CN111511532A - 用于表面制备的剥离层以及使用其的粘接方法 - Google Patents

用于表面制备的剥离层以及使用其的粘接方法 Download PDF

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Publication number
CN111511532A
CN111511532A CN201880082509.1A CN201880082509A CN111511532A CN 111511532 A CN111511532 A CN 111511532A CN 201880082509 A CN201880082509 A CN 201880082509A CN 111511532 A CN111511532 A CN 111511532A
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Prior art keywords
composite substrate
resin
removable
curing
peel ply
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Granted
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CN201880082509.1A
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CN111511532B (zh
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L·麦克亚当斯
D·K·科利
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Cytec Industries Inc
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Cytec Industries Inc
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    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
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Abstract

一种用于在胶粘剂粘接之前对复合基底进行表面制备的方法。该表面制备方法包括将含树脂的剥离层施加到复合基底上,随后共固化。该含树脂的剥离层含有嵌入在其中的不可移除的纺织品载体和可移除的织造织物。共固化后,从该复合基底上移除该剥离层,使得移除该可移除的织造织物,但是该不可移除的纺织品载体和残留树脂膜保留在该复合基底上,从而在该复合基底上产生改性的可粘接表面。可以将具有该改性表面的复合基底粘接到另一个复合基底上,由此该纺织品载体仍为最终粘接结构的组成部分。

Description

用于表面制备的剥离层以及使用其的粘接方法
附图说明
图1展示了根据本披露的一个实施例的具有施加在其上的剥离层的复合基底。
图2示出了在剥离层移除后的图1的复合基底。
图3展示了通过胶粘剂膜粘接在一起的两个基底。
图4是可结合到剥离层中的具有经编经向针织网格图案的载体织物的俯视图。
图5示出了在G1c断裂韧性测试后在放大下的断裂表面。
具体实施方式
金属和非金属基底的胶粘剂粘接是已知的应用于多种工业(包括运输、能源、汽车和航空航天)的方法。基于环氧树脂的胶粘剂被广泛地用于在基底之间形成永久粘接,尤其是在航空航天领域中,这是由于该胶粘剂具有最小化应力集中、降低结构重量、减少组装时间、降低成本并且改进耐腐蚀性的能力。胶粘剂粘接通常通过以下三种方式之一进行:(1)共固化、(2)共粘接和(3)二次粘接。
