CN111688292A - 具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用 - Google Patents

具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用 Download PDF

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CN111688292A
CN111688292A CN202010476840.0A CN202010476840A CN111688292A CN 111688292 A CN111688292 A CN 111688292A CN 202010476840 A CN202010476840 A CN 202010476840A CN 111688292 A CN111688292 A CN 111688292A
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carbon fiber
layer
thermoplastic
thermoplastic resin
prepreg fabric
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朱波
乔琨
曹伟伟
林志涛
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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，尤其涉及一种具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用。所述预浸织物的结构包括自下向上依次铺设的热塑性网膜层、多孔隙骨架层、单向碳纤维强度层、多孔隙骨架层、热塑性网膜层；所述多孔隙骨架层中填充有热塑性树脂粉体，所述粉体的粒径为微米和/或纳米级。本发明通过将热塑性树脂粉体填充在多孔隙骨架层的网格微孔内，在预浸织物加热向单向碳纤维强度层熔渗过程中，通过网格的熔渗导流作用对粉体的热熔流动轨迹进行整流，保证热熔后的粉体流动有序、分布均匀，提高热塑性预浸织物的浸润效果；而不是随机向单向碳纤维强度层的层间渗透，容易影响树脂分布的均一性。

Description

具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑 树脂材料的制备方法与应用
技术领域
本发明涉及碳纤维预浸织物技术领域，尤其涉及一种具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用。
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。
随着热固性树脂基复合材料的广泛应用，其自身材质特性所表现出来的应用特性问题也不断出现，其中由于热固性树脂自身通过固化剂交联之后所形成的三维网络树脂结构，虽然具有较好的力学性能，但是这种不熔不溶的体形结构也带来了不可二次塑化的问题，极大的影响了热固性树脂基复合材料的应用发展。为了提高树脂基复合材料的应用性能同时扩大其应用领域，能二次塑化的热塑性碳纤维复合材料被开发者不断研究，而作为复合材料成型过程的重要中间产品——预浸织物，成为热塑性复合材料制备过程中重点研究的对象。热塑性碳纤维预浸织物的制备过程中，热塑性树脂的加热融入渗透是制备技术过程中的重点和难点，然而，本发明人研究发现：由于热塑性树脂自身的高粘度、低流动性的物性特点，导致树脂在熔融状态下与纤维织物的单丝之间的浸润性受到影响，进而影响热塑性复合材料的性能。
发明内容
针对上述的问题，本发明提出一种具有导流熔渗层的碳纤维热塑性预浸织物，本发明通过将热塑性超细粉体颗粒填充在高强度碳纤维形成的多孔隙骨架中，在热塑性超细粉体颗粒热熔过程对熔体中起到限制流动，保证熔体的流动分布均匀。为实现上述目的，本发明的技术方案如下。
在本发明的第一方面，公开一种具有导流熔渗层的碳纤维热塑性预浸织物，其结构包括自下向上依次铺设的热塑性网膜层、多孔隙骨架层、单向碳纤维强度层、多孔隙骨架层、热塑性网膜层；所述多孔隙骨架层中填充有热塑性树脂粉体，所述粉体的粒径为微米和/或纳米级。
