CN112318979A - 一种轻质防火复合材料的制备方法 - Google Patents

一种轻质防火复合材料的制备方法 Download PDF

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CN112318979A
CN112318979A CN202011210648.3A CN202011210648A CN112318979A CN 112318979 A CN112318979 A CN 112318979A CN 202011210648 A CN202011210648 A CN 202011210648A CN 112318979 A CN112318979 A CN 112318979A
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杨克俭
杨金
杨淦锋
宋庭柏
陈旭东
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Guangdong Juhang Institute For Advanced Materials Co ltd
Guangdong Hangke New Material Co ltd
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

一种轻质防火复合材料的制备方法，包括铺层结构和轻质预浸料，所述铺层结构由表层和中心层组合而成，且铺层结构设置为上下结构，所述表层材质设置为酚醛预浸料，所述中心层材质设置为环氧预浸料，所述铺层结构和轻质预浸料通过热压复合成片板；所述表层设置为上下两层结构，且表层中间设置为中心层；所述酚醛预浸料主要成分为酚醛树脂和纤维；所述环氧预浸料主要成分为环氧树脂、纤维和阻燃剂。本发明通过铺层结构热压复合形成板材，可以同时具有酚醛复合材料的优异防火阻燃性能和环氧复合材料的高结构强度、环保低VOC的性能，满足轨道交通领域的各种应用场景需求。

Description

一种轻质防火复合材料的制备方法
技术领域
本发明涉及复合材料技术领域，尤指一种轻质防火复合材料的制备方法。
背景技术
目前，轨道交通领域的内饰件所用热固性复合材料主要是环氧树脂基复合材料和酚醛树脂基复合材料。环氧树脂基复合材料的优点在于力学强度高、环保低VOC释放，但是由于环氧树脂本身存在的发烟量较大、热释放较高的问题，影响了其复合材料的防火性能等级的提高，限制了环氧树脂基复合材料在轨道交通领域的应用。而酚醛树脂基复合材料虽然其树脂本质阻燃，防火等级高，但是存在游离醛低分子释放量大，不环保，韧性差等问题。
因此，开发一种高力学强度、高阻燃防火的复合材料对扩大复合材料在轨道交通领域的应用有重大的现实意义。
发明内容
鉴于以上问题，本发明提供一种轻质防火复合材料的制备方法，具体如下：
为达到上述目的，本发明采用如下技术方案：一种轻质防火复合材料，包括铺层结构和轻质预浸料，所述铺层结构由表层和中心层组合而成，且铺层结构设置为上下结构，所述表层材质设置为酚醛预浸料，所述中心层材质设置为环氧预浸料，所述铺层结构和轻质预浸料通过热压复合成片板。
优选的，所述表层设置为上下两层结构，且表层中间设置为中心层。
优选的，所述酚醛预浸料主要成分为酚醛树脂和纤维。
优选的，所述环氧预浸料主要成分为环氧树脂、纤维和阻燃剂。
本发明还提供了一种轻质防火复合材料的制备方法，操作步骤包括：
(1)材料装备：准备好要使用的模具，并配制树脂胶液；
(2)成型准备：在模具上涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，用刷子、压辑或刮刀压挤织物，使其均匀浸胶并排除气泡后，再涂刷环氧树脂混合物，铺贴第二层纤维织物和阻燃剂，使其均匀浸胶并排除气泡，然后涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，使其均匀浸胶并排除气泡；
(3)固化：在一定压力作用下，将上述的铺层结构和轻质预浸料加热固化成型，即热压成型，热压成所需宽幅、厚度的片板，再脱模得到复合材料制品。
本发明具有以下有益效果：该轻质防火复合材料的制备方法通过铺层结构热压复合形成板材，可以同时具有酚醛复合材料的优异防火阻燃性能和环氧复合材料的高结构强度、环保低VOC的性能，满足轨道交通领域的各种应用场景需求，如地板、墙板、隔板、风道等产品应用。
具体实施方式
下面的实施例可以帮助本领域的技术人员更全面的理解本发明，但不可以以任何方式限制本发明。
本发明方案提供一种轻质防火复合材料，包括铺层结构和轻质预浸料，铺层结构由表层和中心层组合而成，且铺层结构设置为上下结构，表层材质设置为酚醛预浸料，中心层材质设置为环氧预浸料，铺层结构和轻质预浸料通过热压复合成片板；
表层设置为上下两层结构，且表层中间设置为中心层；采用酚醛预浸料作为铺层结构的表面，起到阻燃层作用；采用环氧预浸料作为铺层结构的夹心中间层，目的是起到保证复合材料的结构强度、环保低VOC释放的目的；酚醛预浸料主要成分为酚醛树脂和纤维；环氧预浸料主要成分为环氧树脂、纤维和阻燃剂。
本方案还提供一种轻质防火复合材料的制备方法，操作步骤包括：
(1)材料装备：准备好要使用的模具，并配制树脂胶液；
(2)成型准备：在模具上涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，用刷子、压辑或刮刀压挤织物，使其均匀浸胶并排除气泡后，再涂刷环氧树脂混合物，铺贴第二层纤维织物和阻燃剂，使其均匀浸胶并排除气泡，然后涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，使其均匀浸胶并排除气泡；
(3)固化：在一定压力作用下，将上述的铺层结构和轻质预浸料加热固化成型，即热压成型，热压成所需宽幅、厚度的片板，再脱模得到复合材料制品。
对比例一：环氧树脂玻璃纤维阻燃板(2mm厚度)，环氧预浸料重量为400g/㎡，配方组成：60wt％玻璃纤维，40wt％环氧树脂。其制备过程采用9层的阻燃环氧树脂预浸料热压复合而成。
对比例二：环氧树脂玻璃纤维阻燃板(2mm厚度)，环氧预浸料重量为400g/㎡，配方组成：60wt％玻璃纤维，15wt％阻燃剂(氢氧化铝和聚磷酸铵组合)，25wt％环氧树脂。其制备过程采用9层的阻燃环氧树脂预浸料热压复合而成。
对比例三：酚醛树脂玻璃纤维阻燃板(2mm厚度)，酚醛预浸料重量为400g/㎡，配方组成：60wt％玻璃纤维，40wt％酚醛树脂。其制备过程采用9层的酚醛树脂预浸料热压复合而成。
对比例四：组合铺层结构的复合材料板材(2mm厚度),其铺层结构从上到下为：1层400g/㎡重量的环氧预浸料(配方组成同对比例二)+1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)+5层环氧预浸料(配方组成：60wt％玻璃纤维，5wt％阻燃剂(氢氧化铝和聚磷酸铵组合)，35wt％环氧树脂。)+1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)+1层400g/㎡重量的环氧预浸料(配方组成同对比例二)，铺层后热压复合制备得到复合材料板材。
对比例五：组合铺层结构的复合材料板材(2mm厚度),其铺层结构从上到下为：1层酚醛预浸料和1层环氧预浸料交替叠加而成，其中，酚醛预浸料配方同对比例三，环氧预浸料配方同对比例二，铺层后热压复合制备得到复合材料板材。
实施例一：高强度防火复合材料板材(2mm厚度),其铺层结构：1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)+7层环氧预浸料(配方组成：60wt％玻璃纤维，5wt％阻燃剂(氢氧化铝和聚磷酸铵组合)，35wt％环氧树脂。)+1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)，铺层后热压复合制备得到复合材料板材。
实施例二：高强度防火复合材料板材(2mm厚度),其铺层结构：1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)+7层环氧预浸料(配方组成同对比例一)+1层400g/㎡重量的酚醛预浸料(配方组成同对比例三)，铺层后热压复合制备得到复合材料板材。
Figure BDA0002758728860000051
从上述对比例1-5和实施例1,2可知，实施例1与对比例1相比，通过表层设计为酚醛树脂体系后，复合材料的防火性能有了显著的提升，同时还保持了原有环氧复合材料优异的力学强度；实施例2与对比例4,5相比，说明只有当酚醛/环氧复合材料铺层结构按照表层为酚醛，中间芯层为环氧的特点铺层结构设计时，才能使复合材料同时实现优异的力学强度和满足轨道交通最高防火标准要求的优异防火性能。
以上对本发明实施例所提供的技术方案进行了详细介绍，本文中应用了具体个例对本发明实施例的原理以及实施方式进行了阐述，以上实施例的说明只适用于帮助理解本发明实施例的原理；同时，对于本领域的一般技术人员，依据本发明实施例，在具体实施方式以及应用范围上均会有改变之处，综上所述，本说明书内容不应理解为对本发明的限制。