“共固化”涉及通过同时固化和粘接来接合未固化的复合零件,其中这些复合零件与胶粘剂一起固化,导致化学粘接。然而,难以将此技术应用于未固化预浸料的粘接以制造具有复杂形状的大型结构零件。未固化的复合材料(例如预浸料)是粘性的(即粘的触感),并且缺乏自支撑所需的刚性。这样,未固化的复合材料难以处理。例如,难以在具有复杂三维形状的工具上组装并且粘接未固化的复合材料。
“共粘接”包括通过胶粘剂粘接将预固化的复合零件接合到未固化的复合零件上,其中该胶粘剂和该未固化的复合零件在粘接期间被固化。预固化的复合材料通常在胶粘剂粘接之前需要附加的表面制备步骤。
“二次粘接”是通过胶粘剂粘接将预固化的复合零件接合在一起,其中只有胶粘剂被固化。这种粘接方法典型地需要在粘接表面处对每个先前固化的复合零件进行表面制备。
在航空航天工业中,典型地将复合材料结构共粘接或二次粘接,并且通常在接合之前需要对预固化的零件进行表面处理。此类表面处理可以包括喷砂处理、砂磨、剥离层施加、涂底漆、等离子体处理、激光烧蚀和本领域已知的其他方法。共粘接和二次粘接两者都需要对每个先前固化的复合零件进行表面制备,以在胶粘性粘接的结构中实现最高水平的粘接层完整性。“粘接层”是指粘接的结构之间的胶粘接头。此类表面处理通过在表面产生微粗糙度来增强粘合性。粗糙化表面允许通过在粘接表面处的机械联锁的更好的粘合性。
尽管传统的表面制备方法可以提供增强的粘合性并消除粘接的复合材料结构中的粘合失效,但它们没有赋予粘接结构额外的强度。因此,当内聚破坏是主要的失效模式时,极限粘接强度几乎完全源自胶粘剂。此外,在某些条件下,如暴露于低温,例如低于75°F(或<24℃)时,当使用常规的表面制备时,粘接的结构的断裂韧性会大大降低。
本文披露了一种粘接方法,该方法可以提供高粘接强度和高断裂韧性,并且克服上述讨论的在低温下机械性能降低的局限性。
本披露的粘接方法包括在胶粘剂粘接之前将含树脂的剥离层施加在复合基底上进行表面制备。含树脂的剥离层由其中嵌入可移除的织物和不可移除的纺织品(本文称为“载体”)的可固化树脂层构成。如在此上下文中使用的术语“嵌入”意指被固定在周围的物质中。当将含树脂的剥离层施加到复合基底上时,不可移除的织物位于可移除的织物与复合基底之间。即,不可移除的载体比可移除的织物更接近复合基底。将剥离层设计成使得其可以与复合基底(例如,预浸料叠层)共固化。在共固化后,将可移除的织物与剥离层树脂中的一些一起剥离掉,在完全固化的复合基底上留下不可移除的载体,该不可移除的载体嵌入到剩余的剥离层树脂的薄膜中。在剥离层移除后,暴露出粗糙化的可粘接表面。可以通过胶粘剂将固化的复合基底与另一个基底粘接。在胶粘剂粘接后,不可移除的载体成为粘接结构的永久部分。
如本文披露的粘接方法可以产生增强的粘接强度,其超出单独的胶粘剂可以提供的粘接强度。可以在低温下看到源自本披露的粘接方法的性能益处。众所周知,经受低温(如-67°F)的粘接的复合材料结构随着其弹性模量的增加而变成脆性且刚性的。因此,复合材料的抗裂纹扩展性随着强度和韧性的伴随降低而降低。结果是,例如,G1c断裂韧性值从5-7in-lb/in2(875-1225J/m2)的起始点降低到大约2-3in-lb/in2(350-525J/m2)。对于复合材料的许多应用,暴露于低温是不可避免的,因此,希望改进复合材料的低温特性如G1c
据信,在胶粘剂粘接层处结合不可移除的纺织品载体,通过最小化在胶粘剂粘接层外的裂纹扩展并将纺织品纤维结合到断口中产生额外的粘接强度和断裂韧性。之所以获得额外的强度和韧性,是因为当断裂通过纺织品载体扩展时需要额外的能量来破坏纤维束。
