CN111621096A - 一种改性聚丙烯发泡珠粒(epp)碳纤维复合材料的制备方法 - Google Patents
一种改性聚丙烯发泡珠粒(epp)碳纤维复合材料的制备方法 Download PDFInfo
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- CN111621096A CN111621096A CN202010410783.6A CN202010410783A CN111621096A CN 111621096 A CN111621096 A CN 111621096A CN 202010410783 A CN202010410783 A CN 202010410783A CN 111621096 A CN111621096 A CN 111621096A
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- Prior art keywords
- polypropylene
- epp
- carbon fiber
- agent
- pressure
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- Chemical & Material Sciences (AREA)
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- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
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- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Composite Materials (AREA)
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Abstract
本发明涉及一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,该方法包括:1.将无规共聚聚丙烯、增粘树脂、相容剂、偶联剂、发泡泡核剂、抗氧剂及抗静电剂混合后通过双螺杆挤出机挤出、水冷切成细小圆柱颗粒,再采用间歇式釜式发泡制备改性聚丙烯发泡珠粒(EPP);2.将聚丙烯发泡珠粒(EPP)通过模塑成型设备制备成EPP制品后,采用手糊、缠绕或预成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过中温热固化成型。本发明在不影响EPP性能情况下改善了其可粘结性,提高与碳纤维预浸料固化后的剥离强度,该方法结合EPP组成的强韧泡沫层,又有碳纤维组成的刚强结构,从而拓展了更多的EPP应用。
Description
技术领域
一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,属于高分子改性加工领域。本发明通过双螺杆设备改性加工聚丙烯材料,添加极性基团和相容剂,再经间歇釜式物理发泡、模塑成型制得EPP制品,改性后的EPP材料使得难粘结的聚丙烯材料可以被环氧树脂类碳纤维预浸料粘结,且固化后剥离强度高,不产生脱层,得到EPP组成强韧泡沫层、碳纤维组成刚强结构的制品。
背景技术
聚合物泡沫材料是以聚合物为连续相,以气泡为分散相的气/固两相复合材料,分散在聚合物基体中的气泡可显著改变聚合物的形态、结构,使之具有质量轻、热导率低、隔热与隔音性能好、能量吸收能力强、比强度高等优点。聚合物发泡材料种类繁多,按基体树脂大体可分为聚氨酯软质与硬质泡沫、聚苯乙烯泡沫和聚烯烃泡沫三大类。随着对发泡技术的不断探索,发泡聚丙烯(EPP)材料以优异的性能受到广泛关注。EPP珠粒是通过对直径为0.6~1.2mm的聚丙烯(PP)细颗粒进行发泡得到的发泡珠粒,用于在成型设备的模腔内进行二次膨胀并使之相互熔接,制备形状复杂的产品。相比其他泡沫材料,EPP珠粒制品具有很多优点:1)优良的力学性能。PP刚性优于聚乙烯,抗冲击性能优于聚苯乙烯,其发泡材料的机械强度更是处于塑料发泡材料的最高等级,具有中等的抗压程度,回弹性优良。2)优良的耐热性和耐低温性。PP有较高的负荷变形温度,EPP通常能耐100~130℃的高温,高于聚苯乙烯泡沫和聚乙烯泡沫的最高使用温度。PP非晶区的玻璃化转变温度低于室温,制品在-30℃也能表现出良好的性能。3)环保材料。相比于聚苯乙烯泡沫加工过程中使用的低级烷烃化合物,利用CO2作为发泡剂制备的EPP是一种无毒无害的环境友好材料。由于PP分子链中有侧甲基,因此更易发生β降解,利于其在自然界中分解,减少白色污染。4)良好的耐化学药品腐蚀性、耐油性等。
