CN112848562B - 一种夹层式复合材料面板及其成型工艺 - Google Patents

一种夹层式复合材料面板及其成型工艺 Download PDF

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CN112848562B
CN112848562B CN202011543168.9A CN202011543168A CN112848562B CN 112848562 B CN112848562 B CN 112848562B CN 202011543168 A CN202011543168 A CN 202011543168A CN 112848562 B CN112848562 B CN 112848562B
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CN112848562A (zh
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刘广顺
杨红娜
朱文飞
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Beijing Aerospace Hexing Technology Co Ltd
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Abstract

本发明提出了一种夹层式复合材料面板及其成型工艺，包括：上蒙皮、芯材和下蒙皮，上蒙皮由表层、夹层和末层组成，下蒙皮与上蒙皮相同，芯材为PET闭孔泡沫预型体；成型时，上蒙皮制备方法为：将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，湿法加压成型得表层；向表层上+45°纵向铺设预浸面材，加热、抽真空后保温，升温后抽真空、保温；再继续‑45°横向铺设预浸面材，加热、抽真空后保温，升温后抽真空、保温得夹层；向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，湿法加压成型。本发明提出的夹层式复合材料面板致密性好、刚度高、一致性佳，其成型工艺简单、易操作，适合规模化生产。

Description

一种夹层式复合材料面板及其成型工艺
技术领域
本发明属于复合材料成型技术领域，特别是指一种夹层式复合材料面板及其成型工艺。
背景技术
传统的轻量化、夹层式复合材料面板多以PU或PVC泡沫作为芯材保温层，选用玻璃纤维织物增强材料作为蒙皮结构层，采用湿法或导入一次成型工艺进行制备。由于残留的空气聚集在中部使得树脂无法浸润玻璃纤维织物，且泡沫会严重影响树脂上下两层之间的流动，使得泡沫下层玻璃纤维织物浸润不充分的问题更加严重，最终得到的夹层式复合材料面板孔隙率高、致密性差、树脂含量分布不均匀、产品的一致性较低，且对操作环境及人员的要求较高，不利于批量化作业。
发明内容
为解决以上现有技术的不足，本发明提出了一种夹层式复合材料面板及其成型工艺。
本发明的技术方案是这样实现的：
一种夹层式复合材料面板，包括：上蒙皮、芯材和下蒙皮，上蒙皮由表层、夹层和末层组成，表层为浸润树脂的玻璃纤维织物，夹层为预浸面材，末层与表层相同，下蒙皮与上蒙皮相同，芯材为PET闭孔泡沫预型体。
本发明以性能优异的预浸面材替代玻璃纤维织物增强织物，有助于搭建气密性好、耐压性高的网状结构，同时提供了良好的浸润体系，有助于最终形成性能优异的复合材料面板。
优选的，夹层式复合材料面板采用C型的夹层设计，且上蒙皮层、芯材、下蒙皮层的厚度比为1：3：1。上蒙皮层与下蒙皮层构建了复合材料面板的对称性“桥梁”，如此厚度比例的设计，不仅能够消除层间的界面应力，还提供了优异的承力载体，有助于提高夹层式复合材料面板的整体刚度。
优选的，表层中，玻璃纤维织物的面密度为100-300g/m2，树脂的重量比为50％-70％。
进一步优选的，夹层为高树脂含量混杂纤维的预浸面材，其面密度为100-200g/m2，树脂为含量40％-45％的改性EP。
更为优选的，夹层的容重80-100g/m2。
本发明还提出上述夹层式复合材料面板的成型工艺，先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂(具体不限，可以根据需要进行选择。)，常温下闭模湿法加压成型得到表层；
第二步，向表层上+45°纵向铺设预浸面材，加热至75-85℃并抽真空至-0.07～-0.09MPa，保持8-12min，再升温至115-125℃并抽真空至-0.05～-0.07MPa，保持3-7min；再继续-45°横向铺设预浸面材，加热至75-85℃并抽真空至-0.07～-0.09MPa，保持8-12min，再升温至115-125℃并抽真空至-0.05～-0.07MPa，保持3-7min，得到夹层；先+45°纵向铺设，再-45°横向铺设，气孔表面张力降低并形成流动趋向性，预浸面材在梯度温度变化下将树脂流动化，因此可以形成刮板原理，实现了树脂的充分填充；
第三步，向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂(树脂与第一步所浸润的树脂一致，具体不限，可以根据需要进行选择。)，常温下闭模湿法加压成型得到末层。
上蒙皮、PET闭孔泡沫预型体、下蒙皮分别成型得到三个低孔隙率层，再将三个低孔隙率层进行叠加，移位进行封闭补位，最终得到致密性较高的夹层式复合材料面板。本发明利用层间界面移位封闭渗漏点的方式提高了夹层式复合材料面板的致密性。与传统成型工艺相比，该工艺设计不仅对操作环境的要求低，而且成型工艺稳定性更高，产品成型流动趋向性更好，非常适合规模化生产。
