CN111421921B - 一种皮芯纤维/碳纤维热塑性复合材料及其制备方法 - Google Patents

一种皮芯纤维/碳纤维热塑性复合材料及其制备方法 Download PDF

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CN111421921B
CN111421921B CN202010156987.1A CN202010156987A CN111421921B CN 111421921 B CN111421921 B CN 111421921B CN 202010156987 A CN202010156987 A CN 202010156987A CN 111421921 B CN111421921 B CN 111421921B
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CN111421921A (zh
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许跃
刘�文
杜齐
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China National Pulp and Paper Research Institute
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Abstract

本发明涉及制浆造纸技术领域，提供了一种皮芯纤维/碳纤维热塑性复合材料及其制备方法，本发明提供的制备方法以皮芯纤维和碳纤维为原料，在制备过程中，皮芯纤维的皮层熔化，将皮芯纤维和碳纤维充分粘结，替代传统方法中的预浸料，有效提高了制备得到的皮芯纤维/碳纤维热塑性复合材料的力学性能。与传统方法相比，本发明提供的方法省去了预浸料的步骤，方法更加简单，更加环保。

Description

一种皮芯纤维/碳纤维热塑性复合材料及其制备方法
技术领域
本发明涉及制浆造纸技术领域，尤其涉及一种皮芯纤维/碳纤维热塑性复合材料及其制备方法。
背景技术
碳纤维增强树脂基复合材料(CFRP)以有机高分子材料为基体、碳纤维为增强材料，通过复合工艺制备而成。作为一种先进的复合材料，CFRP以其优异的轻质高强性能和耐疲劳、耐腐蚀、耐高温、易加工成型等特性，被广泛地用于航空航天、交通运输、结构加固工程以及休闲用品等领域。今后随着CFRP制作方法效率的提高和制作成本的下降，其市场需求将不断扩大，应用领域将不断扩宽。
依据所用基体树脂的不同，CFRP分为热固性树脂复合材料和热塑性树脂复合材料两大类，其中热塑性树脂复合材料具有更广泛的应用。热塑性树脂复合材料的树脂基体一般为聚丙烯(PP)、聚酰胺(PA)、聚碳酸酯(PC)、聚醚酰亚胺(PEI)、聚苯硫醚(PPS)和聚醚醚酮(PEEK)等。由于热塑性树脂基体的熔体粘度一般都超过100Pa·s，很难使碳纤维获得良好的浸渍，进而影响制备得到的热塑性树脂复合材料的力学性能。
发明内容
为了解决上述技术问题，本发明提供了一种皮芯纤维/碳纤维热塑性复合材料及其制备方法，本发明提供的皮芯纤维/碳纤维热塑性复合材料的弯曲强度可达250MPa，拉伸强度为可达150MPa，缺口冲击韧性可达80kJ/m2。
本发明提供了一种皮芯纤维/碳纤维热塑性复合材料的制备方法，包括以下步骤：
(1)将皮芯纤维、碳纤维、消泡剂和水混合后进行分散处理，得到浆料；所述皮芯纤维的皮层熔点为90～130℃；
(2)将所得浆料依次进行脱水成形、压榨、干燥、卷取和分切，得到模压原片；
(3)将若干模压原片叠放在一起后，依次进行模压、预热、保温保压和冷却，得到皮芯纤维/碳纤维热塑性复合材料；
所述若干模压原片的张数为1～50张。
优选的，所述步骤(1)中皮芯纤维和碳纤维的质量比为50～95:5～15；所述消泡剂的质量为浆料绝干浆质量的0.1～1.5％。
优选的，所述步骤(1)中浆料的上网浓度为0.01～0.1wt％。
优选的，所述步骤(1)中皮芯纤维为复合聚酯纤维和/或ES纤维；
所述ES纤维的皮层为聚乙烯，芯层为聚丙烯和/或聚酯。
优选的，所述步骤(1)中皮芯纤维的长度为1～20mm；碳纤维的长度为3～15mm。
优选的，所述步骤(2)得到的模压原片的定量为50～250g/m2。
优选的，所述步骤(2)干燥的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，干燥的温度为90～110℃；
当皮芯纤维为ES纤维时，干燥的温度为100～130℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，干燥的温度为100～120℃。
优选的，所述步骤(3)预热的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，预热的温度为80～100℃；
