CN112848543B - 一种碳陶制动盘用碳纤维预制体及其制备方法和应用 - Google Patents
一种碳陶制动盘用碳纤维预制体及其制备方法和应用 Download PDFInfo
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Abstract
本发明公开了一种碳纤维预制体及其制备方法和应用，首先根据制动盘结构尺寸将碳布(无纬布)和网胎进行仿形裁剪；接着将碳布(无纬布)和网胎交替叠层并逐层针刺并辅助加工得到含通风槽结构的预制体中间层，同时加工出通风槽结构的仿形填充物并填充于中间层内；然后将碳布(无纬布)和网胎交替叠层并逐层针刺制得预制体底层和上层；最后对制得的预制体毛坯进一步加工获得制动盘预制体成品。本发明的碳纤维制动盘预制体能够实现承载、散热、近尺寸一体化制备，提高了原材料利用率、缩短了碳陶制动盘后续生产加工周期，能够大幅度降低碳陶制动盘制造成本，有效推动碳陶材料在航空、轨道交通和汽车制动领域的应用。
Description
技术领域
本发明涉及一种碳纤维预制体及其制备方法和应用，属于碳陶复合材料制备技术领域。
背景技术
碳陶复合材料密度低、强度高、摩擦系数稳定、磨损量小，被公认为继碳碳复合材料后的新一代刹车材料。与钢质制动盘相比，碳陶制动盘重量减轻约三分之二，能载水平提高一倍，使用寿命提高1-2倍，在高速列车、赛车重载车辆以、特种车辆、高档轿车等制动系统应用前景广阔。
目前，碳陶制动盘预制体制备方法可分为两大类：一是采用短纤维热压成型，二是采用长纤维针刺成型。中国专利CN 103553695A公开了一种碳陶复合材料制动盘及制备方法，其是通过将短碳纤维、硅粉、粘接剂、无水乙醇等按配比混匀然后在磨具中压制固化成型得到制动盘预制体坯体，通风槽等散热结构须在坯体增密后方可加工，散热结构简单，可设计性差，也增加了加工难度，此外该方法制备的制动盘力学性能也较低。美国专利US5184387公开了一种环装碳纤维预制体制备方法，其是先将碳纤维单向布针刺至一定厚度后将其分割成多个扇形结构单元，然后将扇形结构单元拼接出环形结构，各单元间纤维取向可设计，上下单元层之间通过针刺连接；该方法能够有效提高原材料利用率，用于制备高性能C/C和C/C-SiC制动盘，但制动盘散热结构仍需后续加工。
发明内容
本发明针对技术的不足，本发明的第一个目的在于提供一种的碳陶制动盘用碳纤维预制体的制备方法。
本发明的第二个目的在于提供上述制备方法所制备的碳陶制动盘用碳纤维预制体。
本发明第三个目的在于提供上述制备方法所制备的碳陶制动盘用碳纤维预制体的应用，将其用于制备碳陶制动盘，可实现近尺寸一体化成型具有承载、散热功能的碳陶制动盘。
为了实现上述目的，本发明采用如下技术方案：
本发明一种碳陶制动盘用碳纤维预制体的制备方法，包括如下步骤：
步骤1：预制体中间层的制备
先采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体中间层粗坯，然后依据图纸，在预制体中间层粗坯加工出通风槽，同时在通风槽中填充上通风槽尺寸匹配的填充物获得预制体中间层，
步骤2碳纤维预制体的制备
在步骤1所得预制体中间层的上面采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体底层，然后将所得预制体翻转，再于预制体中间层的另一面继续采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体上层，按图纸加工后，即得碳纤维预制体。
