱纤维束编织而成;采用第一温度使阵列熔渗树脂层熔融向展纱纤维束中熔渗,且第一温度不能使热熔树脂膜层熔融;然后采用第二温度使熔树脂膜层熔融向非展纱纤维束中熔渗。通过热熔阵列通路的布置完成热熔树脂膜层与阵列熔渗树脂层、阵列熔渗树脂层与混杂纤维之间的熔融复合,保证最终热塑性预浸织物的界面结合特性和其宏观的致密性。
Description
技术领域
本发明属于热塑性预浸织物技术领域;尤其涉及一种层内阵列熔融渗透热塑性预浸织物的制备方法及其应用。
背景技术
本发明背景技术中公开的信息仅仅旨在增加对本发明的总体背景的理解,而不必然被视为承认或以任何形式暗示该信息构成已经成为本领域一般技术人员所公知的现有技术。
热塑性预浸织物是采用单层织物纤维或者单向纤维进行平行排布或者正交等排布方式后,采用热塑性树脂基体对其进行复合形成的单层预浸树脂基体的复合层状原料,采用这种原料可以很好的控制树脂基体在纤维织物中的含量,保证在最终的复合材料叠层制备过程中,方便压制成型,提高生产效率,同时也可以很好的控制最终复合材料产品的树脂含量和界面的稳定结构。
目前,高性能纤维预浸织物主要以玻璃纤维、碳纤维增强的热塑性树脂基体预浸织物为重点研发产品,采用的主要复合浸渍方式有:乳液浸渍法、热熔浸渍法、粉体浸渍法、薄膜层叠法等等。其中以热熔复合工艺为主要的热塑性预浸织物的制备方法,除此之外,各种复合成型的工艺也被不断地研究开发。
发明内容
为了提高热塑性树脂的基体与纤维在微观尺度的界面结合效果,优化热塑性树脂熔体在单丝纤维之间的流动和浸润,本发明提供一种层内阵列熔融渗透热塑性预浸织物的制备方法及其应用;通过热熔阵列通路的布置完成热熔树脂膜层与阵列熔渗树脂层、阵列熔渗树脂层与混杂纤维之间的树脂熔融和纤维复合,有效保证最终热塑性预浸织物的界面结合特性和其宏观的致密性。为实现上述目的,本发明公开如下技术方案。
本发明的第一方面,公开一种层内阵列熔融渗透热塑性预浸织物的制备方法,包括如下步骤:
(1)按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层、阵列熔渗树脂层、中心纤维织物层、阵列熔渗树脂层、热熔树脂膜层;所述阵列熔渗树脂层为热塑性纤维编织的网格结构;所述中心纤维织物层为二维维编织结构,其由展纱纤维束与非展纱纤维束编织而成。
(2)采用二级梯度温度进行熔渗:首先采用第一温度使阵列熔渗树脂层熔融向所述展纱纤维束中熔渗,且第一温度不能使热熔树脂膜层熔融;完成后采用第二温度使熔树脂膜层熔融向所述非展纱纤维束中熔渗,即得。
进一步地,步骤(1)中,所述热熔树脂膜层包括但不限于:聚乙烯、聚丙烯、聚苯乙烯、聚甲醛、聚氯乙烯、聚苯硫醚、聚醚酮、聚醚醚酮、聚醚砜、聚对苯二甲酸乙二醇酯、聚酰胺等热塑性树脂的任意一种,膜层厚度可根据热熔设计要求和力学性能要求进行调节,其热熔温度在130-290℃范围内灵活设计。
进一步地,步骤(1)中,所述的阵列熔渗树脂层由热塑性纤维编织叠合而成。可选地,阵列熔渗树脂层的树脂类型包括但不限于:聚乙烯、聚丙烯、聚苯乙烯、聚甲醛、聚氯乙烯、聚苯硫醚、聚醚酮、聚醚醚酮、聚醚砜、聚对苯二甲酸乙二醇酯、聚酰胺等热塑性树脂中的任意一种。
进一步地,所述阵列熔渗树脂层的阵列结构可采用均布的网格孔结构,也可采用特定设计的网格孔结构。
进一步地,步骤(1)中,所述中心纤维织物层由混杂纤维组成或者单一纤维组成。可选地,中心纤维织物层的纤维种类包括但不限于:玻璃纤维、碳纤维、氧化铝纤维、碳化硅纤维、PBO纤维、氮化硼纤维、氮化硅纤维、玄武岩纤维等中的任意一种。
进一步地,步骤(1)中,所述中心纤维织物层中,展纱纤维束的宽度大于非展纱纤维束宽度,优选为大于1.5倍,例如2倍、2.5倍、3.5倍等。
进一步地,步骤(1)中,中心纤维织物层编织类型包括平纹、斜纹、缎纹等中的任意一种。
进一步地,步骤(2)中,所述第一温度为高于阵列熔渗树脂层熔点的温度,可选为130-150℃的低温进行热熔加工,完成阵列熔渗树脂层与展纱纤维束的结合。
进一步地,步骤(2)中,所述第二温度为高于熔树脂膜层熔点的温度,可选为150-290℃的低温进行热熔加工,完成熔树脂膜层与非展纱纤维束的结合,从而完成热熔树脂膜层、阵列熔渗树脂层与中心纤维织物层的最终熔渗加工。
