CN111516319A - 一种纤维增强混杂芯材及其制备方法 - Google Patents

一种纤维增强混杂芯材及其制备方法 Download PDF

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CN111516319A
CN111516319A CN202010155574.1A CN202010155574A CN111516319A CN 111516319 A CN111516319 A CN 111516319A CN 202010155574 A CN202010155574 A CN 202010155574A CN 111516319 A CN111516319 A CN 111516319A
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fiber
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resin
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胡炜杰
纪红兵
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Guangdong University of Petrochemical Technology
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Abstract

本发明公开了一种纤维增强混杂芯材及其制备方法。其为多层结构，总层数为奇数，奇数层和偶数层相间；所述奇数层为金属层，所述偶数层为纤维增强热固性树脂。本发明的刚强/度能满足高性能要求，又具有一定延展性能，且性价比最优，同时又可利用现有的金属材料加工工艺。本发明的工艺简单、易于标准化生产、产品质量一致性较好。采用本发明技术所制成的材料可直接用于车辆蒙皮、结构件等，可应用于车辆、航空航天、机械、船舶、机器人等领域。且性能可设计，可采用焊接工艺进行连接。通过模具的型面控制，还可制备成圆管型、锥管型或曲面型。

Description

一种纤维增强混杂芯材及其制备方法
技术领域：
本发明涉及新材料技术领域，具体地说，涉及一种纤维增强混杂芯材及其制备方法。
背景技术
为响应节能、减排法规要求，材料轻量化已成为发展趋势。德国大众i3和i8系大量采用了碳纤维复合材料，但由于碳纤维成本较高，碳纤维的全球产量也很有限，约25~28万吨/年，德国宝马采用铝合金与碳纤维配合使用，生产出A、B、C柱、地板，门窗框架、发动机盖、轮毂、顶盖等汽车零部件。我国碳纤维产量约10万吨/年，我国也是全球玻璃纤维第一大生产国，约年产500~600万吨左右，玻璃纤维能够满足中低端产品大大多数要求。但玻璃钢制品存在材料脆性大、延展性不足、成型工艺复杂、后加工困难等问题，同时，玻璃钢产品缺乏韧性和延展性，机加工困难。一般地，碳纤维复合材料价格相对较高，产品脆性大，成型周期较长，加工困难，产品缺乏韧性和延展性。随着碳纤维产量的逐年提高及大丝束的成功量产，碳纤维大量应用日趋成熟。由于现阶段国产铝板或铝合金不能完全满足车辆等高强度和高模量的要求，市场上已有将金属薄板与玻璃纤维结合使用的新材料，如家电外壳等。近些年来，国内外开发出了一些多层复合材料，采用泡沫夹心或软木夹芯等等，芯材比较偏软，对材料的力学性能贡献不大，甚至有些还所有下降，严重影响到设计部门对新型轻质材料的选用。为改善新型材料的整体力学性能，开发系列将玻璃纤维或碳纤维优良特性与轻质金属特性结合起来的新材料，赋予材料一体成型的新特征，具有重要的价值，也适应市场的需求。能满足刚/强度上的高要求，又具有一定延展性或金属特征的新材料，价格空间又合理，又可利用现有的金属钣金加工方法，具有现实的工程意义。
发明内容
本发明的目的是克服现有玻璃纤维复合材料(玻璃钢)和碳纤维热固性复合材料脆性较大、延展性不足、后加工困难、不可焊接等问题，提供一种纤维增强混杂芯材及其制备方法，较好地解决了上述问题。
为了实现上述目的，本发明采用如下技术方案：
一种纤维增强混杂芯材，为多层结构，总层数为奇数，奇数层和偶数层相间；
所述奇数层为金属层，所述偶数层为纤维增强热固性树脂。
作为优选的，在上述的纤维增强混杂芯材中，所述金属层为纯铝板或铝合金板或钛或钛合金板或其它密度≤5.0g/cm3的金属薄板。
作为优选的，在上述的纤维增强混杂芯材中，所述金属层上具有均匀分布的密度为4~60个/cm2多个穿透型微小孔洞或槽孔；
作为优选的，在上述的纤维增强混杂芯材中，所述纤维为短纤维织物或毡或单向丝束片，所述短纤维织物为碳纤维或玻璃纤维或石英纤维或玄武岩纤维。
作为优选的，在上述的纤维增强混杂芯材中，所述奇数层每一层的厚度为0.01mm—5mm，所述偶数层的厚度为0.2mm—8mm。
