CN111347733A - 一种通电熔融复合热塑性预浸织物结构及其应用 - Google Patents

一种通电熔融复合热塑性预浸织物结构及其应用 Download PDF

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CN111347733A
CN111347733A CN202010285975.9A CN202010285975A CN111347733A CN 111347733 A CN111347733 A CN 111347733A CN 202010285975 A CN202010285975 A CN 202010285975A CN 111347733 A CN111347733 A CN 111347733A
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thermoplastic
fabric structure
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fabric
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朱安平
曹伟伟
王永伟
乔琨
高学平
刘玉兰
张敏
狄成瑞
秦溶蔓
朱波
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Shandong Guangyuan New Material Technology Co ltd
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Abstract

本发明涉及碳纤维预浸织物技术领域，尤其涉及一种通电熔融复合热塑性预浸织物结构及其应用，从下向上依次包括：耐温绝缘离型层、热塑熔融膜层、自辐射热熔融混杂织物层、芯部碳纤维增强织物结构层、自辐射热熔融混杂织物层、热塑熔融膜层、耐温绝缘离型层，各相邻的结构层之间直接接触。本发明的预浸织物结构采用夹芯结构，芯部碳纤维增强织物结构层位于中心位置，其上、下表面贴合自辐射热熔融混杂织物层，自辐射热熔融混杂织物层的上、下表面贴合热塑熔融膜层，热塑熔融膜层的上、下表面贴合耐温绝缘离型层包覆。本发明利用自身辐射加热熔融热塑性树脂进行高效制备预浸织物结构，提高长丝碳纤维连续增强热塑性树脂预浸织物的生产效率。