进一步地，所述热塑性网膜层的材质包括聚乙烯、聚丙烯、聚氯乙烯、聚醚酮、聚醚醚酮、聚酰胺、聚酰亚胺、聚甲醛、聚苯硫醚、对苯二甲酸乙二醇酯、对苯二甲酸丁二醇酯等中的任意一种。所述热塑性网膜层采用上述材质制的纤维通过熔渗或者纺粘工艺制备而成。可选地，所述热塑性网膜层的厚度控制在0.05-0.5mm范围内，克重控制在5-10g/m2。
进一步地，所述多孔隙骨架层是由高强度碳纤维通过纤维随机排布或三维编织结构形成的具有多孔特点的结构层。可选地，所述多孔隙骨架层的厚度在 0.05-0.2mm范围内，内部孔隙直径控制在20-50μm范围内，骨架层的克重控制在2-10g/m2。可选地，所述高强度碳纤维选用T300、T700、T800、T1000 碳纤维中的任意一种。
进一步地，所述热塑性树脂粉体的材质包括聚乙烯、聚丙烯、聚氯乙烯、聚醚酮、聚醚醚酮、聚酰胺、聚酰亚胺、聚甲醛、聚苯硫醚、对苯二甲酸乙二醇酯、对苯二甲酸丁二醇酯等中的任意一种。可选地，所述热塑性树脂粉体的粒径控制在20-50nm范围内。所述热塑性树脂粉体可由热塑性树脂在液氮中冷却后粉碎制备而成。
进一步地，所述热塑性树脂粉体的质量占预浸织物整体质量的25-35％。
进一步地，所述单向碳纤维强度层是由高强度碳纤维单向排布展纱处理而成。可选地，所述高强度碳纤维选用T300、T700、T800、T1000碳纤维中的任意一种，可采用3K、6K、12K等中任意一种规格，展纱的碳纤维克重控制在10-30g/m2范围内。
在本发明的第二方面，公开一种碳纤维复合热塑树脂材料的制备方法：将所述具有导流熔渗层的碳纤维热塑性预浸织物加热，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
进一步地，所述加热的温度保持在130-300℃范围，加热时间控制在1-3 小时范围。
在本发明的第三方面，公开所述具有导流熔渗层的碳纤维热塑性预浸织物、碳纤维复合热塑树脂材料在运动器材、体育用品、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：通过将热塑性树脂粉体填充在多孔隙骨架层的网格微孔内，在预浸织物加热向单向碳纤维强度层熔渗过程中，通过网格的熔渗导流作用对粉体的热熔流动轨迹进行整流，保证热熔后的粉体流动有序、分布均匀，提高热塑性预浸织物的浸润效果；而不是随机向单向碳纤维强度层的层间渗透，容易影响树脂分布的均一性，进而影响得到的复合材料的性能。
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为本发明实施例中具有导流熔渗层的碳纤维热塑性预浸织物的结构示意图。图中标记分别代表：1-热塑性网膜层、2-多孔隙骨架层、3-单向碳纤维强度层。
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，本发明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，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，由于热塑性树脂自身的高粘度、低流动性的物性特点，导致树脂在熔融状态下与纤维织物的单丝之间的浸润性受到影响，进而影响热塑性复合材料的性能。因此，本发明提出一种具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用；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
1、一种具有导流熔渗层的碳纤维热塑性预浸织物，参考图1，其包括热塑性网膜层1、多孔隙骨架层2和单向碳纤维强度层3。所述热塑性网膜层1上铺设一层多孔隙骨架层2，该多孔隙骨架层2上铺设一层单向碳纤维强度层3，该单向碳纤维强度层3上再铺设一层多孔隙骨架层2，该多孔隙骨架层2上再铺设一层热塑性网膜层1。所述多孔隙骨架层2中填充有粒径为纳米级的热塑性树脂粉体。
进一步地，所述热塑性网膜层1采用聚乙烯热塑性树脂纤维通过熔喷工艺制备而成，其厚度约为0.05mm，克重约为5g/m2。
所述多孔隙骨架层2是由T300碳纤维随机排布形成的具有多孔特点的结构层，其厚度为0.05mm，内部孔隙直径为20μm，骨架层克重约为2g/m2。
所述热塑性树脂粉体是由聚乙烯在液氮中冷冻后粉碎而成的超细颗粒，其平均粒径约为20nm，且热塑性树脂粉体的质量占预浸织物整体质量的30％。
所述单向碳纤维强度层3采用3K的T300碳纤维单向排布展纱处理而成，其克重大约为10g/m2。