作为优选的，在上述的纤维增强混杂芯材中，所述热固性树脂为环氧树脂或乙烯基树脂或不饱和聚酯树脂或酚醛树脂或AB组份聚氨酯树脂或氰酸酯树脂或三聚氰胺甲醛树脂或呋喃树脂或聚丁二烯树脂或有机硅树脂。
作为优选的，在上述的纤维增强混杂芯材中，所述铝合金板为锰合金铝板或镁合金铝板或铝硅合金或铝铜合金或铝锌合金或铝稀土合金。
作为优选的，在上述的纤维增强混杂芯材中，所述纤维为短纤维织物或毡或单向丝束片为0°单向连续纤维或[0°+90°]双向连续纤维编织物或[±45°]双向连续纤维编织物或多轴向编织物。
作为优选的，在上述的纤维增强混杂芯材中，所述总层数为3层，第1和3层为金属层，第2层为纤维增强热固性树脂；或者总层数为5层，第1、3和5层为金属层，第2和4层为纤维增强热固性树脂；总层数为7层，第1、3、5和7层为金属层，第2、4和6层为纤维增强热固性树脂。
上述纤维增强混杂芯材的制备方法，包括如下步骤：将浸润过热固性树脂的纤维与金属层隔层铺放并叠层轻压后，放置到模具内通过热压一体成型；或套袋抽真空注入预热的热固性树脂，纤维经过充分浸渍后，铺放在下层金属层上，再铺放上层金属薄板，经过轻压送入压机模腔，通过热压复合一体成型工艺，制备出高性能纤维增强混杂芯材。
与现有技术相比，本发明具有如下有益效果：本发明的纤维增强混杂芯材的刚强/度能满足高性能要求，又具有一定延展性能，且性价比最优，同时又可利用现有的金属材料加工工艺。本发明的工艺简单、易于标准化生产、产品质量一致性较好。采用本发明技术所制成的材料可直接用于车辆蒙皮、结构件等，可应用于车辆、航空航天、机械、船舶、机器人等领域。且性能可设计，可采用焊接工艺进行连接。通过模具的型面控制，还可制备成圆管型、锥管型或曲面型。
附图说明
图1为三层结构纤维增强混杂芯材夹层板；
图2为五层结构纤维增强混杂芯材夹层板；
图3 为三层纤维增强混杂芯材产品热压成型示意图；
图4为三层纤维增强混杂芯材产品热压成型后的产品。
其中，310—下表面金属层，320—中间复合材料芯层，330—上表面金属层，510—从下到上第1层金属板，520—从下到上第2层复合材料芯，530—从下到上第3层金属板，340—从下到上第4层复合材料芯，550—从下到上第5层金属面板，600—复合材料夹层板，610—下模，620—上模，630—复合材料夹层板产品。
具体实施方式
实施例1：
如图1所示，一种纤维增强混杂芯材，为三层结构，上、下表层（奇数层）为金属层，金属层为纯铝板，密度为2.7g/cm3，中间层（偶数层）采用连续玻璃纤维增强环氧树脂树脂基复合材料，纯铝板上均匀分布有密度为20个/cm2穿透型圆形孔洞，圆孔直径为Φ1mm。
厚度及方向设计：上、下表层金属纯铝薄板的厚度均为0.6mm，采用[0°+90°]连续玻璃纤维平纹织物做中间层，中间层的厚度为0.6mm。
铺层与热压成型：先将玻璃纤维平纹织物浸渍预热过的低粘度环氧树脂铺，铺放在带孔的铝板上，再覆盖一层铝板，经过对上层铝板的整体轻压，赶出气泡，使纤维充分浸渍，送入模腔，热压成型，固化温度140℃，保压时间40~50min，降温至室温，取件。热压成型如图3和图4所示。
磨边、包装和入库。
实施例2：
如图2所示，一种纤维增强混杂芯材，为五层结构设计，从上到下第1、3、5层为防锈铝合金板，密度为2.65g/cm3，第2和4中间层采用连续碳纤维平纹布增强环氧树脂树脂基复合材料，圆孔直径为Φ0.8mm。
厚度及方向设计：第1、3、5层的防锈铝合金板的厚度均为0.4mm，第2和4中间层采用连续碳平纹布增强复合材料，厚度各为0.6mm。采用[0°+90°]平纹编织布。
铺层与热压成型：先将玻碳纤维平纹织物浸渍预热过的低粘度环氧树脂铺，铺放在带孔的铝合金板上，再覆盖一层铝合金板，经过对上层铝合金板的整体轻压，赶出气泡，使纤维充分浸渍，送入模腔，热压成型，固化温度130℃，保压时间40~50min，降温至室温，取件。
磨边、包装和入库。
实施例3：
一种纤维增强混杂芯材，采用七层结构设计，从上到下第1、3、5、7层为钛合金板，密度为4.51g/cm3，2层、4层和6层采用展宽纱连续碳纤维布增强环氧树脂树脂基复合材料，圆孔直径为Φ1.2mm。
步骤2：厚度及方向设计：第1层、3层、5层、7层的钛合金板的厚度均为0.5mm，第2和4中间层采用展宽纱连续碳纤维布增强复合材料，厚度各为0.6mm。采用[0°+90°]平纹编织布。
铺层与热压成型：先将展宽纱连续碳纤维布浸渍预热过的低粘度环氧树脂铺，铺放在带孔的钛合金板上，再覆盖一层钛合金板，重复交替铺层，至第七层，经过对上层钛合金板的整体轻压，赶出气泡，使纤维充分浸渍，送入模腔，热压成型，固化温度150℃，保压时间40~50min，降温至室温，取件。
磨边，打磨，利用火焰或等离子进行表面活化处理，采用结构胶粘接钛合金板。

