CN112776429A - 一种新型远红外发热器及其制备方法 - Google Patents
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Abstract
本公开提供了一种新型远红外发热器及其制备方法,所述新型远红外发热器包括表面膜、发热片、粘合剂层、芯材和固化片,其中发热片、芯材与固化片依次通过粘合剂层贴合设置,并分别在发热片的上表面和固化片的下表面设置表面膜;一体复合成型。本公开的新型远红外发热器在芳纶蜂窝复合材料板/制件的轻量化的基础上,赋予了其发热功能,实现结构功能一体化,解决了轨道交通和航空航天等领域取暖的问题。
Description
技术领域
本公开涉及复合材料制造领域,尤其涉及一种新型远红外发热器及其制备方法。
背景技术
轨道交通及航空航天领域内饰件多是芳纶蜂窝与热固性预浸料成型制备的三明治结构复合材料制件,这种结构大大降低了零件重量,实现了车辆整体轻量化的要求,同时还具有降低腐蚀、改善噪声、阻尼减震等众多优势。成型后的制件经过喷涂油漆或者水性漆后装配上车。
轨道交通车辆内部的加热方式主要采用空调加热,该加热方式需要在列车里配备一系列的包括空调设备,电气设备,通风循环设备等,不仅增加了车辆自身重量,同时还增加了设计复杂度。随着轨道车辆逐步在向智能、绿色、安全、舒适等方面发展,人们对车辆整体的结构一体化要求越来越高。
这种新型远红外发热器是将发热源和复合材料板进行一体化设计,制成结构与功能化一体的复合材料制件。该制件的发热源是碳纤维,传热以红外传热为主,类似太阳光,是一种环保清洁和高舒适标准的供暖方式。新型远红外发热器是整体发热的平面辐射采暖,制热效果极快,能迅速达到设定温度,且能效低。可代替家用空调,实现采暖与理疗一体的功能。
新型远红外发热器将结构和功能一体化集成,以复合材料制件为载体,除了具有发热功能,成型时可直接在其蒙皮上贴附一层表面膜,代替水性漆和油漆,不仅解决了油漆或者水性漆耐磨及抗化学性较差的缺点,而且该表面膜具有抗菌、耐刮擦,易清洁的作用,降低工序和成本的同时,集成了众多功能的优点,尤其适用于轨道交通内饰件加热,另外也可作为家居取暖装饰件。
目前芳纶蜂窝复合板/制件多是采用预浸料和芳纶蜂窝一次共固化或预浸料固化后再与芳纶蜂窝进行二次胶结的方式进行复合成型,暂无发热和抗菌功能。现有的芳纶蜂窝复合板只能实现轨道交通等领域轻量化的要求,无发热、抗菌、易清洁的功能。
发明内容
为了解决上述技术问题中的至少一个,本公开提供了一种新型远红外发热器,包括表面膜、发热片、粘合剂层、芯材和固化片,
发热片,在多层预浸料中间设置一层发热材料,并在所述发热片的下表面预留接线,所述接线的一端与发热材料相连;
粘合剂层,所述粘合剂层分别设置在芯材的上表面和下表面;
芯材,在所述芯材的上表面设置开复数个凹槽,所述接线的另一端弯曲埋入所述凹槽;
固化片,由多层预浸料组成;
其中发热片、芯材与固化片依次通过粘合剂层贴合设置,并分别在发热片的上表面和固化片的下表面设置表面膜;
一体复合成型。
优选地,所述表面膜是一种聚氟乙烯薄膜(PVF膜),其具有很好的耐候性,能抵御天气和紫外线对制件表面的破坏;耐化学腐蚀:PVF膜对化学物质、溶剂和污渍有极好的抵抗力,易清洁,即使在强酸和强碱中也能保持薄膜的形状和强度;具有较好的耐温性,能够耐受70-150摄氏度的温度;较好的耐污性:由于PVF的摩擦系数较低,PVF膜能保持清洁不受污染。所述表面膜的表面耐刮擦易清洁等特点,另一方面,在成型过程中表面膜可与制件一体成型,减少后续制件喷漆等工艺,其作用类似于装饰面。
预浸料是用树脂基体在严格控制的条件下浸渍连续纤维或织物,制成树脂基体与增强体的组合物,是制造复合材料的中间材料。预浸料的成分即为常见的纤维织物浸渍树脂材料,纤维织物常为玻璃纤维、碳纤维、芳纶纤维等,树脂常为环氧树脂、双马来酰亚胺树脂等。一般的热塑性复合材料的刚度相对弱于热固性复合材料。当热塑性复合材料蒙皮直接与蜂窝复合后,其力学性能弯曲强度刚度等如果达不到要求,则可以加入热固性预浸料进行力学性能补强。例如碳纤环氧、玻纤环氧预浸料,其是具有较好力学性能的热固性复合材料。通过热固性复合材料与热塑性复合材料的复合混用而把两者缺点进行弥补。另外有时预浸料层同时充当粘合剂层和补强(替换掉粘合剂层)。优选地,所述预浸料为玻纤环氧预浸料。所述单层预浸料的厚度为0.25-1mm。