在实际操作过程中，在进行预制体的制备之前，先将所需用到的碳布、无纬布、网胎裁剪成制动盘相应圆环状坯料。在本发明中，所用的碳布、无纬布、网胎中的碳纤维为T700级。在实际操作过程中，采用东丽T700-12K或同级别其他型号。
另外，在实际操作过程中，在碳纤维预制体加工完后，若检查有连接不牢固的地方，进行人工补刺。
本发明将碳纤维预制体分层制备，先预制出带通风槽的预制体中间层，这样可以制备异型、复杂图案的通风槽，使得用其制备的碳陶制动盘散热性能更佳。
优选的方案，步骤1中，填充物的材料选自PE/PU/PS泡棉，珍珠棉板，EVA板中的一种
优选的方案，所述步骤1以及步骤2中，碳布、无纬布的面密度均为280～360g/m2。
优选的方案，所述步骤1以及步骤2中，所述网胎面的密度为80～120g/m2。
优选的方案，所述步骤1以及步骤2中，所述针刺密度均为30～40针/cm2。
优选的方案，所述步骤1以及步骤2中，碳布或无纬布在层叠过程中的铺设方式如下：方式一，相邻两层碳布或无纬布中的长碳纤维取向按照0°/90°铺设，方式二相邻四层碳布或无纬布中的长碳纤维取向按照-45°/0°/45°/90°铺设，
优选的方案，步骤2中，所述碳纤维预制体的密度为0.50～0.60g/cm3。
本发明还提供上述制备方法所制备的碳陶制动盘用碳纤维预制体。
本发明还提供上述制备方法所制备的碳陶制动盘用碳纤维预制体的应用，将所述碳纤维预制体制备碳陶制动盘。
优选的方案，所述碳陶制动盘的制备过程为，将碳纤维预制体化学气相沉积获得密度为为1.45～1.55g/cm3碳碳预制体，再经熔融渗硅获得碳陶制动盘。
进一步的优选，化学气相沉积过程中，碳源气体选自甲烷、丙烯、天然气中的至少一种，稀释气体选自H2、Ar、N2中的至少一种。
进一步的优选，化学气相沉积过程中，沉积的温度为920～1050℃，沉积的压力为3～5kPa，沉积的时间为100～150h。
发明人发现，预先加工了散热槽以后，在气体沉积时候缩短了气体扩散路径，沉积效率会显著提高，缩短沉积时间30～50h。
进一步的优选，所述熔融渗硅在真空气氛下进行，所述熔融渗硅的温度为1600～1850℃，，熔融渗硅的时间为1～3h。
进一步的优选，碳陶制动盘的密度为2.0～2.3g/cm3
实际操作过程中，将熔融渗硅后的制动盘进行端面精磨即可得到碳陶制动盘成品。
附图说明
图1为实施例1中切割通风槽后预制体中间层示意图；
图2为实施例1中制备底层后预制体示意图；
图3为实施例1中制备上层后预制体示意图；
图4为实施例1中预制体成品示意图，其中1为预制体中间层，2为填充物，3为预制体底层，4为预制体上层。
图5实施例2切割通风槽后预制体中间层示意图。
图6实施例2切割通风槽后预制体中间层实物图。
图7对比例1切割通风槽后预制体中间层示意图。
以下结合附图和具体实施方式对本发明做进一步说明。
具体实施方式
实施例1
制动盘用碳纤维预制体的制备
步骤1：无纬布和网胎仿形裁剪
碳陶制动盘外径680mm、内径420mm、厚度55mm，其采用预制体外径720mm、内径400mm、厚度59mm；将密度为80g/m2的碳纤维网胎和300g/m2的无纬布裁剪成外径740mm、内径380mm圆环备用。
骤2：预制体中间层制备
将步骤1中圆环依次按照一层无纬布一层网胎交替叠层并逐层针刺，相邻两次无纬布纤维按0°/90°排布，针刺密度40针/cm2；中间层厚度25mm，待达到厚度后加工出通风槽结构(图1)；同时仿形加工出通风槽PU泡棉板填充物，并填充于通风槽内。
步骤3：预制体底层及上层制备
预制体中间层上面同步骤2工艺依次铺设无纬布与网胎并逐层针刺制备出预制体底层，预制体底层厚20mm(图2)；然后将预制体翻转，接着采用同样的方法制备出预制体上层，预制体上层厚14mm。