当皮芯纤维为ES纤维时，预热的温度为100～120℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，预热的温度为90～110℃。
优选的，所述步骤(3)保温保压的压力为0.5～10MPa；
所述保温保压的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，保温保压的温度为160～240℃；
当皮芯纤维为ES纤维时，保温保压的温度为120～150℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，保温保压的温度为140～180℃。
本发明还提供了上述技术方案所述制备方法制备得到的皮芯纤维/碳纤维热塑性复合材料。
有益效果
本发明提供了一种皮芯纤维/碳纤维热塑性复合材料的制备方法，本发明提供的方法以皮芯纤维为原料，并将皮芯纤维的皮层熔点控制在90～130℃范围内，使得在制备过程中，皮芯纤维的皮层熔化，将皮芯纤维和碳纤维充分粘结，替代传统方法中的预浸料，有效提高了皮芯纤维/碳纤维热塑性复合材料的力学性能。与传统方法相比，本发明提供的方法省去了预浸料的步骤，方法更加简单，更加环保。
本发明还提供了上述方法制备得到的皮芯纤维/碳纤维热塑性复合材料，本发明提供的皮芯纤维/碳纤维热塑性复合材料中皮芯纤维和碳纤维均匀分散，有效提高了皮芯纤维/碳纤维热塑性复合材料的力学性能。实施例结果表明，本发明制备得到的的皮芯纤维/碳纤维热塑性复合材料的弯曲强度可达250MPa，拉伸强度可达150MPa，缺口冲击韧性可达80kJ/m2。
具体实施方式
本发明提供了一种皮芯纤维/碳纤维热塑性复合材料的制备方法，包括以下步骤：
(1)将皮芯纤维、碳纤维、消泡剂和水混合后进行分散处理，得到浆料；所述皮芯纤维的皮层熔点为90～130℃；
(2)将所得浆料依次进行脱水成形、压榨、干燥、卷取和分切，得到模压原片；
(3)将若干模压原片叠放在一起后，依次进行模压、预热、保温保压和冷却，得到皮芯纤维/碳纤维热塑性复合材料；
所述若干模压原片的张数为1～50张。
本发明将皮芯纤维、碳纤维、消泡剂和水混合后进行分散处理，得到浆料。
在本发明中，所有原料如无特殊说明，均为市售商品。
在本发明中，所述皮芯纤维优选为复合聚酯纤维和/或ES纤维；当所述皮芯纤维优选为复合聚酯纤维和ES纤维的混合物时，本发明对混合物中复合聚酯纤维和ES纤维的质量比没有特别要求，任意比例均可。在本发明中，所述复合聚酯纤维为市售商品，优选日本帝人TJ04CN，所述复合聚酯纤维的皮层熔点优选为90～110℃；所述ES纤维的皮层为聚乙烯，芯层优选为聚丙烯和/或聚酯，所述ES纤维的皮层熔点优选为100～130℃。在本发明中，所述皮芯纤维的长度优选为1～20mm，更优选为3～18mm。
在本发明中，所述碳纤维的长度优选为3～15mm，更优选为3～10mm；所述碳纤维的品级优选为T400、T700、T800或T1000。
在本发明中，所述皮芯纤维和碳纤维的质量比优选为50～95:5～15。本发明优选将皮芯纤维和碳纤维的质量比控制在上述范围内，能够使皮芯纤维和碳纤维充分混合，有利于提高皮芯纤维/碳纤维热塑性复合材料的力学性能。
在本发明中，所述消泡剂优选为有机硅消泡剂、聚醚型消泡剂或有机硅消泡剂和聚醚型消泡剂的混合物。在本发明中，所述消泡剂的质量优选为浆料绝干浆质量的0.1～1.5％，更优选为0.5～1％。在本发明中，所述消泡剂的使用可以缓解皮芯纤维抄纸过程中的漂浮问题，继而解决纤维分散问题，本发明无需添加分散剂，即可使纤维充分分散，减少了化学品的使用，对环境友好。
本发明将皮芯纤维、碳纤维、消泡剂和水混合后进行分散处理，得到浆料。在本发明中，所述分散处理优选在水力分散机中进行，所述分散处理的时间优选为1min。在本发明中，碎浆浓度优选为3wt％～4wt％。在本发明中，所述浆料的上网浓度优选为0.01～0.1wt％。
得到浆料后，本发明将所得浆料依次进行脱水成形、压榨、干燥、卷取和分切，得到模压原片。本发明对脱水成形和压榨的具体实施方式没有特别要求，采用本领域技术人员熟知的方式即可。在本发明中，所述模压原片的定量优选为50～250g/m2。
在本发明中，所述干燥的温度优选与皮芯纤维的种类有关：当皮芯纤维优选为复合聚酯纤维时，所述干燥的温度优选为90～110℃，更优选为95～105℃。在本发明中，为避免湿纸幅在干燥过程中发生粘缸，需要对一缸干燥和二缸干燥的温度进行控制，合理调节干燥温度和干燥速率，所述一缸干燥的温度优选为90～100℃，所述二缸干燥的温度优选为100～110℃。在本发明中，当皮芯纤维优选为ES纤维时，所述干燥的温度优选为100～130℃，更优选为110～120℃，所述干燥优选包括依次进行的一缸干燥和二缸干燥，为避免粘钢，需要对一缸干燥和二缸干燥的温度进行控制，所述一缸干燥的温度优选为100～120℃，所述二缸干燥的温度优选为120～130℃。在本发明中，当皮芯纤维优选为复合聚酯纤维和ES纤维的混合物时，所述干燥的温度优选为100～120℃，所述干燥优选包括依次进行的一缸干燥和二缸干燥，所述一缸干燥的温度优选为100～110℃，所述二缸干燥的温度优选为110～120℃。在本发明中，干燥温度低了，皮芯纤维不熔化，干燥温度高了，会粘缸。