图1和图2展示了本披露的含树脂的剥离层如何用于产生可粘接表面。参考图1,首先将可固化的剥离层10层压到未固化的或可固化的复合基底20的最外表面上。可固化的剥离层10由嵌入在可固化基质树脂13中的可移除的织造织物11和不可移除的载体12构成。未固化/可固化的复合基底20由用未固化或可固化的基质树脂灌注或浸渍的增强纤维构成,该基质树脂的组成与剥离层基质树脂13的组成不同。
接下来,通过在一个或多个升高的温度下加热持续预定时间段直到复合基底完全固化来进行剥离层10和复合基底20的共固化。可以配制剥离层树脂13,使得在相同固化条件下,当复合基底20完全固化时,该剥离层树脂完全固化或仅部分固化。作为共固化的结果,剥离层树脂与复合基质树脂混杂并反应。控制剥离层基质树脂的流变学和固化动力学,以在剥离层基质树脂与复合基底的基质树脂之间获得所希望的混杂量,以最大化这些树脂的共固化,从而确保共固化后足够量的剥离层树脂保留在表面上。
共固化后,将可移除的织物11剥离掉,以产生如图2示出的粗糙的可粘接表面。在移除织物11后,不可移除的载体12和残留的剥离层树脂薄层保留在复合基底20上。更具体地,不可移除的载体12嵌入在残留树脂的膜中。剩余的具有嵌入的载体的残留树脂膜可以具有移除之前的剥离层的原始厚度的约50%至约25%的厚度。残留的树脂膜和嵌入的不可移除的载体12产生改性的可粘接表面。
剥离层10和复合基底11的共固化可以在范围从室温至375°F(191℃)的温度下在范围从0psi-80psi(0MPa-0.55MPa)的压力下持续1小时至12小时来进行。此外,可以在高压釜中或通过在其中不施加外压的非高压釜(out-of-autoclave)方法来实现共固化。
如图3示出的,具有预处理的可粘接表面(来自图2)的固化的复合基底20可以通过夹在这些基底之间的可固化的胶粘剂膜14接合到另一个复合基底30上。第二复合基底30可以是固化的复合基底,该复合基底已经经受了与对于复合基底20所述的相同的剥离层表面制备,以便形成对应的可粘接表面。然后使接合的复合基底20和30在一个或多个升高的温度下经受热处理以固化胶粘剂,产生粘接结构-这被称为二次粘接。
可替代地,第二复合基底30的可粘接表面可以通过其他已知的表面处理(包括但不限于喷砂、喷砂处理、干剥离层表面制备等)来制备。“干剥离层”是通常由尼龙、玻璃或聚酯制成的干燥织造织物(不含树脂),将其施加到复合基底的粘接表面上随后固化。固化后,移除干剥离层以暴露出有纹理的粘接表面。
在另一个实施例中,当复合基底30被接合到固化的复合基底20上时呈未固化状态。在这种情况下,在随后的加热步骤中同时固化未固化的复合基底30和可固化的胶粘剂膜14-这被称为共粘接。
在根据本文披露的方法进行复合基底20和30的共粘接或二次粘接期间,将不可移除的载体整合到最终的粘接结构中,并且因此与胶粘剂膜14的树脂熔合在一起。结果是,当向胶粘接头上施加荷载时,载体能够吸收能量并增加粘接的基底之间的粘接强度。例如,当裂纹通过胶粘剂粘接层扩展时,载体能够提供额外的强度,因为为了使裂纹通过粘接结构继续迁移,需要能量来破坏载体中的纤维。
剥离层
本披露的含树脂的剥离层具有基于该剥离层的总重量按重量计至少20%的树脂含量,这取决于被浸渍的织物的具体类型。在某些实施例中,树脂含量是在按重量计20%-80%或20%-50%的范围内。
剥离层中的可移除的织物是由多个以编织图案织造的纱线构成的织造织物。每根纱线由捻在一起的多根连续纤维长丝(或单纤维)构成。织造织物可以具有在50gsm(g/m2)至250gsm、优选70gsm至220gsm的范围内的织物重量,以及在50μm至250μm、优选100μm至200μm的范围内的厚度。织造织物的纱线可以由各种合成材料形成,包括但不限于聚酯(聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯、聚对苯二甲酸三亚甲酯、聚乳酸、及其共聚物)、聚乙烯、聚丙烯、聚酰胺(尼龙)、弹性体材料(如