Description

一种通电熔融复合热塑性预浸织物结构及其应用
技术领域
本发明涉及碳纤维预浸织物技术领域，尤其涉及一种通电熔融复合热塑性预浸织物结构及其应用。
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。
热塑性树脂与碳纤维复合制备的单向纤维排布或者二维平面纤维排布的热塑性预浸渍单层产品，因其较为稳定的含胶量，连续长纤维增强的织物结构，成为热塑性树脂基复合材料产品制备不可缺少的高性能中间原料。这种中间原料产品可经过任意剪裁、叠层而通过模压压制工艺制备各种不同类型的热塑性复合材料，有效提高生产效率，保证基体树脂的界面结合效果和基体树脂的稳定树脂含量。
目前，常用的可用于产业化的热塑性纤维预浸织物的浸渍方式包括乳液浸渍法、热熔浸渍法、薄膜叠层压制法、粉体热熔法等。这些方法适宜于热塑性长丝连续纤维预浸织物的高效生产，但同时也因为热塑性树脂的高粘度带来了流动性差等问题，也存在生产效率不高，熔融浸渍时间较长，界面渗透效果不佳等诸多问题。
发明内容
针对上述问题，本发明利用碳纤维自身通电可释放辐射热量的特性，设计开发了一种利用其自身辐射加热熔融热塑性树脂高效地制备热塑性预浸织物结构，可有效提高长丝碳纤维连续增强热塑性树脂预浸织物的生产效率，所需的外热能耗低，具有较高的工业化推广潜力。为实现上述目的，本发明公开如下的技术方案。
本发明的第一方面，公开一种通电熔融复合热塑性预浸织物结构，其从下向上依次包括：耐温绝缘离型层、热塑熔融膜层、自辐射热熔融混杂织物层、芯部碳纤维增强织物结构层、自辐射热熔融混杂织物层、热塑熔融膜层、耐温绝缘离型层，上述各相邻的结构层之间直接接触。即本发明的预浸织物结构采用夹芯结构，其中芯部碳纤维增强织物结构层位于芯部/中心位置，其上、下表面贴合自辐射热熔融混杂织物层，自辐射热熔融混杂织物层的上、下表面贴合热塑熔融膜层，热塑熔融膜层的上、下表面贴合耐温绝缘离型层包覆。
进一步地，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维与碳纤维混杂编织而成，且所述碳纤维丝束中混杂掺入碳纤维加捻单丝束。织物碳纤维组分丝束中混杂掺入加捻单丝细束，该单丝束可与预浸设备的电极通电辊接触后通入电流，产生辐射热，对预浸织物整体进行辐射加热，从而实现混杂织物层内的热塑纤维熔融和热塑熔融膜层的熔融。
可选地，所述自辐射热熔融混杂织物层的单束纤维中，碳纤维的重量含量在40-70％之间灵活调整。
进一步地，所述自辐射热熔融混杂织物层的单束纤维中，碳纤维包括T300、T700、T800、T1000等中的任意一种。
进一步地，所述加捻单丝束包括T300、T700中的任意一种，加捻捻度控制在5-20n/m之间。
进一步地，所述芯部碳纤维增强织物结构层为高强度碳纤维的二维编织结构，可选地，采用平纹、斜纹、缎纹或者单向排布的任意一种纤维结构类型。
可选地，所述高强度碳纤维包括T300、T700、T800、T1000等其中的任意一种或几种混杂编织而成。
进一步地，所述热塑热熔纤维包括聚乙烯、聚丙烯、聚苯乙烯、聚苯硫醚、聚醚醚酮、聚醚酮、聚对苯二甲酸乙二醇酯、聚甲醛等中的任意一种。
进一步地，所述热塑熔融膜层为热塑树脂，可选地，包括聚乙烯、聚丙烯、聚苯乙烯、聚苯硫醚、聚醚醚酮、聚醚酮、聚对苯二甲酸乙二醇酯、聚甲醛热熔胶膜或热熔网膜中的任意一种。可选地，所述热塑熔融膜层的层厚度控制在0.05-0.2mm范围内。通过设置热塑熔融膜层，可以在自辐射热熔融混杂织物层的作用下熔融后向碳纤维中渗透，从而调节预浸织物结构中整体的树脂含量，保证预浸织物结构的性能。
进一步地，所述耐温绝缘离型层为聚四氟乙烯涂布的超细玻璃纤维复合层。可选地，所述耐温绝缘离型层的厚度控制在0.1-0.4mm范围内。在本发明中，离型层用于内层复合结构的整体防护与隔离。另外，离型层也具有促进熔融树脂向预浸织物内部进行定向流动的作用以及对预浸织物整体定型的作用。
本发明的第二方面，公开所述通电熔融复合热塑性预浸织物结构在汽车领域、机械领域、航空航天领域等中的应用。
与现有技术相比，本发明具有以下有益效果：
(1)本发明通过在自辐射热熔融混杂织物层的单束纤维中掺入加捻单丝束，通电后能够进行自辐射加热，然后利用产生的热量使热塑热熔纤维熔融向碳纤维中渗透，同时该自辐射热量也可快速将热塑熔融膜层熔融，从而调整预浸织物结构中整体的树脂含量，最终通过碳纤维的自辐射加热完成整个热塑性预浸织物结构的熔融渗透，形成预浸织物整体。
(2)本发明通过自辐射热熔融混杂织物层的自辐射产生的热量熔融自身的热塑热熔纤维，是碳纤维进行第一次预浸，然后通过热塑熔融膜层作为补充和调节进行第二次预浸，保证整个预浸织物结构形成性能可靠的整体。
(3)本发明的这种预浸织物结构不采用传统的乳液浸渍法、热熔浸渍法等实现织物预浸，避免了热塑性树脂的高粘度带来的流动性差及其导致的生产效率较低等问题，只需按照顺序将各结构层铺设好后对自辐射热熔融混杂织物层的加捻单丝束通电即可完成预浸织物的制备，效率显著提高，经测试，本发明相对于热熔浸渍法制备等面积预浸织物时，效率提高幅度稳定在2.8倍以上。
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为本发明实施例中电熔融复合热塑性预浸织物结构的结构示意图。
图2为本发明实施例中自辐射热熔融混杂织物层的结构示意图。
附图中标记分别代表：1-耐温绝缘离型层、2-热塑熔融膜层、3-自辐射热熔融混杂织物层、4-芯部碳纤维增强织物结构层、5-热塑热熔纤维、6-碳纤维、7-碳纤维加捻单丝束。
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。
为了方便叙述，本发明中如果出现“上”、“下”、“左”“右”字样，仅表示与附图本身的上、下、左、右方向一致，并不对结构起限定作用,仅仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的设备或元件需要具有特定的方位，以特定的方位构造和操作，因此不能理解为对本发明的限制。
术语解释部分:本发明中的术语“安装”、“相连”、“连接”、“固定”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或为一体；可以是机械连接，也可以是电连接，可以是直接连接，也可以是通过中间媒介间接相连，可以是两个元件内部连接，或者两个元件的相互作用关系，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明的具体含义。