优选地,所述芯材选自芳纶蜂窝、铝蜂窝、PMI泡沫中的一种或多种。所述芯材的厚度为5-30mm,密度为48-144kg/m3。
优选地,所述复数个凹槽以固定的距离彼此间隔,并且所述凹槽彼此连通。对所述凹槽的尺寸不做限定,只要能够容纳所述接线即可。优选地,所述凹槽为方形或U形。将接线通路置于一条凹槽通道内即可,一方面更为整洁美观,另一方面,复数个凹槽使得热空气通过凹槽通道流通,增加内外冷热空气循环,提高热传导效率。
优选地,所述发热片由2-4层预浸料叠加构成,所述发热片的厚度为0.5-4mm。所述固化片由2-4层预浸料叠加构成,所述固化片的厚度为0.5-4mm。
优选地,所述粘合剂层由粘合剂组成,所述粘合剂选自热固性树脂、反应性聚合物中的一种或多种。
优选地,所述复合成型是通过热压、真空袋压或热压罐的工艺进行的。
优选地,所述发热材料选自碳纤维复合发热材料。
本公开提供了一种制备上述新型远红外发热器的制备方法,包括:
(1)准备发热片,在多层预浸料中间设置一层发热材料,并在发热片下表面预留接线,所述接线与发热材料连接;
(2)裁切芯材,在所述芯材的上表面设置开复数个凹槽,所述接线的另一端弯曲埋入所述凹槽;
(3)在芯材的上表面和下表面分别设置粘合剂层;
(4)准备固化片,设置多层预浸料层;
(5)将发热片、芯材与固化片依次通过粘合剂层贴合设置,并在发热片的上表面和固化片的下表面分别设置表面膜;
(6)施加压力和温度进行固化成型,完成后脱模得到一种新型远红外发热器。
优选地,所述方法还包括,在步骤(1)中一体复合成型制备发热片。
优选地,所述方法还包括,在步骤(4)中一体复合成型制备固化片。
优选地,所述复合成型压力为0.1-0.5MPa,温度为50-135℃,时间为30min-2h。
优选地,所得新型远红外发热器的密度为3-6kg/m2。
本公开提供了一种新型远红外发热器,其具有如下优点:
1.新型远红外发热器在芳纶蜂窝复合材料板/制件的轻量化的基础上,赋予了其发热功能,实现结构功能一体化,解决了轨道交通和航空航天等领域取暖的问题。
2.用表面膜替代了水性漆,使芳纶蜂窝复合材料板/制件具有抗菌、耐刮擦、易清洁等功能。
3.新型远红外发热器采用开槽蜂窝,大大提高了热循环效率。
附图说明
附图示出了本公开的示例性实施方式,并与其说明一起用于解释本公开的原理,其中包括了这些附图以提供对本公开的进一步理解,并且附图包括在本说明书中并构成本说明书的一部分。
图1为示出了本公开的新型远红外发热器的一个示例性实施方式的结构示意图;
图2为示出了制备新型远红外发热器的一个示例性实施方式的示意图;
图3为示出了制备新型远红外发热器的另一个示例性实施方式的示意图;
图4为示出了本公开的新型远红外发热器所用芯材及凹槽的一个示例性实施方式的示意图。
附图标记
1.表面膜;2.预浸料;3.发热片;4.导线;5.粘合剂层;6.芯材;7.凹槽。
具体实施方式
下面结合附图和实施方式对本公开作进一步的详细说明。可以理解的是,此处所描述的具体实施方式仅用于解释相关内容,而非对本公开的限定。另外还需要说明的是,为了便于描述,附图中仅示出了与本公开相关的部分。
需要说明的是,在不冲突的情况下,本公开中的实施方式及实施方式中的特征可以相互组合。下面将参考附图并结合实施方式来详细说明本公开。
实施例
实施例1(二次胶结成型)
裁剪两片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维纸上铺上另一层预浸料并预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。最后通过施加压力0.3MPa,在120℃和1.5h下进行固化成型,完成后得到一种碳纤维复合发热材料与玻纤预浸料复合制成夹层结构的发热片。所述单层玻纤预浸料的厚度为0.25mm。