Figure BDA0002547618630000051
)和高性能纤维(如聚芳酰胺(例如凯夫拉))、聚酰亚胺、聚乙烯亚胺(PEI)、聚噁唑(例如Zylon、聚苯并咪唑(PBI)、聚醚醚酮(PEEK)、及玻璃。此外,织造织物可以根据需要具有热定型外观或其他常规外观。此外,编织图案不受限制,并且可以是平纹编织、斜纹编织、方平编织、缎纹编织等。
不可移除的载体是选自织造和针织织物、以及随机布置的纤维的非织造垫或面纱的纺织品。不可移除的载体优选地是轻质的,并且通常构成剥离层的按重量计小于20%。载体可以具有在5gsm至100gsm,在一些实施例中,5gsm至25gsm的范围内的面积重量。载体可以具有在10μm至250μm,在一些实施例中,125μm至175μm的范围内的厚度。载体织物/面纱的纤维可以具有在40μm-50μm的范围内的纤维直径。此种织物/面纱的轻质性质不允许树脂完全灌注到纤维束中,从而导致可用于胶粘剂粘接的表面处的剥离层树脂浓度高。不可移除的载体的织造或针织图案优选地是开口网格(open mesh)针织图案(通过网格看见织物),流体可以容易地流过该图案。在一个实施例中,不可移除的载体织物具有经编经向针织网格图案,如在图4中示出的经编针织物经编网格图案。用于载体织物的纤维组成可以选自以上对于可移除的织造织物列出的相同合成材料。在一个实施例中,不可移除的载体是由聚酰胺(尼龙)或聚酯纤维构成的针织织物。
针织织物是由针织产生的纺织品。其特性与织造织物的区别在于其是更柔性的。针织是用于生产由一维纱线或线制成的二维织物的技术。在编织中,线总是直的,纵向地(经线)或横向地(纬线)平行递送(running)。相比之下,针织织物中的纱线遵循曲折的路径(路线),在纱线的平均路径的上方和下方对称地形成对称线圈。这些曲折线圈可以容易地在不同方向上拉伸,得到比织造织物更具弹性的针织织物。
剥离层的基质树脂由包含至少一种热固性树脂、固化剂和任选的添加剂(如填料和改性剂)的可固化树脂组合物形成。
合适的热固性树脂包括但不限于环氧树脂、酚醛树脂、苯酚、氰酸酯、双马来酰亚胺、苯并噁嗪、聚苯并噁嗪、聚苯并噁唑酮、其组合及其前体。
特别合适的是每分子具有多个环氧基团的多官能环氧树脂(或聚环氧化物)。聚环氧化物可以是饱和的、不饱和的、环状的、或非环状的、脂族的、芳族的、或杂环的聚环氧化物化合物。合适的聚环氧化物的实例包括通过在碱存在下表氯醇或表溴醇与多酚的反应制备的聚缩水甘油醚。因此,合适的多酚是例如间苯二酚、邻苯二酚、氢醌、双酚A(双(4-羟苯基)-2,2-丙烷)、双酚F(双(4-羟苯基)-甲烷)、氟4,4’-二羟基二苯甲酮、双酚Z(4,4′-亚环己基双酚)和1,5-羟基萘。作为聚缩水甘油醚的基础的其他合适的多酚是已知的酚醛清漆树脂类型的苯酚和甲醛或乙醛的缩合产物。
合适的环氧树脂的实例包括双酚A或双酚F的二缩水甘油醚,例如EPONTM 828(液体环氧树脂),由陶氏化学公司(Dow Chemical Co.)供应的D.E.R.331、D.E.R.661(固体环氧树脂S);氨基酚的三缩水甘油醚,例如来自亨斯迈先进材料公司(Huntsman AdvancedMaterials)的
Figure BDA0002547618630000061
MY 0510、MY 0500、MY 0600、MY 0610。另外的实例包括基于苯酚的酚醛清漆环氧树脂,从陶氏化学公司作为DEN 428、DEN 431、DEN 438、DEN 439、和DEN 485可商购的;从汽巴-嘉基公司(Ciba-Geigy Corp.)作为ECN 1235、ECN 1273、和ECN1299可商购的基于甲酚的酚醛清漆环氧树脂;从亨斯迈先进材料公司作为