聚烯烃属难粘材料,主要是由于其表面能较低,无官能基团,结构规整,结晶度高等因素所致。不经表面处理,聚烯烃很难被一般胶粘剂粘接,需要在EPP中共混加入改性剂,本发明是添加增粘树脂和相容剂,来增加界面粘结性。
EPP材料的一些制备及应用已经被相关专利公开:无锡会通轻质材料CN103509203A公布了以一种易结晶的聚丙烯和一种高熔点的聚丙烯为原料,配合结晶成核剂制备一种增强的聚丙烯发泡珠粒;
CN109897212A公布了以一种在EPP成品表面热熔涂覆一层改性层、冷却并且成型,形成一层类似注塑工艺效果的塑胶(或橡胶)表皮,克服传统EPP发泡产品表面易结垢、不耐磨、不耐压、耐候差,不便于二次加工的缺点。CN208324459U公布了以一种汽车用复合板,包括从上到下依次设置的第一高分子膜层、第一玻璃纤维层、第一IXPP层、EPP层、第二IXPP层、第二玻璃纤维层和第二高分子膜层,各层之间通过一次热压成型。中国石油化工股份有限公司
CN104974369A公布了以一种以宽分子量分布的高熔体强度聚丙烯为原料,以有机过氧化物为EPP珠粒的表面改性剂,制备出泡孔直径均匀、泡孔致密、孔分布均匀、闭孔结构的聚丙烯发泡珠粒,广泛用于汽车制造、包装、建筑保温、体育器材、生活用品及航空航天等领域。CN105802009A公布了以一种EPP塑料合金。
碳纤维预浸料固化后的强度可以达到钢材的6~12倍,密度只有钢材四分之一;未固化前可根据模具形状做成任何形状,成型容易,便于加工;耐腐蚀,寿命长。本发明在不影响EPP性能情况下改善了材料的可粘结性,提高了与碳纤维预浸料固化后的剥离强度,使EPP碳纤维复合材料兼顾两者优点,可以广泛应用到汽车、家具用品、体育休闲、航空航天、包装运输、军工等领域。
发明内容
本发明的目的在于提供一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,一般聚烯烃属于难粘材料,本发明通过双螺杆设备改性加工聚丙烯材料,添加极性基团和相容剂,再经间歇釜式物理发泡、模塑成型制得EPP制品,改性后的EPP材料解决了聚丙烯材料难粘结的问题,可以被环氧树脂类碳纤维预浸料很好的粘结,且固化后剥离强度高,不产生脱层,在碳纤维刚强结构的覆盖下,EPP制品硬度、强度、抗形变性、抗撕裂性、耐磨性等大幅提高。
1.为实现上述目的,发明一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法具体是首先制备改性聚丙烯发泡珠粒(EPP):将无规共聚聚丙烯60~80份,增粘树脂10~20份、相容剂10~20份、偶联剂0.1~0.5份、发泡泡核剂0.5~3份、复合抗氧剂0.3~0.9份,以及抗静电剂1~12份混合后通过双螺杆挤出机挤出、水冷切成细小圆柱颗粒后,采用间歇式釜式发泡制备改性聚丙烯发泡珠粒(EPP)。再将聚丙烯发泡珠粒(EPP)通过模塑成型设备制备成EPP制品后,采用手糊、缠绕或预成型工艺将碳纤维预浸料与EPP制品粘结到一起,通过中温热固化成型。
2.本发明所述的无规共聚聚丙烯为丙烯在无规共聚聚丙烯中的摩尔含量为55%~99%,无规共聚聚丙烯中还包括乙烯、1-丁烯、1-戊烯中的至少一种单体,其摩尔含量为1%~45%,为了便于后期模塑成型,所述无规共聚聚丙烯熔点在105℃~138℃,共聚物分子量分布Mw/Mn=3~18,熔融流动指数(190℃,2.16Kg)2~12g/10min。
3.本发明所述的增粘树脂具体包括萜烯树脂、EVA(VA值43)、改性松香138、改性松香145、C5石油树脂、C9石油树脂中的至少一种。
4.根据权利要求1所述的相容剂包括马来酸酐接枝聚丙烯(PP-g-MAH)、丙烯酸接枝聚丙烯(PP-g-AA)、甲基丙烯酸缩水甘油酯熔融接枝聚丙烯(PP-g-GMA)中的至少一种。.