优选的，第二步，向表层上+45°纵向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min；再继续-45°横向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min，得到夹层。该工艺参数下，所得到的夹层性能更为优异。
本发明提出的夹层式复合材料面板致密性好、刚度高、一致性佳，其成型工艺简单、易操作，所需的中间工序少、零部件少，而且可重复性高，非常适合规模化生产。
具体实施方式
下面将结合本发明的实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
一种夹层式复合材料面板，包括：上蒙皮、芯材和下蒙皮，上蒙皮层、芯材、下蒙皮层的厚度比为1：3：1；上蒙皮由表层、夹层和末层组成，表层为浸润树脂的玻璃纤维织物，玻璃纤维织物的面密度为300g/m2，树脂的重量比为60％，夹层为改性EP含量为45％的硼-碳混杂纤维的预浸面材(面密度为100g/m2)，末层与表层相同，下蒙皮与上蒙皮相同，芯材为容重90g/m2的P ET闭孔泡沫预型体。
上述夹层式复合材料面板的成型工艺为：先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到表层；
第二步，向表层上+45°纵向铺设预浸面材，加热至75℃并抽真空至-0.07MPa，保持10min，再升温至115℃并抽真空至0.05MPa，保持5min；再继续-45°横向铺设预浸面材，加热至75℃并抽真空至-0.07MPa，保持10min，再升温至115℃并抽真空至-0.05MPa，保持5min，得到夹层；
第三步，向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到末层。
实施例2
一种夹层式复合材料面板，包括：上蒙皮、芯材和下蒙皮，上蒙皮层、芯材、下蒙皮层的厚度比为1：3：1；上蒙皮由表层、夹层和末层组成，表层为浸润树脂的玻璃纤维织物，玻璃纤维织物的面密度为100g/m2，树脂的重量比为70％，夹层为改性EP含量为40％的亚麻-碳混杂纤维的预浸面材(面密度为150g/m2)，末层与表层相同，下蒙皮与上蒙皮相同，芯材为容重100g/m2的PET闭孔泡沫预型体。
上述夹层式复合材料面板的成型工艺为：先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到表层；
第二步，向表层上+45°纵向铺设预浸面材，加热至80℃并抽真空至-0.09MPa，保持12min，再升温至120℃并抽真空至-0.07MPa，保持7min；再继续-45°横向铺设预浸面材，加热至80℃并抽真空至-0.09MPa，保持12min，再升温至120℃并抽真空至-0.07MPa，保持7min，得到夹层；
第三步，向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到末层。
实施例3
一种夹层式复合材料面板，包括：上蒙皮、芯材和下蒙皮，上蒙皮层、芯材、下蒙皮层的厚度比为1：3：1；上蒙皮由表层、夹层和末层组成，表层为浸润树脂的玻璃纤维织物，玻璃纤维织物的面密度为200g/m2，树脂的重量比为50％，夹层为改性EP含量43％的聚乙烯-碳混杂纤维的预浸面材(面密度为200g/m2)，末层与表层相同，下蒙皮与上蒙皮相同，芯材为容重80g/m2的PET闭孔泡沫预型体。
上述夹层式复合材料面板的成型工艺为：先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到表层；
第二步，向表层上+45°纵向铺设预浸面材，加热至85℃并抽真空至-0.08MPa，保持8min，再升温至125℃并抽真空至-0.06MPa，保持3min；再继续-45°横向铺设预浸面材，加热至85℃并抽真空至-0.08MPa，保持8min，再升温至125℃并抽真空至-0.06MPa，保持3min，得到夹层；
第三步，向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到末层。
实施例4
一种夹层式复合材料面板，包括：上蒙皮、芯材和下蒙皮，上蒙皮层、芯材、下蒙皮层的厚度比为1：3：1；上蒙皮由表层、夹层和末层组成，表层为浸润树脂的玻璃纤维织物，玻璃纤维织物的面密度为200g/m2，树脂的重量比为60％，夹层为改性EP含量42％的碳-玻璃混杂纤维的预浸面材(面密度为150g/m2)，末层与表层相同，下蒙皮与上蒙皮相同，芯材为容重90g/m2的P ET闭孔泡沫预型体。
上述夹层式复合材料面板的成型工艺为：先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到表层；
第二步，向表层上+45°纵向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min；再继续-45°横向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min，得到夹层；
第三步，向夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到末层。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，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。