Figure BDA0002547618630000062
71756、
Figure BDA0002547618630000063
556、和
Figure BDA0002547618630000064
756可商购的烃酚醛清漆环氧树脂。
用于剥离层树脂的合适的固化剂可以包括但不限于脂族胺和芳族胺、三氟化硼络合物、胍、双氰胺、双脲(例如2,4-甲苯双-(二甲基脲)、4,4’-亚甲基双-(苯基二甲基脲))、和二氨基-二苯砜(例如4,4’-二氨基二苯砜或4,4’-DDS)。可以使用一种或多种固化剂,并且基于树脂组合物的总重量,一种或多种固化剂的总量可以在按重量计2%至20%的范围内。
还可以将呈微粒形式(例如粉末)的无机填料添加到剥离层树脂组合物中作为流变改性组分,以控制树脂组合物的流动并防止在其中附聚。合适的无机填料包括但不限于气相二氧化硅、滑石、云母、碳酸钙、氧化铝、研磨或沉淀的白垩、石英粉、氧化锌、氧化钙、和二氧化钛。如果存在填料,则基于树脂组合物的总重量,剥离层树脂组合物中该填料的量可以是按重量计从0.5%至40%、优选按重量计1%-10%、更优选按重量计1%-5%。
可以调节剥离层树脂组合物的化学计量,使得该组合物含有的与100%的一种或多种热固性树脂反应所必需的一种或多种固化剂的量不足,并且因此,由于这种不足,在预定的固化周期结束时,将存在来自热固性树脂材料的未反应或未交联的官能团。与复合基底共固化后,热固性树脂材料含有未反应/未交联的官能团,这是本文披露的改性的可粘接表面的化学活性官能团的来源。
可替代地,配制剥离层树脂组合物,使得其在共固化期间以比复合基底的固化速率更慢的速率固化。在一个实施例中,选择用于剥离层树脂和复合基底的基质树脂的固化剂以允许不同的固化速率。在另一个实施例中,将一种或多种固化抑制剂添加到剥离层树脂中以减慢热固性树脂与固化剂之间的反应速率。因此,共固化后复合基底完全固化,而剥离层树脂仅部分固化。
在一个实施例中,以基于该树脂组合物的总重量的重量百分比计,剥离层的树脂组合物含有:45%-55%苯酚酚醛清漆环氧树脂;5%-15%含二环戊二烯的酚醛清漆环氧树脂,20%-30%双酚A的二缩水甘油醚;15%-25%氨基苯酚的三缩水甘油醚;5%-15%作为固化剂的BF3,以及1%-5%无机填料。
含树脂的剥离层可以通过以下形成:将树脂组合物涂覆到纺织品载体上以使用常规溶液或热熔涂覆方法完全浸渍纺织品,从而形成其中嵌入有载体的树脂层。然后将可移除的织物压入所得树脂层中。对于热熔涂覆,将树脂组合物(不含任何溶剂)加热以形成熔融材料。对于溶液涂覆,根据需要,还可以将一种或多种有机溶剂添加到树脂组合物中以促进组分的混合。此类溶剂的实例可包括但不限于甲基乙基酮(MEK)、丙酮、二甲基乙酰胺、以及N-甲基吡咯烷酮。
如果使用溶剂,然后将湿剥离层干燥以将挥发物含量优选地降低至按重量计小于2%。干燥可以通过在室温下空气干燥过夜,随后在140°F至170°F(或60℃至77℃)下进行烘箱干燥或通过根据需要在升高的温度下进行烘箱干燥以减少干燥时间来进行。随后,可以通过在相对侧上施用可移除的离型纸或合成膜(例如聚酯膜)来保护干燥的剥离层。在使用剥离层进行表面粘接之前,要移除这些离型纸或合成膜。
复合基底
在此上下文中,复合基底是指纤维增强的复合材料(含有用树脂组合物浸渍或灌注的增强纤维),包括预浸料或预浸料叠层(如用于制造航空航天复合材料结构的那些)。如本文使用的术语“预浸料”是指已经用可固化基质树脂浸渍的纤维材料层(例如单向的丝束或带、非织造垫、或织物层)。复合基底中的基质树脂可以处于未固化或部分固化的状态。纤维增强材料可以呈织造或非织造织物层、或单向带的形式。“单向带”是指沿相同方向对齐的增强纤维层。如本文使用的术语“预浸料叠层”是指已经以堆叠排列方式铺叠的多个预浸料层。