步骤4：预制体加工
将步骤3获得的预制体坯体(图3)加工至外径720mm、内径400mm，得到制动盘用预制体成品(图4)。
所制得的碳纤维预制体的密度为0.45g/cm3。
碳陶制动盘的制备
将碳纤维预制体进行化学气相沉积，化学气相沉积过程中，通入丙烯(12L/min)：氮气(10L/min)沉积的温度为1000℃，沉积的压力为3～5kPa，沉积的时间为120h。获得密度为1.48g/cm3的碳碳预制体，再经熔融渗硅获得碳陶制动盘，熔融渗硅在真空气氛下进行，所述熔融渗硅的温度为1720℃，熔融渗硅的时间为2h。碳陶制动盘的密度为2.1g/cm3，所获得成品再进行精磨即可。
本发明实施例1的制备过程，在化学气相沉积过程中，达到相同的密度，相比未开加工槽的碳纤维预制体，沉积获得同等密度，可以节约30-50h，后续加工减少4小时。
采用1:1台架考架考核模拟考核乘用轿车120公里时速紧急制动工况，实施例1所制备的碳陶制动盘，制动时盘温度在120℃。
实施例2：
步骤1：碳布和网胎仿形裁剪
碳陶制动盘外径680mm、内径420mm、厚度55mm，其采用预制体外径720mm、内径400mm、厚度59mm；将密度为80g/m2的碳纤维网胎和360g/m2的碳布裁剪成外径740mm、内径380mm圆环备用。
步骤2：预制体中间层制备
将步骤1中圆环依次按照一层碳布一层网胎交替叠层并逐层针刺，针刺密度40针/cm2；中间层厚度25mm，待达到厚度后根据设计图置加工出复杂图案的通风槽结构(如图5)；同时仿形加工出通风槽EVA板填充物，并填充于通风槽内。
步骤3：预制体底层及上层制备
预制体中间层上面同步骤2工艺依次铺设碳布与网胎并逐层针刺制备出预制体底层，预制体底层厚20mm；然后将预制体翻转，接着采用同样的方法制备出预制体上层，预制体上层厚14mm。
步骤4：预制体加工
将步骤3获得的预制体坯体加工至外径720mm、内径400mm，得到制动盘用预制体成品。
所制得的碳纤维预制体的密度为0.55g/cm3。
碳陶制动盘的制备
将碳纤维预制体进行化学气相沉积，化学气相沉积过程中，通入丙烯(7L/min)氮气(10L/min)沉积的温度为1050℃，沉积的压力为3～5kPa，沉积的时间为140h。获得密度为1.55g/cm3的碳碳预制体，再经熔融渗硅获得碳陶制动盘，熔融渗硅在真空气氛下进行，所述熔融渗硅的温度为1820℃，熔融渗硅的时间为2h。碳陶制动盘的密度为2.3g/cm3，所获得成品再进行精磨即可。
采用1:1台架考架考核模拟考核乘用轿车120公里时速紧急制动工况，实施例1所制备的碳陶制动盘，制动时盘温度在110℃。
实施例3
步骤1：无纬布和网胎仿形裁剪
碳陶制动盘外径680mm、内径420mm、厚度55mm，其采用预制体外径720mm、内径400mm、厚度59mm；将密度为120g/m2的碳纤维网胎和320g/m2的无纬布裁剪成外径740mm、内径380mm圆环备用。
步骤2：预制体中间层制备
将步骤1中圆环依次按照一层无纬布一层网胎交替叠层并逐层针刺，相邻四层无纬布纤维按-45°/0°/45°/90°排布，针刺密度40针/cm2；中间层厚度25mm，待达到厚度后加工出通风槽结构；同时仿形加工出通风槽PU泡棉板填充物，并填充于通风槽内。
步骤3：预制体底层及上层制备
预制体中间层上面同步骤2工艺依次铺设无纬布与网胎并逐层针刺制备出预制体底层，预制体底层厚20mm；然后将预制体翻转，接着采用同样的方法制备出预制体上层，预制体上层厚14mm。
步骤4：预制体加工