Claims (5)

1.一种轻质防火复合材料，包括铺层结构和轻质预浸料，其特征在于：所述铺层结构由表层和中心层组合而成，且铺层结构设置为上下结构，所述表层材质设置为酚醛预浸料，所述中心层材质设置为环氧预浸料，所述铺层结构和轻质预浸料通过热压复合成片板。
2.根据权利要求1所述的一种轻质防火复合材料，其特征在于：所述表层设置为上下两层结构，且表层中间设置为中心层。
3.根据权利要求1所述的一种轻质防火复合材料，其特征在于：所述酚醛预浸料主要成分为酚醛树脂和纤维。
4.根据权利要求1所述的一种轻质防火复合材料，其特征在于：所述环氧预浸料主要成分为环氧树脂、纤维和阻燃剂。
5.一种轻质防火复合材料的制备方法，其特征在于，操作步骤包括：
(1)材料装备：准备好要使用的模具，并配制树脂胶液；
(2)成型准备：在模具上涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，用刷子、压辑或刮刀压挤织物，使其均匀浸胶并排除气泡后，再涂刷环氧树脂混合物，铺贴第二层纤维织物和阻燃剂，使其均匀浸胶并排除气泡，然后涂刷含有固化剂的酚醛树脂混合物，再在其上铺贴一层按要求剪裁好的纤维织物，使其均匀浸胶并排除气泡；
(3)固化：在一定压力作用下，将上述的铺层结构和轻质预浸料加热固化成型，即热压成型，热压成所需宽幅、厚度的片板，再脱模得到复合材料制品。
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CN114350111A (zh) * 2021-12-24 2022-04-15 常州市贝美家居科技有限公司 一种地板及其制备方法
CN114571815A (zh) * 2022-03-10 2022-06-03 浙江葆润应用材料有限公司 一种用于电池包的多层防火pcm复合材料

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