根据一个实施例,可以将多个未固化的预浸料层与作为最外层的可固化的含树脂的剥离层一起铺叠,随后共固化该叠层。作为实例,预浸料层的数量可以是2-100层、或10-50层。
预浸料层的铺叠可以手动或通过自动化方法如自动铺带(ATL)进行。叠层内的预浸料层可以相对于彼此以选定的取向放置。例如,预浸料叠层可以包含具有单向纤维架构的预浸料层,其中纤维以相对于叠层的最大维度(如长度)的选定的角度θ例如0°、45°、或90°定向。应进一步理解,在某些实施例中,预浸料可以具有纤维架构的任何组合,如单向对齐的纤维、多向纤维、和织造织物。
预浸料可以通过用基质树脂浸渍一层连续纤维或织造织物,产生柔韧并且粘性的材料片来制造。这经常被称为预浸过程。可以指定纤维、其定向和树脂基质的配制品的精确规格,以实现对于预浸料的预期用途的最佳性能。每平方米纤维的体积也可根据要求指定。
术语“浸渍”是指将可固化基质树脂材料引入到增强纤维中,以便用该树脂部分或完全包封纤维。用于制造预浸料的基质树脂可以采取树脂膜或液体的形式。此外,基质树脂在粘接之前处于可固化/未固化的状态。可以通过施加热和/或压力促进浸渍。
复合基底中的增强纤维可以采取短切纤维、连续纤维、长丝、丝束、束、片、层、及其组合的形式。连续纤维可以进一步采用单向(在一个方向上对齐)、多向(在不同方向上对齐)、非织造、织造、针织、缝合、缠绕、和编织构造,以及卷曲纤维垫、毡垫、和短切垫的结构的任何一种。织造纤维结构可以包含多个织造丝束,每个丝束由多根长丝(例如数千根长丝)构成。在另外的实施例中,丝束可以通过交叉丝束针法、引纬针织针法、或少量的树脂粘接剂(如热塑性树脂)保持在适当的位置。
纤维材料包括但不限于玻璃(包括电气-或E-玻璃)、碳、石墨、芳族聚酰胺、聚酰胺、高模量聚乙烯(PE)、聚酯、聚-对亚苯基-苯并噁唑(PBO)、硼、石英、玄武岩、陶瓷、及其组合。
通常,复合基底的基质树脂与剥离层的基质树脂类似。它含有一种或多种热固性树脂和固化剂作为主要组分,与以下添加剂组合:如催化剂、共聚单体、流变控制剂、增粘剂、流变改性剂、无机或有机填料、热塑性或弹性体增韧剂、稳定剂、抑制剂、颜料/染料、阻燃剂、反应性稀释剂、以及本领域技术人员众所周知的用于使树脂基质的特性在固化之前或之后改性的其他添加剂。
适用于复合基底的基质树脂的热固性树脂是以上参照剥离层树脂组合物描述的那些。用于复合基底的基质树脂的合适的环氧树脂包括芳族二胺、芳族单伯胺、氨基苯酚、多元酚、多元醇、多元羧酸的多缩水甘油基衍生物。合适的环氧树脂的实例包括双酚(如双酚A、双酚F、双酚S和双酚K)的多缩水甘油醚;以及基于甲酚和苯酚的酚醛清漆环氧树脂的聚缩水甘油醚。
用于热固性树脂的固化剂选自已知的固化剂,例如胍(包括取代的胍)、脲(包括取代的脲)、三聚氰胺树脂、胍胺衍生物、胺(包括伯胺和仲胺、脂族胺和芳族胺)、酰胺、酸酐(包括聚羧酸酐)、及其混合物。
增韧剂可以包括热塑性和弹性体聚合物,以及聚合物颗粒,如核-壳橡胶颗粒、聚酰亚胺颗粒、聚酰胺颗粒等。
无机填料可以包括气相二氧化硅石英粉、氧化铝、片状填料(如云母)、滑石或粘土(例如高岭土)。
胶粘剂
用于粘接复合基底的胶粘剂是适用于与未固化的或可固化的复合基底共固化的可固化组合物。可固化胶粘剂组合物可以包含一种或多种热固性树脂、一种或多种固化剂和/或一种或多种催化剂,以及任选地包含增韧剂、填充材料、流动控制剂、染料等。热固性树脂包括但不限于环氧树脂、不饱和聚酯树脂、双马来酰亚胺、聚酰亚胺、氰酸酯、酚醛树脂等。
可用于可固化胶粘剂组合物的环氧树脂包括每分子具有多个环氧基团的多官能环氧树脂,如对于剥离层和复合基底的基质树脂披露的那些。