Claims (10)

1.一种纤维增强混杂芯材，其特征在于为多层结构，总层数为奇数，奇数层和偶数层相间；
所述奇数层为金属层，所述偶数层为纤维增强热固性树脂。
2.如权利要求1所述的纤维增强混杂芯材，其特征在于所述金属层为纯铝板或铝合金板或钛或钛合金板或其它密度≤5.0g/cm3的金属薄板。
3.如权利要求1所述的纤维增强混杂芯材，其特征在于所述金属层上具有均匀分布的密度为4~60个/cm2多个穿透型微小孔洞或槽孔。
4.如权利要求1所述的纤维增强混杂芯材，其特征在于所述纤维为短纤维织物或毡或单向丝束片，所述短纤维织物为碳纤维或玻璃纤维或石英纤维或玄武岩纤维。
5.如权利要求1所述的纤维增强混杂芯材，其特征在于所述奇数层每一层的厚度为0.01mm—5mm，所述偶数层的厚度为0.2mm—8mm。
6.如权利要求1所述的纤维增强混杂芯材，其特征在于所述热固性树脂为环氧树脂或乙烯基树脂或不饱和聚酯树脂或酚醛树脂或AB组份聚氨酯树脂或氰酸酯树脂或三聚氰胺甲醛树脂或呋喃树脂或聚丁二烯树脂或有机硅树脂。
7.如权利要求2所述的纤维增强混杂芯材，其特征在于所述铝合金板为锰合金铝板或镁合金铝板或铝硅合金或铝铜合金或铝锌合金或铝稀土合金。
8.如权利要求4所述的纤维增强混杂芯材，其特征在于所述纤维为短纤维织物或毡或单向丝束片为0°单向连续纤维或[0°+90°]双向连续纤维编织物或[±45°]双向连续纤维编织物或多轴向编织物。
9.如权利要求1所述的纤维增强混杂芯材，其特征在于，所述总层数为3层，第1和3层为金属层，第2层为纤维增强热固性树脂；或者总层数为5层，第1、3和5层为金属层，第2和4层为纤维增强热固性树脂；总层数为7层，第1、3、5和7层为金属层，第2、4和6层为纤维增强热固性树脂。
10.权利要求1所述纤维增强混杂芯材的制备方法，其特征在于包括如下步骤：将浸润过热固性树脂的纤维与金属层隔层铺放并叠层轻压后，放置到模具内通过热压一体成型；或套袋抽真空注入预热的热固性树脂，纤维经过充分浸渍后，铺放在下层金属层上，再铺放上层金属薄板，经过轻压送入压机模腔，通过热压复合一体成型工艺，制备出高性能纤维增强混杂芯材。
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Application publication date: 20200811