进一步地,步骤(2)中,所述熔渗过程可在平板硫化设备、热塑性预浸装备的连续加热对辊装备中进行加热加压。
进一步地,步骤(2)中,所述热熔的压力控制在1-6MPa之间。
本发明的第二方面,公开所述层内阵列熔融渗透热塑性预浸织物的制备方法得到的产品在汽车、防弹产品、管道、承载零件、耐磨零件、耐腐蚀零件等中的应用。
本发明制备方法的特点是:热熔过程中,阵列熔渗树脂层的热塑性纤维和中心纤维织物层中的纤维束形成凹凸匹配的啮合结构组合,当熔渗过程开始时,通过热压驱动,热塑性纤维在高压高温下驱动下滑移进入展纱纤维束的单丝纤维之间,形成混合纤维束,在持续热熔时间下,热塑纤维热熔与展纱纤维束浸润,进而浸润其他非展纱纤维束,之后在持续热压过程中,热熔树脂膜层加热熔融,完成对非展纱纤维的二次熔渗,形成热塑性复合材料的致密性界面。
与现有技术相比,本发明取得了以下几方面的有益效果:通过复合材料的结构内部布置了一种热塑性纤维网格形成的阵列熔渗树脂层与混杂纤维织物匹配的凹凸结合结构,当复合熔渗过程开始时,配合热熔装备的高温高压驱动完成热塑纤维与混杂纤维的相对层间滑移,形成热塑纤维与混杂纤维的混杂整体结构,之后在进行熔融渗透,有效提高树脂在混杂纤维织物内的浸渍渗透效果,从而提高了热塑性树脂的基体与纤维在微观尺度的界面结合效果,优化热塑性树脂熔体在单丝纤维之间的流动和浸润,保证了最终热塑性预浸织物的界面结合特性和其宏观的致密性。
附图说明
构成本发明的一部分的说明书附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。
图1为本发明实施例中待结合层的结构示意图;图中标记代表:1-热熔树脂膜层、2-阵列熔渗树脂层、3-中心纤维织物层、4-展纱纤维束、5-非展纱纤维束。
具体实施方式
应该指出,以下详细说明都是例示性的,旨在对本发明提供进一步的说明。除非另有指明,本文使用的所有技术和科学术语具有与本发明所属技术领域的普通技术人员通常理解的相同含义。
需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图限制根据本发明的示例性实施方式。如在这里所使用的,除非上下文另外明确指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说明书中使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
正如前文所述,为了提高热塑性树脂的基体与纤维在微观尺度的界面结合效果,优化热塑性树脂熔体在单丝纤维之间的流动和浸润,本发明提出了一种层内阵列熔融渗透热塑性预浸织物的制备方法;现结合说明书附图和具体实施方式对本发明进一步说明。
第一实施例
一种层内阵列熔融渗透热塑性预浸织物的制备,包括如下步骤:
(1)参考图1,按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层1、阵列熔渗树脂层2、中心纤维织物层3、阵列熔渗树脂层2、热熔树脂膜层1。
所述热熔树脂膜层1为0.5mm厚的热熔温度为260℃的聚对苯二甲酸乙二醇酯树脂膜,其贴覆在阵列熔渗树脂层2的一个表面上(即不与阵列熔渗树脂层2接触的一个表面)。
所述阵列熔渗树脂层2为采用平纹二维方式编织的聚氯乙烯网格结构,其为每隔4mm排布直径0.8mm的网孔形成阵列结构。
所述中心纤维织物层3为0.3mm厚度的平纹二维编织结构的混杂纤维织物层,该织物层采用数量比为1:1的碳纤维与玻璃纤维的混杂纱线,其中,碳纤维纱线束的50%、玻璃纤维的50%均为展纱纤维4,其与纤维束为宽度2mm的非展纱纤维5,所述展纱纤维4宽度为非展纱纤维5的2倍。
(2)采用二级梯度温度进行熔渗:首先采用260℃的温度使阵列熔渗树脂层2熔融向所述展纱纤维束4中熔渗;完成后采用270℃的温度使熔树脂膜层1熔融向所述非展纱纤维束中熔渗,整个热熔过程平板硫化设备的连续加热对辊装备中进行加热加压,压力控制在2MPa,最终形成致密性界面的热塑性预浸织物。
第二实施例
一种层内阵列熔融渗透热塑性预浸织物的制备,包括如下步骤:
(1)参考图1,按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层1、阵列熔渗树脂层2、中心纤维织物层3、阵列熔渗树脂层2、热熔树脂膜层1。
所述热熔树脂膜层1为0.4mm厚的热熔温度为250℃的聚苯硫醚树脂膜,其贴覆在阵列熔渗树脂层2的外表面上(即不与阵列熔渗树脂层2接触的一个表面)。
所述阵列熔渗树脂层2为采用缎纹二维方式编织的聚酰胺网格结构,其为每隔5mm排布直径0.6mm的网孔形成阵列结构。
所述中心纤维织物层3为0.2mm厚度的平纹二维编织结构的混杂纤维织物层,该织物层采用数量比为1:1的碳化硅纤维与玻璃纤维的混杂纱线,其中,碳纤维纱线束的50%、玻璃纤维的50%均为展纱纤维4,其与纤维束为宽度1mm的非展纱纤维5,所述展纱纤维4宽度为非展纱纤维5的2倍。
(2)采用二级梯度温度进行熔渗:首先采用150℃的温度使阵列熔渗树脂层2熔融向所述展纱纤维束4中熔渗;完成后采用250℃的温度使熔树脂膜层1熔融向所述非展纱纤维束中熔渗,整个热熔过程平板硫化设备的连续加热对辊装备中进行加热加压,压力控制在1.5MPa,最终形成致密性界面的热塑性预浸织物。
第三实施例
一种层内阵列熔融渗透热塑性预浸织物的制备,包括如下步骤:
(1)参考图1,按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层1、阵列熔渗树脂层2、中心纤维织物层3、阵列熔渗树脂层2、热熔树脂膜层1。
所述热熔树脂膜层1为0.6mm厚的热熔温度为240℃的聚丙烯树脂膜,其贴覆在阵列熔渗树脂层2的外表面上(即不与阵列熔渗树脂层2接触的一个表面)。
所述阵列熔渗树脂层2为采用平纹二维方式编织的聚酰胺网格结构,其为每隔3mm排布直径0.8mm的网孔形成阵列结构。
所述中心纤维织物层3为0.3mm厚度的缎纹二维编织结构的混杂纤维织物层,该织物层采用数量比为4:1的碳纤维与玻璃纤维的混杂纱线,其中,碳纤维纱线束的50%、玻璃纤维的50%均为展纱纤维4,其与纤维束为宽度4mm的非展纱纤维5,所述展纱纤维4宽度为非展纱纤维5的2倍。
(2)采用二级梯度温度进行熔渗:首先采用150℃的温度使阵列熔渗树脂层2熔融向所述展纱纤维束4中熔渗;完成后采用240℃的温度使熔树脂膜层1熔融向所述非展纱纤维束中熔渗,整个热熔过程平板硫化设备的连续加热对辊装备中进行加热加压,压力控制在3MPa,最终形成致密性界面的热塑性预浸织物。
第四实施例
一种层内阵列熔融渗透热塑性预浸织物的制备,包括如下步骤:
(1)参考图1,按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层1、阵列熔渗树脂层2、中心纤维织物层3、阵列熔渗树脂层2、热熔树脂膜层1。
所述热熔树脂膜层1为0.45mm厚的热熔温度为180℃的聚氯乙烯树脂膜,其贴覆在阵列熔渗树脂层2的外表面上(即不与阵列熔渗树脂层2接触的一个表面)。
所述阵列熔渗树脂层2为采用平纹二维方式编织的聚酰胺网格结构,其为每隔5mm排布直径0.6mm的网孔形成阵列结构。
所述中心纤维织物层3为0.3mm厚度的平纹二维编织结构的混杂纤维织物层,该织物层采用数量比为3:1的碳纤维与玻璃纤维的混杂纱线,其中,碳纤维纱线束的50%、玻璃纤维的50%均为展纱纤维4,其与纤维束为宽度4mm的非展纱纤维5,所述展纱纤维4宽度为非展纱纤维5的2倍。
(2)采用二级梯度温度进行熔渗:首先采用160℃的温度使阵列熔渗树脂层2熔融向所述展纱纤维束4中熔渗;完成后采用265℃的温度使熔树脂膜层1熔融向所述非展纱纤维束中熔渗,整个热熔过程平板硫化设备的连续加热对辊装备中进行加热加压,压力控制在4MPa,最终形成致密性界面的热塑性预浸织物。
以上所述仅为本发明的优选实施例,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (17)
1.一种层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,包括如下步骤:
(1)按照从下到上的顺序依次铺设下列待结合层:热熔树脂膜层、阵列熔渗树脂层、中心纤维织物层、阵列熔渗树脂层、热熔树脂膜层;所述阵列熔渗树脂层为热塑性纤维编织的网格结构;所述中心纤维织物层为二维编织结构,其由展纱纤维束与非展纱纤维束编织而成;阵列熔渗树脂层的热塑性纤维和中心纤维织物层中的纤维束形成凹凸匹配的啮合结构组合;
(2)采用二级梯度温度进行熔渗:首先采用第一温度使阵列熔渗树脂层熔融向所述展纱纤维束中熔渗,且第一温度不能使热熔树脂膜层熔融;完成后采用第二温度使热熔树脂膜层熔融向所述非展纱纤维束中熔渗,即得。
2.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,所述热熔树脂膜层包括:聚乙烯、聚丙烯、聚苯乙烯、聚甲醛、聚氯乙烯、聚苯硫醚、聚醚酮、聚醚醚酮、聚醚砜、聚对苯二甲酸乙二醇酯、聚酰胺中的任意一种。
3.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,所述的阵列熔渗树脂层由热塑性纤维编织叠合而成。
4.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,阵列熔渗树脂层的树脂类型包括:聚乙烯、聚丙烯、聚苯乙烯、聚甲醛、聚氯乙烯、聚苯硫醚、聚醚酮、聚醚醚酮、聚醚砜、聚对苯二甲酸乙二醇酯、聚酰胺中的任意一种。
5.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,所述阵列熔渗树脂层的阵列结构采用均布的网格孔结构。
6.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,所述中心纤维织物层由混杂纤维组成或者单一纤维组成。
7.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,中心纤维织物层的纤维种类包括玻璃纤维、碳纤维、氧化铝纤维、碳化硅纤维、PBO纤维、氮化硼纤维、氮化硅纤维、玄武岩纤维中的任意一种。
8.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,所述中心纤维织物层中,展纱纤维束的宽度大于非展纱纤维束宽度。
9.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,展纱纤维束的宽度大于非展纱纤维束宽度为大于1.5倍。
10.如权利要求1所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(1)中,所述中心纤维织物层编织类型包括平纹、斜纹、缎纹中的任意一种。
11.如权利要求1-10任一项所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(2)中,所述第一温度为高于阵列熔渗树脂层熔点的温度。
12.如权利要求11所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,第一温度为130-150℃。
13.如权利要求1-10任一项所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(2)中,所述第二温度为高于热熔树脂膜层熔点的温度。
14.如权利要求13所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,第二温度为150-290℃。
15.如权利要求1-10任一项所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,步骤(2)中,所述熔渗过程在平板硫化设备、热塑性预浸装备的连续加热对辊装备中进行加热加压。
16.如权利要求15所述的层内阵列熔融渗透热塑性预浸织物制备方法,其特征在于,所述加压压力控制在1-6MPa之间。
17.权利要求1-10任一项所述层内阵列熔融渗透热塑性预浸织物制备方法得到的产品在汽车、防弹产品、管道、承载零件、耐磨零件、耐腐蚀零件中的应用。
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