干燥完成后，本发明依次进行卷取和分切，得到模压原片。本发明优选按照成型尺寸要求进行分切。
得到模压原片后，本发明将若干模压原片叠放在一起后，依次进行模压、预热、保温保压和冷却，得到皮芯纤维/碳纤维热塑性复合材料；所述若干模压原片的张数为1～50张。
在本发明中，所述模压的压力优选为0.5～10MPa，更优选为2～6MPa。
模压完成后，本发明对模压得到的制品进行预热处理。在本发明中，所述预热的温度优选与皮芯纤维的种类有关，当皮芯纤维优选为复合聚酯纤维时，所述预热的温度优选为80～100℃，更优选为85～95℃。在本发明中，当皮芯纤维优选为ES纤维时，所述预热的温度优选为100～120℃，更优选为105～115℃。在本发明中，当皮芯纤维优选为复合聚酯纤维和ES纤维的混合物时，所述预热的温度优选为90～110℃。在本发明中，所述预热的时间与皮芯纤维的种类无关，所述预热的时间优选为5～20min，更优选为10～15min。
预热完成后，本发明对预热后的制品进行保温保压处理。在本发明中，所述保温保压的压力优选为0.5～10MPa，更优选为1～8MPa，所述保温保压的压力与皮芯纤维种类无关。在本发明中，所述保温保压的温度优选与皮芯纤维的种类有关，当皮芯纤维优选为复合聚酯纤维时，所述保温保压的温度优选为160～240℃，更优选为180～210℃；当皮芯纤维优选为ES纤维时，所述保温保压的温度优选为120～150℃，更优选为130～140℃；当皮芯纤维优选为复合聚酯纤维和ES纤维的混合物时，所述保温保压的温度优选为140～180℃，更优选为150～170℃。在本发明中，所述保温保压的时间与皮芯纤维的种类无关，所述保温保压的时间优选为10～30min，更优选为15～25min。
本发明在制备过程中皮芯纤维的皮层先熔化，将皮芯纤维和碳纤维充分粘结，可以替代传统方法中的预浸料，方法简单。
本发明还提供了上述技术方案所述制备方法制备得到的皮芯纤维/碳纤维热塑性复合材料，所述皮芯纤维/碳纤维热塑性复合材料的厚度优选为1～15mm。本发明提供的皮芯纤维/碳纤维热塑性复合材料中皮芯纤维和碳纤维能够均匀混合，有效提高了复合材料的力学性能。实施例结果表明，本发明制备得到的皮芯纤维/碳纤维热塑性复合材料的弯曲强度可达250MPa，拉伸强度为可达150MPa，缺口冲击韧性可达80kJ/m2。
下面将结合本发明中的实施例，对本发明中的技术方案进行清楚、完整地描述。
实施例1
将80kg长度为6mm的皮芯复合聚酯纤维、80kg长度为3mm的ES纤维、40kg长度为6mm的T800碳纤维、1.0kg有机硅消泡剂和水放入水力碎浆机中分散2min(转速348r/min，碎浆浓度3wt％)，得到浆料；其中ES纤维的皮层纤维为聚乙烯，ES纤维的芯层纤维为聚丙烯，复合聚酯纤维的皮层熔点为110℃，ES纤维的皮层熔点为130℃；浆料的上网浓度为0.04wt％；
将得到的浆料用斜网纸机进行脱水成形和压榨后进入干燥部，干燥部一缸、二缸温度分别为105℃和115℃，经卷取、分切，并按照成型尺寸要求裁切原片后得到定量100g/m2模压原片；
在平板热压机中将5张模压原片叠放在一起后进行模压、预热、保温保压和冷却处理，其中模压的压力为2.5MPa；预热温度为120℃，预热时间10min；保温保压的温度为170℃，保温保压的压力为3.0MPa，保温保压的时间10min，最终制得的皮芯纤维/碳纤维热塑性复合材料的厚度为7mm，弯曲强度为239.84MPa，拉伸强度为101.90MPa，缺口冲击韧性为68.25kJ/m2。
实施例2
将80kg长度为6mm的皮芯复合聚酯纤维、80kg长度为3mm的ES纤维、40kg长度为6mm的T800碳纤维、1.0kg有机硅消泡剂和水放入水力碎浆机中分散2min(转速348r/min，碎浆浓度4wt％)，得到浆料；其中ES纤维的皮层纤维为聚乙烯，ES纤维的芯层纤维为聚丙烯，复合聚酯纤维的皮层熔点为110℃，ES纤维的皮层熔点为130℃；浆料的上网浓度为0.05wt％；
将得到的浆料用斜网纸机进行脱水成形和压榨后进入干燥部，干燥部一缸、二缸温度分别为105℃和115℃，经卷取、分切，并按照成型尺寸要求裁切原片后得到定量100g/m2模压原片；
在平板热压机中将6张模压原片叠放在一起后进行模压、预热、保温保压和冷却处理，其中模压的压力为2.5MPa；预热温度为120℃，预热时间10min；保温保压的温度为180℃，保温保压的压力为3.5MPa，保温保压的时间15min，最终制得的皮芯纤维/碳纤维热塑性复合材料的厚度为7mm，弯曲强度为250.0MPa，拉伸强度为150.2MPa，缺口冲击韧性为80.3kJ/m2。
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来说，在不脱离本发明原理的前提下，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。