2、一种碳纤维复合热塑树脂材料的制备，将本实施例的具有导流熔渗层的碳纤维热塑性预浸织物加热至280℃保温1.5小时，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
第二实施例
1、一种具有导流熔渗层的碳纤维热塑性预浸织物，参考图1，其结构同第一实施例，区别在于：
所述热塑性网膜层1采用聚丙烯热塑性树脂纤维通过纺粘工艺制备而成，其厚度约为0.5mm，克重约为8g/m2。
所述多孔隙骨架层2是由T700碳纤维三维四向编织形成的具有多孔特点的结构层，其厚度为0.2mm，内部孔隙直径为50μm，骨架层克重约为10g/m2。
所述热塑性树脂粉体是由聚丙烯在液氮中冷冻后粉碎而成的超细颗粒，其平均粒径约为50nm，且热塑性树脂粉体的质量占预浸织物整体质量的28％。
所述单向碳纤维强度层3采用12K的T800碳纤维单向排布展纱处理而成，其克重大约为15g/m2。
2、一种碳纤维复合热塑树脂材料的制备，将本实施例的具有导流熔渗层的碳纤维热塑性预浸织物加热至130℃保温3小时，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
第三实施例
1、一种具有导流熔渗层的碳纤维热塑性预浸织物，参考图1，其结构同第一实施例，区别在于：
所述热塑性网膜层1采用聚酰胺热塑性树脂纤维通过纺粘工艺制备而成，其厚度约为0.4mm，克重约为10g/m2。
所述多孔隙骨架层2是由T800碳纤维随机排布形成的具有多孔特点的结构层，其厚度为0.09mm，内部孔隙直径为27μm，骨架层克重约为6g/m2。
所述热塑性树脂粉体是由聚酰胺在液氮中冷冻后粉碎而成的超细颗粒，其平均粒径约为27nm，且热塑性树脂粉体的质量占预浸织物整体质量的25％。
所述单向碳纤维强度层3采用6K的T1000碳纤维单向排布展纱处理而成，其克重大约为18g/m2。
2、一种碳纤维复合热塑树脂材料的制备，将本实施例的具有导流熔渗层的碳纤维热塑性预浸织物加热至200℃保温2小时，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
第四实施例
1、一种具有导流熔渗层的碳纤维热塑性预浸织物，参考图1，其结构同第一实施例，区别在于：
所述热塑性网膜层1采用对苯二甲酸丁二醇酯热塑性树脂纤维通过纺粘工艺制备而成，其厚度约为0.3mm，克重约为8g/m2。
所述多孔隙骨架层2是由T1000碳纤维三维五向编织形成的具有多孔特点的结构层，其厚度为0.1mm，内部孔隙直径为40μm，骨架层克重约为6g/m2。
所述热塑性树脂粉体是由对苯二甲酸乙二醇酯在液氮中冷冻后粉碎而成的超细颗粒，其平均粒径约为45nm，且热塑性树脂粉体的质量占预浸织物整体质量的35％。
所述单向碳纤维强度层3采用12K的T300碳纤维单向排布展纱处理而成，其克重大约为25g/m2。
2、一种碳纤维复合热塑树脂材料的制备，将本实施例的具有导流熔渗层的碳纤维热塑性预浸织物加热至300℃保温1小时，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
第五实施例
1、一种具有导流熔渗层的碳纤维热塑性预浸织物，参考图1，其结构同第一实施例，区别在于：
所述热塑性网膜层1采用聚苯硫醚热塑性树脂纤维通过纺粘工艺制备而成，其厚度约为0.2mm，克重约为6g/m2。
所述多孔隙骨架层2是由T800碳纤维三维五向编织形成的具有多孔特点的结构层，其厚度为0.2mm，内部孔隙直径为30μm，骨架层克重约为5g/m2。
所述热塑性树脂粉体是由对聚苯硫醚在液氮中冷冻后粉碎而成的超细颗粒，其平均粒径约为40nm，且热塑性树脂粉体的质量占预浸织物整体质量的 33％。
所述单向碳纤维强度层3采用12K的T800碳纤维单向排布展纱处理而成，其克重大约为30g/m2。
2、一种碳纤维复合热塑树脂材料的制备，将本实施例的具有导流熔渗层的碳纤维热塑性预浸织物加热至150℃保温2.5小时，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
最后，需要说明的是，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。上述虽然结合附图对本发明的具体实施方式进行了描述，但并非对本发明保护范围的限制，所属领域技术人员应该明白，在本发明的技术方案的基础上，本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本发明的保护范围以内。