裁剪两片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面平整附上表面膜。通过施加压力0.3MPa,在120℃和1.5h下进行固化成型,得到一种与发热片厚度基本相同的固化片。所述固化片的厚度为0.5mm。
将夹芯材料芳纶蜂窝芯上沿水平方向开数条凹槽,用于发热片预埋接线线路和冷热空气的内外循环。所述芯材的厚度为10mm。
将发热片预留接线头的一面施环氧结构胶,与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面施胶与芳纶蜂窝的未开凹槽面对应,施加压力0.15MPa,温度60℃,时间60min进行固化成型,得到一种新型远红外发热器。
实施例2(二次胶结成型)
裁剪三片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维复合发热材料上铺上另一层预浸料并预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。最后通过施加压力0.5MPa,在130℃和1h下进行固化成型,完成后得到一种碳纤维复合发热材料与玻纤预浸料复合制成夹层结构的发热片。所述单层玻纤预浸料的厚度为0.25mm。
裁剪两片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面平整附上表面膜。通过施加压力0.5MPa,在130℃和1h条件下进行固化成型,得到一种与发热片厚度基本相同的固化片。所述固化片与发热片的厚度为0.5mm。
将夹芯材料芳纶蜂窝芯上沿垂直方向开数条凹槽,用于发热片预埋接线线路和冷热空气的内外循环。所述芯材的厚度为15mm。
将发热片预留接线头的一面施环氧结构胶,与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面施胶与芳纶蜂窝的未开凹槽面对应,施加压力0.2MPa,温度50℃,时间90min,得到一种新型远红外发热器。
实施例3(二次胶结成型)
裁剪四片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维复合发热材料上铺上另一层预浸料并预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。最后通过施加压力0.6MPa,在135℃和1h下进行固化成型,完成后得到一种碳纤维复合发热材料与玻纤预浸料复合制成夹层结构的发热片。所述单层玻纤预浸料的厚度为0.25mm。
裁剪三片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面平整附上表面膜。通过施加压力0.6MPa,在135℃和1h条件下进行固化成型,得到一种与发热片厚度基本相同的固化片。所述固化片的厚度为0.75mm。
将夹芯材料芳纶蜂窝芯上沿垂直方向开数条凹槽,用于发热片预埋接线线路和冷热空气的内外循环。所述芯材的厚度为20mm。
将发热片预留接线头的一面施环氧结构胶,与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面施胶与芳纶蜂窝的未开凹槽面对应,施加压力0.25MPa,温度60℃,时间60min进行固化成型,得到一种新型远红外发热器。
实施例4(一次共固化成型)
裁剪三片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维复合发热材料上铺上另一层预浸料,预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。