正如前文所述，目前的热塑性纤维预浸织物的浸渍方式因为热塑性树脂的高粘度带来了流动性差等问题，也存在生产效率不高，熔融浸渍时间较长，界面渗透效果不佳等诸多问题。因此，本发明提出了一种通电熔融复合热塑性预浸织物结构；现结合说明书附图和具体实施例对本发明进一步说明。
第一实施例
一种通电熔融复合热塑性预浸织物结构，参考图1，从下向上依次包括：耐温绝缘离型层1、热塑熔融膜层2、自辐射热熔融混杂织物层3、芯部碳纤维增强织物结构层4、自辐射热熔融混杂织物层3、热塑熔融膜层2、耐温绝缘离型层1，上述各相邻的结构层之间通过贴合的方式直接接触，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维5与碳纤维6混杂编织而成，且所述碳纤维5丝束中混杂掺入碳纤维加捻单丝束7(参考图2)。所述耐温绝缘离型层1为0.1mm厚度的聚四氟乙烯涂布的超细玻璃纤维。所述热塑熔融膜层2为0.05mm厚度的聚乙烯热熔胶膜网膜。所述自辐射热熔融混杂织物层3中的单束纤维由T300碳纤维与聚乙烯纤维混杂编织而成，纤维结构类型为平纹编织，单束纤维中T300碳纤维的重量百分数为40％。同时，所述T300碳纤维编织束内部引入捻度为5n/m的T300单丝束作为通电自辐射加热功能纤维束，该单丝束与预浸设备的电极通电辊接触后通入电流，产生辐射热，对整个预浸织物整体进行辐射加热以实现混杂织物层内的热塑纤维熔融和热塑熔融膜层熔融。所述芯部碳纤维增强织物结构层4由T300碳纤维采用平纹编织而成，芯部碳纤维增强织物结构层4的主要作用是提供整个预浸织物结构的力学支撑和力学增强功能。
第二实施例
一种通电熔融复合热塑性预浸织物结构，参考图1，从下向上依次包括：耐温绝缘离型层1、热塑熔融膜层2、自辐射热熔融混杂织物层3、芯部碳纤维增强织物结构层4、自辐射热熔融混杂织物层3、热塑熔融膜层2、耐温绝缘离型层1，上述各相邻的结构层之间通过贴合的方式直接接触，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维5与碳纤维6混杂编织而成，且所述碳纤维5丝束中混杂掺入碳纤维加捻单丝束7(参考图2)。所述耐温绝缘离型层1为0.4mm厚度的聚四氟乙烯涂布的超细玻璃纤维。所述热塑熔融膜层2为0.2mm厚度的聚甲醛热熔胶膜网膜。所述自辐射热熔融混杂织物层3中的单束纤维由T700碳纤维与聚苯硫醚纤维混杂编织而成，纤维结构类型为平纹编织，单束纤维中T700碳纤维的重量百分数为70％。同时，所述T700碳纤维编织束内部引入捻度为20n/m的T700单丝束作为通电自辐射加热功能纤维束，该单丝束与预浸设备的电极通电辊接触后通入电流，产生辐射热，对整个预浸织物整体进行辐射加热以实现混杂织物层内的热塑纤维熔融和热塑熔融膜层熔融。所述芯部碳纤维增强织物结构层4由T800碳纤维采用缎纹编织而成，芯部碳纤维增强织物结构层4的主要作用是提供整个预浸织物结构的力学支撑和力学增强功能。
第三实施例
一种通电熔融复合热塑性预浸织物结构，参考图1，从下向上依次包括：耐温绝缘离型层1、热塑熔融膜层2、自辐射热熔融混杂织物层3、芯部碳纤维增强织物结构层4、自辐射热熔融混杂织物层3、热塑熔融膜层2、耐温绝缘离型层1，上述各相邻的结构层之间通过贴合的方式直接接触，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维5与碳纤维6混杂编织而成，且所述碳纤维5丝束中混杂掺入碳纤维加捻单丝束7(参考图2)。所述耐温绝缘离型层1为0.2mm厚度的聚四氟乙烯涂布的超细玻璃纤维。所述热塑熔融膜层2为0.08mm厚度的聚丙烯热熔胶膜网膜。所述自辐射热熔融混杂织物层3中的单束纤维由T800碳纤维与聚对苯二甲酸乙二醇酯纤维混杂编织而成，纤维结构类型为平纹编织，单束纤维中T800碳纤维的重量百分数为50％。同时，所述T800碳纤维编织束内部引入捻度为12n/m的T700单丝束作为通电自辐射加热功能纤维束，该单丝束与预浸设备的电极通电辊接触后通入电流，产生辐射热，对整个预浸织物整体进行辐射加热以实现混杂织物层内的热塑纤维熔融和热塑熔融膜层熔融。所述芯部碳纤维增强织物结构层4由T800碳纤维采用缎纹编织而成，芯部碳纤维增强织物结构层4的主要作用是提供整个预浸织物结构的力学支撑和力学增强功能。
第四实施例
一种通电熔融复合热塑性预浸织物结构，参考图1，从下向上依次包括：耐温绝缘离型层1、热塑熔融膜层2、自辐射热熔融混杂织物层3、芯部碳纤维增强织物结构层4、自辐射热熔融混杂织物层3、热塑熔融膜层2、耐温绝缘离型层1，上述各相邻的结构层之间通过贴合的方式直接接触，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维5与碳纤维6混杂编织而成，且所述碳纤维5丝束中混杂掺入碳纤维加捻单丝束7(参考图2)。所述耐温绝缘离型层1为0.3mm厚度的聚四氟乙烯涂布的超细玻璃纤维。所述热塑熔融膜层2为0.1mm厚度的聚醚醚酮热熔胶膜网膜。所述自辐射热熔融混杂织物层3中的单束纤维由T1000碳纤维与聚对苯二甲酸乙二醇酯纤维混杂编织而成，纤维结构类型为缎纹编织，单束纤维中T1000碳纤维的重量百分数为65％。同时，所述T800碳纤维编织束内部引入捻度为16n/m的T300单丝束作为通电自辐射加热功能纤维束，该单丝束与预浸设备的电极通电辊接触后通入电流，产生辐射热，对整个预浸织物整体进行辐射加热以实现混杂织物层内的热塑纤维熔融和热塑熔融膜层熔融。所述芯部碳纤维增强织物结构层4由T1000碳纤维采用缎纹编织而成，芯部碳纤维增强织物结构层4的主要作用是提供整个预浸织物结构的力学支撑和力学增强功能。
经测试，制备等面积(以100m2为例)预浸织物时，相对于热熔浸渍法，本发明实施例1-4采用的时间降低幅度分别为2.83倍、2.91倍、2.86倍3.04倍，可以看出，本发明提出的预浸织物结构能够显著提高生产效率，而且由于本发明的这种预浸织物结构不需要采用传统的将织物浸渍后在进行固化的方法，而是采用自身碳纤维从内部进行加热的方式，能够显著降低能耗。
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 (10)