5.本发明所述的偶联剂为硅烷偶联剂、钛酸酯偶联剂、铝酸酯偶联剂中的至少一种。
6.本发明所述的发泡泡核剂,其特征在于:粒径为30~100纳米的碳酸钙、滑石粉、二氧化硅、氯化钙、硫酸钙、氯化钠、硫酸钠中的至少一种。
7.本发明所述的复合抗氧剂包括主抗氧剂和辅抗氧剂,其重量配比为1~1.5:2~4,主抗氧剂包括抗氧剂1010、1098、1076中的至少一种,辅抗氧剂包括168、300、626中的至少一种。
8.本发明所述的抗静电剂属于高分子型永久抗静电剂,包括聚醚酯酰胺型(PEEA)、离子聚合物型(E-MMA-Na/Li/Zn)、季铵盐型(QASI)、接枝聚合物型(PPW-g-AAS)中的至少一种。
9.本发明所述1~8任意一项所述的一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,具体包括以下步骤:
(1)将无规共聚聚丙烯、增粘树脂、相容剂、偶联剂、发泡泡核剂、抗氧剂及抗静电剂混合后通过双螺杆挤出机(挤出温度150~190℃)挤出直径0.6~1.1mm细条,水冷切成长1~1.5mm圆柱颗粒,得到改性聚丙烯细粒。
(2)将聚丙烯细粒、分散剂、水投入到高压釜中,聚丙烯细粒与水的重量比例为1~2:2~3,分散剂为每升水中添加0.05~0.25g十二烷基苯磺酸钠和0.2~0.5g非煅烧高岭土。升温至50℃,在搅拌(800~1300转每分钟)条件下将物理发泡剂注入到高压釜中,同时将高压釜的温度升高至110~150℃,压力升高至2.0~8.0MPa,达到设定的温度和压力后,保持15~50min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为10~22MPa/s,降温速率为30~50℃/s。洗涤烘干得到发泡倍率在6~33倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.1~0.4mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽(0.3~0.6mpa)成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用手糊、缠绕或预成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过中温热固化成型,固化温度为90~110℃,时间10~25min,得到最终制品。
10.本发明9所述的方法所述物理发泡剂为二氧化碳、氮气中的一种或两种;所述碳纤维预浸料为中温固化环氧树脂类碳纤维预浸料。
具体实施方式
实施例1
(1).制备改性聚丙烯细粒:将无规共聚(1-丁烯)聚丙烯700g(熔点128℃,分子量分布Mw/Mn=13,熔融流动指数7g/10min),萜烯树脂150g、甲基丙烯酸缩水甘油酯熔融接枝聚丙烯(PP-g-GMA)140g、钛酸酯偶联剂2g、50纳米的碳酸钙发泡泡核剂10g、抗氧剂1010、168分别1g、2g,以及抗静电剂季铵盐型(QASI)80g用高速混料机混合后通过双螺杆挤出机挤出直径0.8mm细条,水冷切成长1.2mm圆柱改性聚丙烯细粒。
(2).称取600g聚丙烯细粒,将聚丙烯细粒、十二烷基苯磺酸钠0.1g、0.4g非煅烧高岭土、1000ml水投入到高压釜中。升温至50℃,在搅拌(900转每分钟)条件下将二氧化碳注入到高压釜中,同时将高压釜的温度升高至130℃,压力升高至2.5MPa,达到设定的温度和压力后,保持30min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为11MPa/s,降温速率为50℃/s。洗涤烘干得到发泡倍率在13倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.1mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽0.3mpa成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用手糊成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过热固化成型,固化温度为100℃,时间15min,得到最终制品。
实施例2
(1).制备改性聚丙烯细粒:将无规共聚(1-戊烯)聚丙烯400g(熔点135℃,分子量分布Mw/Mn=15,熔融流动指数6g/10min),EVA89g、丙烯酸接枝聚丙烯(PP-g-AA)83g、硅烷偶联剂1.2g、40纳米的二氧化硅发泡泡核剂5.9g、抗氧剂1078、626分别0.6g、1.3g,以及抗静电剂季铵盐型(QASI)47g用高速混料机混合后通过双螺杆挤出机挤出直径0.7mm细条,水冷切成长1.1mm圆柱改性聚丙烯细粒。
(2).称取350g聚丙烯细粒,将聚丙烯细粒、十二烷基苯磺酸钠0.06g、0.24g非煅烧高岭土、600ml水投入到高压釜中。升温至50℃,在搅拌(900转每分钟)条件下将二氧化碳注入到高压釜中,同时将高压釜的温度升高至140℃,压力升高至2.9MPa,达到设定的温度和压力后,保持35min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为12MPa/s,降温速率为50℃/s。洗涤烘干得到发泡倍率在15倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.2mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽0.4mpa成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用预成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过热固化成型,固化温度为100℃,时间10min,得到目标制品。