固化剂可以包括例如胍(包括取代的胍)、脲(包括取代的脲)、三聚氰胺树脂、胍胺衍生物、胺(包括伯胺和仲胺、脂族胺和芳族胺)、酰胺、酸酐、及其混合物。合适的固化剂包括潜伏性基于胺的固化剂,其可以在大于160°F(71℃)、优选大于200°F、例如350°F的温度下活化。合适的潜伏性基于胺的固化剂的实例包括双氰胺(DICY)、胍胺、胍、氨基胍、及其衍生物。特别合适的潜伏性基于胺的固化剂是双氰胺(DICY)。
固化加速剂可以与潜伏性基于胺的固化剂结合使用,以促进在环氧树脂与基于胺的固化剂之间的固化反应。合适的固化促进剂可以包括烷基和芳基取代的脲(包括芳族或脂环族二甲基脲)、基于甲苯二胺或亚甲基二苯胺的双脲。双脲的实例是2,4-甲苯双(二甲基脲)。作为实例,双氰胺可以与作为固化加速剂的取代的双脲组合使用。
增韧剂可以包括热塑性或弹性聚合物、以及聚合物颗粒如核-壳橡胶颗粒。合适的热塑性聚合物包括具有或不具有反应性官能团的聚芳基砜。具有官能团的聚芳基砜的实例包括例如具有末端胺官能团的聚醚砜-聚醚醚砜(PES-PEES)共聚物。合适的弹性聚合物包括羧基封端的丁二烯腈聚合物(CTBN)和胺封端的丁二烯丙烯腈(ATBN)弹性体。
无机填料可以呈微粒形式(例如粉末、薄片),并且可以包括气相二氧化硅石英粉、氧化铝、云母、滑石和粘土(例如高岭土)。
在一个实施例中,胶粘剂是在高于200°F(93℃),例如350°F(176.7℃)的温度下可固化的基于环氧树脂的组合物。
如本文披露的使用含树脂的剥离层进行的表面制备为粘接结构提供了额外的强度和韧性,并且特别适用于改进在低温(例如低于75°F(或低于24℃))下的断裂韧性。这种表面制备方法的另一个优点是它可以促进复合基底之间强且更持久的粘接。
实例
基于表1示出的配方制备可固化剥离层树脂组合物。这些量是以重量份计。
表1
Figure BDA0002547618630000111
使用热熔方法,将树脂组合物涂覆到具有10gsm面积重量和147μm厚度的聚酯针织织物(“针织载体”)上,以形成具有嵌入的针织织物的树脂层。针织织物具有图4示出的经编针织物针织图案。涂覆后,将来自DIATEX公司的面积重量为100gsm以及厚度为147μm的织造聚酯织物(“可移除的剥离层织物”)在真空下压入同一树脂层中。然后将所得树脂浸渍的织物层用作剥离层进行表面制备。
为了对比,以相同的方式形成第二剥离层,除了仅将可移除的剥离层织物嵌入树脂层中,不使用针织载体。
将制备的剥离层材料中的每一种与10层CYCOM 977-2预浸料材料手动铺叠,以形成其中剥离层作为外层的层压体。CYCOM 977-2(从氰特工程材料公司(Cytec EngineeredMaterials)可获得)是含有用环氧基树脂浸渍的单向碳纤维的预浸料材料。通过在80psi(0.55MPa)下在350°F(176.7℃)下加热2小时来固化未固化的层压体。
固化后,用手移除每个固化的层压体上的剥离层(聚酯织物连同一些固化的树脂),以产生具有可粘接表面的固化的复合面板。对于含有针织载体的剥离层,该针织载体和剥离层树脂的部分保留在固化的复合面板上。
然后,使用基于环氧树脂的胶粘剂FM 309-1(从氰特工程材料公司可获得的)通过二次粘接将具有改性表面的固化的复合面板粘接到另一个相同的复合面板上。粘接板的固化是通过在350°F在40psi(0.28MPa)下加热两小时来进行。
通过根据ASTM D5528测量G1c断裂韧性来确定粘接制品的机械性能。结果在表2中示出。
表2
Figure BDA0002547618630000121
图5示出了在G1c断裂韧性测试后在放大下的断裂表面,并展示了针织载体如何参与内聚破坏。针织载体中的断裂的纤维线圈为复合接头提供了额外的强度,从而产生增加的G1c性能。
术语