1.一种通电熔融复合热塑性预浸织物结构，其特征在于，从下向上依次包括：耐温绝缘离型层、热塑熔融膜层、自辐射热熔融混杂织物层、芯部碳纤维增强织物结构层、自辐射热熔融混杂织物层、热塑熔融膜层、耐温绝缘离型层，各相邻的层之间直接接触。
2.如权利要求1所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述自辐射热熔融混杂织物层的单束纤维由热塑热熔纤维与碳纤维混杂编织而成，且所述碳纤维丝束中混杂掺入碳纤维加捻单丝束。
3.如权利要求2所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述单束纤维中，碳纤维的重量含量在40-70％之间。
4.如权利要求2所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述单束纤维中的碳纤维包括T300、T700、T800、T1000中的任意一种。
5.如权利要求2所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述加捻单丝束包括T300、T700中的任意一种，优选地，加捻捻度控制在5-20n/m之间。
6.如权利要求2所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述热塑热熔纤维包括聚乙烯、聚丙烯、聚苯乙烯、聚苯硫醚、聚醚醚酮、聚醚酮、聚对苯二甲酸乙二醇酯、聚甲醛中的任意一种。
7.如权利要求1-6任一项所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述芯部碳纤维增强织物结构层为高强度碳纤维的二维编织结构，优选地，采用平纹、斜纹、缎纹或者单向排布的任意一种纤维结构类型；
优选地，所述高强度碳纤维包括T300、T700、T800、T1000其中的任意一种或几种混杂编织而成。
8.如权利要求1-6任一项所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述热塑熔融膜层为热塑树脂，可选地，包括聚乙烯、聚丙烯、聚苯乙烯、聚苯硫醚、聚醚醚酮、聚醚酮、聚对苯二甲酸乙二醇酯、聚甲醛热熔胶膜或热熔网膜中的任意一种；优选地，所述热塑熔融膜层的层厚度控制在0.05-0.2mm范围内。
9.如权利要求1-6任一项所述的通电熔融复合热塑性预浸织物结构，其特征在于，所述耐温绝缘离型层为聚四氟乙烯涂布的超细玻璃纤维复合层；优选地，所述耐温绝缘离型层的厚度控制在0.1-0.4mm范围内。
10.权利要求1-9任一项所述的通电熔融复合热塑性预浸织物结构在汽车领域、机械领域、航空航天领域中的应用。
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CN108422587A (zh) * 2018-03-27 2018-08-21 山东中恒景新碳纤维科技发展有限公司 一种辐射加热制备热塑性预浸织物的方法
CN110014667A (zh) * 2019-03-13 2019-07-16 惠州市纵胜电子材料有限公司 一种快速模压成型片材的制备方法
CN212555294U (zh) * 2020-04-13 2021-02-19 山东宽原新材料科技有限公司 一种通电熔融复合热塑性预浸织物结构

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