实施例3
(1).制备改性聚丙烯细粒:将无规共聚(乙烯)聚丙烯920g(熔点137℃,分子量分布Mw/Mn=15,熔融流动指数8g/10min),萜烯树脂195g、甲基丙烯酸缩水甘油酯熔融接枝聚丙烯(PP-g-GMA)182g、钛酸酯偶联剂2.6g、50纳米的碳酸钙发泡泡核剂8g、80纳米硫酸钙5g、抗氧剂1098、300分别1.5g、2.7g,以及抗静电剂季铵盐型(QASI)106g用高速混料机混合后通过双螺杆挤出机挤出直径0.9mm细条,水冷切成长1.5mm圆柱改性聚丙烯细粒。
(2).称取760g聚丙烯细粒,将聚丙烯细粒、十二烷基苯磺酸钠0.15g、0.55g非煅烧高岭土、1300ml水投入到高压釜中。升温至50℃,在搅拌(1000转每分钟)条件下将二氧化碳注入到高压釜中,同时将高压釜的温度升高至130℃,压力升高至1.5MPa,再通入氮气压力达到3.5MPa,温度保持130℃,保持30min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为17MPa/s,降温速率为40℃/s。洗涤烘干得到发泡倍率在19倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.3mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽0.4mpa成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用缠绕成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过热固化成型,固化温度为100℃,时间15min,得到目标制品。
实施例4
(1).制备改性聚丙烯细粒:将无规共聚(1-丁烯、乙烯)聚丙烯1600g(熔点118℃,分子量分布Mw/Mn=16,熔融流动指数10g/10min),100g改性松香145、C5石油树脂252g、马来酸酐接枝聚丙烯(PP-g-MAH)122g、甲基丙烯酸缩水甘油酯熔融接枝聚丙烯(PP-g-GMA)200g、铝酸酯偶联剂4.8g、50纳米的氯化钙13g、100纳米碳酸钙13g、抗氧剂1010、168分别2.5g、6g,以及抗静电剂聚醚酯酰胺型(PEEA)180g用高速混料机混合后通过双螺杆挤出机挤出直径0.6mm细条,水冷切成长1.0mm圆柱改性聚丙烯细粒。
(2).称取1200g聚丙烯细粒,将聚丙烯细粒、十二烷基苯磺酸钠0.2g、0.5g非煅烧高岭土、1500ml水投入到高压釜中。升温至50℃,在搅拌(800转每分钟)条件下将氮气注入到高压釜中,同时将高压釜的温度升高至124℃,压力升高至5.5MPa,达到设定的温度和压力后,保持50min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为21MPa/s,降温速率为30℃/s。相比二氧化碳,氮气在聚丙烯中的饱和度低,洗涤烘干得到发泡倍率在18倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.2mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽0.3mpa成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用手糊成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过热固化成型,固化温度为80℃,时间20min,得到目标复合材料。
上述实施例对本发明做了详细说明。当然,上述说明并非对本发明的限制,本发明也不仅限于上述例子,相关技术人员在本发明的实质范围内所作出的变化、改型、添加或减少、替换,也属于本发明的保护范围。
Claims (10)
1.一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,其特征在于制备改性聚丙烯发泡珠粒(EPP):将无规共聚聚丙烯60~80份、增粘树脂10~20份、相容剂10~20份、偶联剂0.1~0.5份、发泡泡核剂0.5~3份、复合抗氧剂0.3~0.9份,以及抗静电剂1~12份混合后通过双螺杆挤出机挤出、水冷切成细小圆柱颗粒后,采用间歇式釜式发泡制备改性聚丙烯发泡珠粒(EPP)。再将聚丙烯发泡珠粒(EPP)通过模塑成型设备制备成EPP制品后,采用手糊、缠绕或预成型工艺将碳纤维预浸料与EPP制品粘结到一起,通过热固化成型。
2.根据权利要求1所述的无规共聚聚丙烯,其特征在于:丙烯在无规共聚聚丙烯中的摩尔含量为55%~99%,无规共聚聚丙烯中还包括乙烯、1-丁烯、1-戊烯中的至少一种单体,其摩尔含量为1%~45%,为了便于后期模塑成型,所述无规共聚聚丙烯熔点在105℃~138℃,共聚物分子量分布Mw/Mn=3~18,熔融流动指数(190℃,2.16Kg)2~12g/10min。
3.根据权利要求1所述的增粘树脂,其特征在于:包括萜烯树脂、EVA(VA值43)、改性松香138、改性松香145、C5石油树脂、C9石油树脂中的至少一种。
4.根据权利要求1所述的相容剂,其特征在于:相容剂包括马来酸酐接枝聚丙烯(PP-g-MAH)、丙烯酸接枝聚丙烯(PP-g-AA)、甲基丙烯酸缩水甘油酯熔融接枝聚丙烯(PP-g-GMA)中的至少一种。.