裁剪两片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面附上表面膜。将夹芯材料芳纶蜂窝芯上沿水平方向开数条凹槽,用于发热片预埋接线线路和冷热空气的流通。将发热片预留接线头的一面与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面与芳纶蜂窝的未开凹槽面对应。所述单层玻纤预浸料的厚度为0.25mm。所述芯材的厚度为12mm。
通过施加压力0.3MPa,在120℃和1.5h下进行固化成型,完成后得到一种新型远红外发热器。
实施例5(一次共固化成型)
裁剪两片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维复合发热材料上铺上另一层预浸料,预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。
裁剪两片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面附上表面膜。将夹芯材料芳纶蜂窝芯上沿垂直方向开数条凹槽,用于发热片预埋接线线路和冷热空气的流通。将发热片预留接线头的一面与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面与芳纶蜂窝的未开凹槽面对应。所述单层玻纤预浸料的厚度为0.25mm。所述芯材的厚度为8mm。
通过施加压力0.4MPa,在135℃和1h下进行固化成型,完成后得到一种新型远红外发热器。
实施例6(一次共固化成型)
裁剪四片尺寸相同的玻纤预浸料和一片尺寸略小于预浸料尺寸的碳纤维复合发热材料,将碳纤维复合发热材料用铜片连接后铺在一层预浸料上,然后再在碳纤维复合发热材料上铺上另一层预浸料,预留接线头。在其中未预留接线头的一面预浸料的外表面附上表面膜。
裁剪四片尺寸与上相同的玻纤预浸料,叠合成双层,在其中一面预浸料的外表面附上表面膜。将夹芯材料芳纶蜂窝芯上沿垂直方向开数条凹槽,用于发热片预埋接线线路和冷热空气的流通。将发热片预留接线头的一面与芳纶蜂窝开凹槽一面对应,将固化片表面未附表面膜的一面与芳纶蜂窝的未开凹槽面对应。所述单层玻纤预浸料层的厚度为0.25mm。所述芯材的厚度为20mm。
通过施加压力0.5MPa,在130℃和1h下进行固化成型,完成后得到一种新型远红外发热器。
本公开将双层预浸料之间预埋碳纤维发热片,与芳纶蜂窝通过一次成型或二次胶结的方式制成三明治结构。利用碳纤维的导电和导热性实现了新型远红外发热器的发热功能。
复合前在蜂窝上开凹槽内置连接导线,赋予新型远红外发热器实用性和美观度,同时开凹槽和孔洞使热流形成内外循环,有利于提高了热循环效率。
复合前在新型远红外发热器表面附表面膜,实现了抗菌、耐刮擦、易清洁等功能。
将加热功能和抗菌等功能与轻量化要求结合起来一体成型,具有可操作性强、工艺简单、节省能耗等特点。
在本说明书的描述中,参考术语“一个实施例/方式”、“一些实施例/方式”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例/方式或示例描述的具体特征、结构、材料或者特点包含于本申请的至少一个实施例/方式或示例中。在本说明书中,对上述术语的示意性表述不必须针对的是相同的实施例/方式或示例。而且,描述的具体特征、结构、材料或者特点可以在任一个或多个实施例/方式或示例中以合适的方式结合。此外,在不相互矛盾的情况下,本领域的技术人员可以将本说明书中描述的不同实施例/方式或示例以及不同实施例/方式或示例的特征进行结合和组合。
此外,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本申请的描述中,“多个”的含义是至少两个,例如两个,三个等,除非另有明确具体的限定。
本领域的技术人员应当理解,上述实施方式仅仅是为了清楚地说明本公开,而并非是对本公开的范围进行限定。对于所属领域的技术人员而言,在上述公开的基础上还可以做出其它变化或变型,并且这些变化或变型仍处于本公开的范围内。