将步骤3获得的坯体加工至外径720mm、内径400mm的预制体成品。
所制得的碳纤维预制体的密度为0.55g/cm3。
碳陶制动盘的制备
将碳纤维预制体进行化学气相沉积，化学气相沉积过程中，通入丙烯(20L/min)氮气(10L/min)沉积的温度为960℃，沉积的压力为3～5kPa，沉积的时间为130h。获得密度为1.53g/cm3的碳碳预制体，再经熔融渗硅获得碳陶制动盘，熔融渗硅在真空气氛下进行，所述熔融渗硅的温度为1680℃，熔融渗硅的时间为2h。碳陶制动盘的密度为2.2g/cm3，所获得成品再进行精磨即可。
采用1:1台架考架考核模拟考核乘用轿车120公里时速紧急制动工况，实施例1所制备的碳陶制动盘，制动时盘温度在118℃。
对比例1
其他条件均与实施例2相同，仅是未在碳纤维预制体中间设置通风槽，而是制备碳碳复合材料后，才得以加工成通风槽，仅能加工成直线型通风槽(图7)，且加工时间将所制备的碳纤维预制体，采用化学气相沉积增密至1.5g/m2，耗时180h。
采用1:1台架考架考核模拟考核乘用轿车120公里时速紧急制动工况，实施例1所制备的碳陶制动盘，制动时盘温度在145℃。
Claims (5)
1.一种碳陶制动盘用碳纤维预制体的应用，其特征在于：将碳纤维预制体用于制备碳陶制动盘；
所述碳陶制动盘的制备过程为，将碳纤维预制体化学气相沉积获得密度为1.45~1.55g/cm3碳碳预制体，再经熔融渗硅获得碳陶制动盘；
所述碳纤维预制体的制备方法包括如下步骤：
步骤1：预制体中间层的制备
先采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体中间层粗坯，然后依据图纸，在预制体中间层粗坯加工出通风槽，同时在通风槽中填充上通风槽尺寸匹配的填充物获得预制体中间层，填充物的材料选自PE/ PU/PS泡棉，珍珠棉板，EVA板中的至少一种；
步骤2 碳纤维预制体的制备
在步骤1所得预制体中间层的上面采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体底层，然后将所得预制体翻转，再于预制体中间层的另一面继续采用一层碳布或无纬布与一层网胎交替叠层并逐层针刺制得预制体上层，按图纸加工后，即得碳纤维预制体；
所述化学气相沉积过程中，沉积的温度为920~1050℃，沉积的压力为3~5kPa，沉积的时间为100~150h。
2.根据权利要求1所述的一种碳陶制动盘用碳纤维预制体的应用，其特征在于：所述步骤1以及步骤2中，碳布、无纬布的面密度均为280~360g/m2；
所述步骤1以及步骤2中，所述网胎面的密度为80~120g/m2；
所述步骤1以及步骤2中，所述针刺密度均为30~40针/cm2。
3.根据权利要求1所述的一种碳陶制动盘用碳纤维预制体的应用，其特征在于：所述步骤1以及步骤2中，碳布或无纬布在层叠过程中的铺设方式如下：方式一，相邻两层碳布或无纬布中的长碳纤维取向按照0°/90°铺设，方式二 相邻四层碳布或无纬布中的长碳纤维取向按照-45°/0°/45°/90°铺设。
4.根据权利要求1所述的一种碳陶制动盘用碳纤维预制体的应用，其特征在于：步骤2中，所述碳纤维预制体的密度为0.50~0.60g/cm3。
5.根据权利要求1所述的一种碳陶制动盘用碳纤维预制体的应用，其特征在于：所述熔融渗硅在真空气氛下进行，所述熔融渗硅的温度为1600~1900℃，熔融渗硅的时间为1~3h，碳陶制动盘的密度为2.0~2.3g/cm3。
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