5.根据权利要求1所述的偶联剂,其特征在于:所述偶联剂为硅烷偶联剂、钛酸酯偶联剂、铝酸酯偶联剂中的至少一种。
6.根据权利要求1所述的发泡泡核剂,其特征在于:粒径为30~100纳米的碳酸钙、滑石粉、二氧化硅、氯化钙、硫酸钙、氯化钠、硫酸钠中的至少一种。
7.根据权利要求1所述的复合抗氧剂,其特征在于:包括主抗氧剂和辅抗氧剂,其重量配比为1~1.5:2~4,主抗氧剂包括抗氧剂1010、1098、1076中的至少一种,辅抗氧剂包括168、300、626中的至少一种。
8.根据权利要求1所述的抗静电剂,其特征在于:属于高分子型永久抗静电剂,包括聚醚酯酰胺型(PEEA)、离子聚合物型(E-MMA-Na/Li/Zn)、季铵盐型(QASI)、接枝聚合物型(PPW-g-AAS)中的至少一种。
9.根据权利要求1~8任意一项所述的一种改性聚丙烯发泡珠粒(EPP)碳纤维复合材料的制备方法,其特征在于,包括以下步骤:
(1)将无规共聚聚丙烯、增粘树脂、相容剂、偶联剂、发泡泡核剂、抗氧剂及抗静电剂混合后通过双螺杆挤出机(挤出温度150~190℃)挤出直径0.6~1.1mm细条,水冷切成长1~1.5mm圆柱颗粒,得到改性聚丙烯细粒。
(2)将聚丙烯细粒、分散剂、水投入到高压釜中,聚丙烯细粒与水的重量比例为1~2:2~3,分散剂为每升水中添加0.05~0.25g十二烷基苯磺酸钠和0.2~0.5g非煅烧高岭土。升温至50℃,在搅拌(800~1300转每分钟)条件下将物理发泡剂注入到高压釜中,同时将高压釜的温度升高至110~150℃,压力升高至2.0~8.0MPa,达到设定的温度和压力后,保持15~50min,使发泡剂渗透到聚丙烯细粒中;
(3)通过连接补压罐保持高压釜内压力不变,打开高压釜下出料口控制出料量,聚丙烯细粒、水、分散剂混合物高速喷射入冷水冷却收集管道,出料口的压降速率为10~22MPa/s,降温速率为30~50℃/s。洗涤烘干得到发泡倍率在6~33倍之间的聚丙烯发泡珠粒,熟化24h后备用;
(4)将熟化的聚丙烯发泡珠粒在含浸罐中含浸0.1~0.4mpa的空气压力,再将含浸后的聚丙烯发泡珠粒注入到模塑成型设备,通入高压蒸汽(0.3~0.6mpa)成型得到聚丙烯发泡珠粒制品。
(5)将制备得到的EPP制品,采用手糊、缠绕或预成型工艺将碳纤维预浸料与EPP制品粘结到一起,再通过热固化成型,固化温度为90~110℃,时间10~25min,得到最终制品。
10.根据权利要求9所述的方法,其特征在于,所述物理发泡剂为二氧化碳、氮气中的一种或两种;所述碳纤维预浸料为非热压罐中温固化环氧树脂类碳纤维预浸料,碳纤维为编织布。
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