Claims (10)
1.一种新型远红外发热器,包括表面膜、发热片、粘合剂层、芯材和固化片,其特征在于,
发热片,在双层预浸料层中间设置一层发热材料,并在所述发热片的下表面预留接线,所述接线的一端与发热材料相连;
粘合剂层,所述粘合剂层分别设置在芯材的上表面和下表面;
芯材,在所述芯材的上表面设置开复数个凹槽,所述接线的另一端弯曲埋入所述凹槽;
固化片,由双层预浸料层组成;
其中发热片、芯材与固化片依次通过粘合剂层贴合设置,并分别在发热片的上表面和固化片的下表面设置表面膜;
一体复合成型。
2.根据权利要求1所述的新型远红外发热器,其特征在于,所述芯材选自芳纶蜂窝、铝蜂窝、PMI泡沫中的一种或多种。
3.根据权利要求1所述的新型远红外发热器,其特征在于,所述粘合剂层由粘合剂组成,所述粘合剂选自热固性树脂、反应性聚合物中的一种或多种。
4.根据权利要求1所述的新型远红外发热器,其特征在于,所述复合成型是通过热压、真空袋压或热压罐的工艺进行的。
5.根据权利要求1所述的新型远红外发热器,其特征在于,所述发热材料选自碳纤维复合发热材料。
6.根据权利要求1所述的新型远红外发热器,其特征在于,所述预浸料选自纤维织物浸渍树脂材料,优选为玻纤环氧预浸料。
7.一种制备根据权利要求1所述的新型远红外发热器的制备方法,其特征在于,包括:
(1)准备发热片,在双层预浸料层中间设置一层发热材料,并在发热片下表面预留接线,所述接线与发热材料连接;
(2)裁切芯材,在所述芯材的上表面设置开复数个凹槽,所述接线的另一端弯曲埋入所述凹槽;
(3)在芯材的上表面和下表面分别设置粘合剂层;
(4)准备固化片,设置双层预浸料层;
(5)将发热片、芯材与固化片依次通过粘合剂层贴合设置,并在发热片的上表面和固化片的下表面分别设置表面膜;
(6)施加压力和温度进行固化成型,完成后脱模得到一种新型远红外发热器。
8.根据权利要求7所述的新型远红外发热器的制备方法,其特征在于,还包括,在步骤(1)中一体复合成型制备发热片。
9.根据权利要求7所述的新型远红外发热器的制备方法,其特征在于,还包括,在步骤(4)中一体复合成型制备固化片。
10.根据权利要求7-9任一项所述的新型远红外发热器的制备方法,其特征在于,所述芯材复合成型压力为0.1-0.5MPa。
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CN102506430A (zh) * | 2011-09-28 | 2012-06-20 | 苏婉玲 | 炭纤维复合材料红外线发热板 |
CN109177349A (zh) * | 2018-09-27 | 2019-01-11 | 株洲时代新材料科技股份有限公司 | 一种泡沫蜂窝夹芯板及其制备方法和应用 |
CN110001152A (zh) * | 2019-04-12 | 2019-07-12 | 广州鸿力复合材料有限公司 | 一种自发热蜂窝复合板及其制造方法 |
CN110072302A (zh) * | 2019-04-26 | 2019-07-30 | 江苏骏源新材料有限公司 | 远红外碳纤维发热板及其制备方法 |
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CN102506430A (zh) * | 2011-09-28 | 2012-06-20 | 苏婉玲 | 炭纤维复合材料红外线发热板 |
CN109177349A (zh) * | 2018-09-27 | 2019-01-11 | 株洲时代新材料科技股份有限公司 | 一种泡沫蜂窝夹芯板及其制备方法和应用 |
CN110001152A (zh) * | 2019-04-12 | 2019-07-12 | 广州鸿力复合材料有限公司 | 一种自发热蜂窝复合板及其制造方法 |
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