与数量关联使用的修饰语“大约”或“约”包括所述值并且具有上下文指示的含义(例如,包括与具体数量的测量相关联的误差度)。如本文使用的后缀“(s)”旨在包括其所修饰的术语的单数和复数二者,从而包括一种或多种该术语(例如,金属(metal(s))包括一种或多种金属)。本文披露的范围是包括端值且可独立组合的(例如,“最高达约25wt%,或更特别地5wt%至20wt%”的范围),包括端点和这些范围的所有中间值。

Claims (14)

1.一种用于对复合基底进行表面制备的方法,该方法包括:
(a)提供包含用可固化基质树脂浸渍的增强纤维的复合基底;
(b)提供含树脂的剥离层,其包括可固化树脂层,在该可固化树脂层中嵌入了不可移除的纺织品载体和可移除的织造织物;
(c)使该含树脂的剥离层与该复合基底的表面接触;
(d)将该剥离层和该复合基底共固化;以及
(e)从该复合基底的该表面移除该剥离层,使得该可移除的织造织物与一些剥离层的树脂一起移除,但是该不可移除的纺织品载体和残留树脂膜保留在该复合基底上,从而在该复合基底上产生改性表面,
其中该纺织品载体呈织造织物、针织织物或非织造面纱的形式。
2.根据权利要求1所述的方法,其中,该不可移除的纺织品载体和该可移除的织造织物包含纤维或纱线,这些纤维或纱线由选自以下的材料制成:聚酯、聚乙烯、聚丙烯、聚酰胺(尼龙)、弹性体材料、聚芳酰胺、聚酰亚胺、聚乙烯亚胺(PEI)、聚噁唑、聚苯并咪唑(PBI)、聚醚醚酮(PEEK)、玻璃、及其组合。
3.根据权利要求1或2所述的方法,其中,该不可移除的纺织品载体是具有开口网格针织图案的针织织物。
4.根据权利要求3所述的方法,其中,该针织织物包括针织聚酯纱线。
5.根据前述权利要求中任一项所述的方法,其中,该不可移除的纺织品载体具有在5gsm至100gsm的范围内的面积重量。
6.根据前述权利要求中任一项所述的方法,其中,该不可移除的纺织品载体具有在10μm至250μm的范围内的厚度。
7.根据前述权利要求中任一项所述的方法,其中,该可移除的织造织物具有在50gsm至250gsm的范围内的面积重量。
8.根据前述权利要求中任一项所述的方法,其中,该可移除的织造织物具有在50μm至250μm的范围内的厚度。
9.根据前述权利要求中任一项所述的方法,其中,该剥离层的该可固化树脂层由包含以下的组合物形成:
至少一种具有至少2的环氧官能度的环氧化酚醛清漆树脂;
选自多元酚的二缩水甘油醚的双官能环氧树脂;
选自氨基酚的三缩水甘油醚的三官能环氧树脂;
固化剂;以及
无机填料颗粒,
其中该含树脂的剥离层具有基于该剥离层的总重量按重量计至少20%的树脂含量。
10.根据前述权利要求中任一项所述的方法,其中,在共固化后该复合基底完全固化,但该剥离层的树脂层仅部分固化。
11.一种粘接方法,该方法包括:
(i)提供包含用可固化基质树脂浸渍的增强纤维的第一复合基底;
(ii)使用根据权利要求1至10中任一项所述的用于进行表面制备的方法在该第一复合基底上形成改性表面;
(iii)将具有该改性表面的该第一复合基底与第二复合基底用在这些复合基底之间的可固化胶粘剂膜进行接合,所述胶粘剂膜与该第一复合基底的该改性表面接触;以及
(iv)将这些接合的复合基底固化。
12.根据权利要求11所述的粘接方法,其中,该胶粘剂膜包含一种或多种环氧树脂和固化剂。
13.根据权利要求11或12所述的粘接方法,其中,在接合到固化的第一复合基底之前,将该第二复合基底固化。
14.根据权利要求11或12所述的粘接方法,其中,在接合到该第一复合基底之前,该第二复合基底未固化或部分固化,并且在(iv)的固化期间,该胶粘剂膜和该第二复合基底同时固化。
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