Claims (10)

1.一种皮芯纤维/碳纤维热塑性复合材料的制备方法，包括以下步骤：
(1)将皮芯纤维、碳纤维、消泡剂和水混合后进行分散处理，得到浆料；所述皮芯纤维的皮层熔点为90～130℃；
(2)将所得浆料依次进行脱水成形、压榨、干燥、卷取和分切，得到模压原片；
(3)将若干模压原片叠放在一起后，依次进行模压、预热、保温保压和冷却，得到皮芯纤维/碳纤维热塑性复合材料；
所述若干模压原片的张数为1～50张。
2.根据权利要求1所述的制备方法，其特征在于，所述步骤(1)中皮芯纤维和碳纤维的质量比为50～95:5～15；所述消泡剂的质量为浆料绝干浆质量的0.1～1.5％。
3.根据权利要求1所述的制备方法，其特征在于，所述步骤(1)中浆料的上网浓度为0.01～0.1wt％。
4.根据权利要求1～3任一项所述的制备方法，其特征在于，所述步骤(1)中皮芯纤维为复合聚酯纤维和/或ES纤维；
所述ES纤维的皮层为聚乙烯，芯层为聚丙烯和/或聚酯。
5.根据权利要求1～3任一项所述的制备方法，其特征在于，所述步骤(1)中皮芯纤维的长度为1～20mm；碳纤维的长度为3～15mm。
6.根据权利要求1所述的制备方法，其特征在于，所述步骤(2)得到的模压原片的定量为50～250g/m2。
7.根据权利要求1所述的制备方法，其特征在于，所述步骤(2)干燥的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，干燥的温度为90～110℃；
当皮芯纤维为ES纤维时，干燥的温度为100～130℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，干燥的温度为100～120℃。
8.根据权利要求1所述的制备方法，其特征在于，所述步骤(3)预热的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，预热的温度为80～100℃；
当皮芯纤维为ES纤维时，预热的温度为100～120℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，预热的温度为90～110℃。
9.根据权利要求1所述的制备方法，其特征在于，所述步骤(3)保温保压的压力为0.5～10MPa；
所述保温保压的温度与皮芯纤维的种类有关，
当皮芯纤维为复合聚酯纤维时，保温保压的温度为160～240℃；
当皮芯纤维为ES纤维时，保温保压的温度为120～150℃；
当皮芯纤维为复合聚酯纤维和ES纤维的混合物时，保温保压的温度为140～180℃。
10.权利要求1～9任一项所述制备方法制备得到的皮芯纤维/碳纤维热塑性复合材料。
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