Claims (10)

1.一种具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，包括自下向上依次铺设的热塑性网膜层、多孔隙骨架层、单向碳纤维强度层、多孔隙骨架层、热塑性网膜层；所述多孔隙骨架层中填充有热塑性树脂粉体，所述粉体的粒径为微米和/或纳米级。
2.根据权利要求1所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述热塑性网膜层的材质包括聚乙烯、聚丙烯、聚氯乙烯、聚醚酮、聚醚醚酮、聚酰胺、聚酰亚胺、聚甲醛、聚苯硫醚、对苯二甲酸乙二醇酯、对苯二甲酸丁二醇酯中的任意一种；
优选地，所述热塑性网膜层采用上述材质制的纤维通过熔渗或者纺粘工艺制备而成；
或者，所述热塑性网膜层的厚度控制在0.05-0.5mm范围内，克重控制在5-10g/m2。
3.根据权利要求1所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述多孔隙骨架层是由高强度碳纤维通过纤维随机排布或三维编织结构形成的具有多孔特点的结构层；优选地，所述高强度碳纤维选用T300、T700、T800、T1000碳纤维中的任意一种。
4.根据权利要求1所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述多孔隙骨架层的厚度在0.05-0.2mm范围内，内部孔隙直径控制在20-50μm范围内，骨架层的克重控制在2-10g/m2。
5.根据权利要求1所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述热塑性树脂粉体的材质包括聚乙烯、聚丙烯、聚氯乙烯、聚醚酮、聚醚醚酮、聚酰胺、聚酰亚胺、聚甲醛、聚苯硫醚、对苯二甲酸乙二醇酯、对苯二甲酸丁二醇酯中的任意一种；
或者，所述热塑性树脂粉体的粒径控制在20-50nm范围内；
或者，所述热塑性树脂粉体由热塑性树脂在液氮中冷却后粉碎制备而成。
6.根据权利要求1所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述热塑性树脂粉体的质量占预浸织物整体质量的25-35％。
7.根据权利要求1-6任一项所述的具有导流熔渗层的碳纤维热塑性预浸织物，其特征在于，所述单向碳纤维强度层是由高强度碳纤维单向排布展纱处理而成；
优选地，所述高强度碳纤维选用T300、T700、T800、T1000碳纤维中的任意一种，其规格优选为3K、6K、12K中任意一种；
优选地，所述展纱的碳纤维克重控制在10-30g/m2范围内。
8.一种碳纤维复合热塑树脂材料的制备方法，其特征在于，将权利要求1-7任一项所述的具有导流熔渗层的碳纤维热塑性预浸织物加热，使热塑性树脂粉体和热塑性网膜层向单向碳纤维强度层熔渗，即得。
9.根据权利要求8所述的碳纤维复合热塑树脂材料的制备方法，其特征在于，所述加热的温度保持在130-300℃范围，加热时间控制在1-3小时范围。
10.权利要求1-7任一项所述的具有导流熔渗层的碳纤维热塑性预浸织物或者权利要求8或9所述的方法制备的碳纤维复合热塑树脂材料在运动器材、体育用品、航空航天领域中的应用。
CN202010476840.0A 2020-05-29 2020-05-29 具有导流熔渗层的碳纤维热塑性预浸织物及碳纤维复合热塑树脂材料的制备方法与应用 Pending CN111688292A (zh)

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