Claims (4)

1.一种夹层式复合材料面板，其特征在于：包括：上蒙皮、芯材和下蒙皮，所述上蒙皮由表层、夹层和末层组成，所述表层为浸润树脂的玻璃纤维织物，所述夹层为预浸面材，所述末层与所述表层相同，所述下蒙皮与所述上蒙皮相同，所述芯材为PET闭孔泡沫预型体；所述上蒙皮层、所述芯材、所述下蒙皮层的厚度比为1：3：1；所述表层中，所述玻璃纤维织物的面密度为100-300g/m2，所述树脂的重量比为50％-70％；所述夹层为高树脂含量混杂纤维的预浸面材，其面密度为100-200g/m2，所述树脂为含量40％-45％的改性EP。
2.根据权利要求1所述的夹层式复合材料面板，其特征在于：所述芯材的容重为80-100g/m2。
3.一种如权利要求1或2所述的夹层式复合材料面板的成型工艺，先制备上蒙皮和下蒙皮，再将上蒙皮置于上模具中、将下蒙皮置于下模具中，在下蒙皮上放置成型的PET闭孔泡沫预型体，合上模具并加热成型，成型之后开模即可，其特征在于：上蒙皮与下蒙皮的制备方法为：
第一步，将玻璃纤维织物铺设于模具表面，在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到表层；
第二步，向所述表层上+45°纵向铺设预浸面材，加热至75-85℃并抽真空至-0.07～-0.09MPa，保持8-12min，再升温至115-125℃并抽真空至-0.05～-0.07MPa，保持3-7min；再继续-45°横向铺设预浸面材，加热至75-85℃并抽真空至-0.07～-0.09MPa，保持8-12min，再升温至115-125℃并抽真空至-0.05～-0.07MPa，保持3-7min，得到夹层；
第三步，向所述夹层的表面再铺设一层玻璃纤维织物，再在玻璃纤维织物上均匀浸润树脂，常温下闭模湿法加压成型得到末层。
4.根据权利要求3所述的夹层式复合材料面板的成型工艺，其特征在于：第二步，向所述表层上+45°纵向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min；再继续-45°横向铺设预浸面材，加热至80℃并抽真空至-0.08MPa，保持10min，再升温至120℃并抽真空至-0.06MPa，保持5min，得到夹层。
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