CN113121955B - 一种超薄无卤阻燃且具有低粗糙度的玻纤板材及其制备方法 - Google Patents
一种超薄无卤阻燃且具有低粗糙度的玻纤板材及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种超薄无卤阻燃且具有低粗糙度的玻纤板材,将树脂混合液浸渍在电子级玻璃纤维布上制得半固化片;所述半固化片的上下两侧叠置离型膜,同时,所述离型膜的外侧叠置钢板,然后放入压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材;所述树脂混合液包括树脂40~160份,橡胶1~30份,填料5~65份,固化剂1.0~20.0份,促进剂0.003~3.0份,溶剂10~60份。该发明可以解决超薄板在加工过程中容易出现裂纹、爆板且合格率低的问题,同时经一步热压后即可得到低粗糙度的环氧玻纤板材,不需再经后续加工即可得到低粗糙度的效果,同时玻纤板材无卤阻燃。
Description
技术领域
本发明涉及增强材料技术领域,更具体地说,它涉及一种超薄无卤阻燃且具有低粗糙度的玻纤板材及其制备方法。
背景技术
近年来,随着科技的发展,树脂玻纤材料的性能越来越接近金属材料的性能,出现了很多替代金属材料的树脂玻纤材料,但对于精密仪器内的部分高要求的金属材料的替代依然比较难。某款精密仪器中金属材料要求使用树脂玻纤材料进行替代,要求树脂玻纤材料有良好的表面粗糙度和光泽度(Ra≤0.06,Rz≤0.6),无卤阻燃且Tg达到150℃以上,材料厚度超薄(0.1-0.2mm),并在此情况下不降低其强度与加工性,如后续加工中不易损坏,不出现撕裂、爆板等情况。目前现有市场上有满足单个条件的树脂玻纤材料,但并没有同时满足以上条件的产品。
发明内容
针对现有技术存在的不足,本发明在于提供一种超薄无卤阻燃且具有低粗糙度的玻纤板材及其制备方法,通过电子级玻璃纤维的处理、树脂配方及成型工艺的调整,可一次成型出超薄无卤阻燃且具有低粗糙度的玻纤板材。
为实现上述目的,本发明提供了如下技术方案:将树脂混合液浸渍在电子级玻璃纤维布上制得半固化片;
所述半固化片的上下两侧叠置离型膜,同时,离型膜的外侧叠置钢板,然后放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材;
所述树脂混合液按重量份计包括树脂40~160份,橡胶1~30份,填料5~65份,固化剂1.0~20.0份,催化剂0.003~3.0份,溶剂10~60份。
作为优选,所述树脂混合液按重量份计包括树脂50~150份,橡胶1~20份,填料10~50份,固化剂1.0~10.0份,催化剂0.005~2.0份,溶剂20~50份。
一种如上所述的玻纤板材的制备方法,包括如下步骤:
步骤一)、将电子级玻璃纤维布在250-300℃下烘烤10-30min,待冷却后放入醇类处理剂与偶联剂的混合物中超声处理,自然干燥后在烘箱内进行烘干;高温处理后的电子级玻纤布去除了玻纤表面的上浆剂及其他杂质,混合物的处理使玻纤与树脂的浸润性变得更强,超声处理能够使这个效果更加显著,整个处理的效果主要是为了提高玻纤与树脂的浸润性。
步骤二)、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的树脂混合液;橡胶可以提高板材的韧性及粘结力。
步骤三)、将树脂混合液浸渍到步骤一)中经处理后得到的电子级玻璃纤维布上,然后,放入烘箱烘烤得到半固化片;
步骤四)、在半固化片表面叠置离型膜和钢板,放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材。
作为优选,步骤一)中,所述醇类处理剂为甲醇、乙醇、丁醇、异丁醇中的一种或多种;所述偶联剂为KH550、KH560、KH570中的一种或多种。
作为优选,步骤二)中,所述树脂为含磷环氧树脂、双官能团环氧树脂、多官能团环氧树脂、含磷酚醛环氧树脂、苯氧树脂中的一种或多种。含磷环氧和含磷酚醛主要起到阻燃的效果,磷系材料可阻燃,同时使用磷系材料代替卤素材料可以起到无卤的效果,含磷酚醛的TG较高,可以提高整体板材的TG。
作为优选,步骤二)中,所述橡胶为丁腈橡胶、核壳橡胶、聚氨酯橡胶、丁苯橡胶中的一种或多种。为了提高板材的韧性及粘结力。
作为优选,步骤二)中,所述填料为氢氧化铝、滑石粉、钛白粉、硅微粉中的一种或多种。氢氧化铝也起到阻燃效果,填料对加工性能会有所提高。
作为优选,步骤二)中,所述固化剂为电子级双氰胺(DCD)、4,4-二氨基二苯砜(DDS)中的一种或两种。
作为优选,步骤二)中,所述溶剂为二甲基甲酰胺(DMF)、丁酮、甲苯中的一种或多种。
作为优选,步骤三)中,将树脂混合液浸渍到步骤一)中经处理后得到的电子级玻璃纤维布上,然后经烘箱140℃~200℃加热3-10min,冷却后得到半固化片。
综上所述,本发明具有以下有益效果:本发明提供了一种超薄无卤阻燃且具有低粗糙度的玻纤板材及其制备方法,可以解决超薄板在加工过程中容易出现裂纹、爆板且合格率低的问题,同时经一步热压后即可得到低粗糙度的环氧玻纤板材,不需再经后续加工即可得到低粗糙度的效果,同时板材玻纤无卤阻燃,TG>150℃且<170℃。
具体实施方式
本实施例公开了一种超薄无卤阻燃且具有低粗糙度的玻纤板材,将树脂混合液浸渍在电子级玻璃纤维布上制得半固化片;
半固化片的上下两侧叠置离型膜,同时,离型膜的外侧叠置钢板,然后放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材;
树脂混合液按重量份计包括树脂40~160份,橡胶1~30份,填料5~65份,固化剂1.0~20.0份,催化剂0.003~3.0份,溶剂10~60份。其中,电子级玻璃纤维布为1080电子布或者2116电子布,因板材超薄(0.1-0.2mm),因此克重过大的玻纤不宜使用,同时克重小的玻纤对于加工方面也有提升,减少撕裂爆板的情况。
作为优选,其中,树脂混合液按重量份计包括树脂50~150份,橡胶1~20份,填料10~50份,固化剂1.0~10.0份,催化剂0.005~2.0份,溶剂20~50份。
一种如上所述的玻纤板材的制备方法,包括如下步骤:
步骤一)、将电子级玻璃纤维布在250~300℃下第一次烘烤10~30min,待冷却后放入醇类处理剂与偶联剂的混合物中超声处理120~180min,晾干后在通平行风的80~100℃烘箱内第二次烘烤30~180min至烘干;醇类处理剂为甲醇、乙醇、丁醇、异丁醇中的一种或多种;所述偶联剂为KH550、KH560、KH570中的一种或多种。
步骤二)、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的树脂混合液;所述树脂为含磷环氧树脂、双官能团环氧树脂、多官能团环氧树脂、含磷酚醛环氧树脂、苯氧树脂中的一种或多种。所述橡胶为丁腈橡胶、核壳橡胶、聚氨酯橡胶、丁苯橡胶中的一种或多种。所述填料为氢氧化铝、滑石粉、钛白粉、硅微粉中的一种或多种。所述固化剂为电子级双氰胺(DCD)、4,4-二氨基二苯砜中(DDS)的一种或两种。所述溶剂为二甲基甲酰胺(DMF)、丁酮、甲苯中的一种或多种。
步骤三)、将树脂混合液浸渍到步骤一)中经处理后得到的电子级玻璃纤维布上,然后经烘箱140℃~200℃加热3~10min,冷却后得到流动度3%~15%的半固化片;
步骤四)、在半固化片表面叠置离型膜和钢板,放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材。具体的,半固化片表面叠置离型膜和钢板后形成叠配结构,该叠配结构在温度80℃~230℃,压力0.5~5Mpa的层板热压机中真空高温高压成型,分解后得到超薄(0.1~0.2mm)的有强度的易加工的无卤阻燃且Tg大于150℃小于170℃的低粗糙度(Ra≤0.1,Rz≤1.0)的环氧玻纤板材。
其中步骤四)中的离型膜为低粗糙度(Ra≤0.06,Rz≤0.6)的聚丙烯(PP)、聚对苯二甲酸乙二醇酯(PET)、聚酰胺(PA)、聚四氟乙烯(PTFE)中的一种;钢板为镜面钢板,且在该镜面钢板表面镀上一层PTFE膜,进而得到镀层镜面钢板,其粗糙度可达Ra≤0.1,Rz≤1.0。
实施例1~5的具体组份及其用量如下表1:
表1实施例1~5的组份及其用量
其中,偶联剂1:KH550和KH560的混合物;偶联剂2:KH550、KH560和KH570的混合物;2MI=1:表示单一组分的2-甲基咪唑。
对比例1、一种常规板材
步骤一、将所需的树脂、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤二、将树脂混合液浸渍到处理后电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤三、在半固化片表面叠置常规离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材。
对比例2、一种超薄不处理的无卤阻燃且具有低粗糙度的玻纤板材
步骤一、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤二、将树脂混合液浸渍到电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤三、在半固化片表面叠置低粗糙度的离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材。
对比例3、一种超薄不含橡胶的无卤阻燃且具有低粗糙度的玻纤板材
步骤一、将电子级玻璃纤维布在250~300℃高温下烘烤10~30min后待冷却后放入醇类处理剂与偶联剂的混合物中超声处理120~180min,晾干后在通平行风的80~100℃烘箱内烘30~180min至烘干。
步骤二、将所需的树脂、填料、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤三、将树脂混合液浸渍到处理后的电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤四、在半固化片表面叠置低粗糙度的离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材;
对比例4、一种超薄的无卤阻燃的玻纤板材
步骤一、将电子级玻璃纤维布在250~300℃高温下烘烤10~30min后待冷却后放入醇类处理剂与偶联剂的混合物(比例10:1~100:1)中超声处理120~180min,晾干后在通平行风的80~100℃烘箱内烘30~180min至烘干。
步骤二、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤三、将树脂混合液浸渍到处理后的电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤四、在半固化片表面叠置常规离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材;
对比例5、一种超薄的无卤阻燃的玻纤板材
步骤一、将电子级玻璃纤维布在200℃高温下烘烤10~30min后待冷却后放入醇类处理剂与偶联剂的混合物中超声处理120~180min,晾干后在通平行风的70~80℃烘箱内烘30~180min至烘干。
步骤二、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤三、将树脂混合液浸渍到处理后的电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤四、在半固化片表面叠置低粗糙度的离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材。
对比例6、一种超薄的无卤阻燃的玻纤板材
步骤一、将电子级玻璃纤维布在200℃高温下烘烤10~30min后待冷却后放入醇类处理剂与偶联剂的混合物中超声处理120~180min,晾干后在通平行风的70~80℃烘箱内烘30~180min至烘干。
步骤二、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的无卤树脂混合液;
步骤三、将树脂混合液浸渍到处理后的电子级玻璃纤维布上,放入140~200℃烘箱烘烤3~10min得到流动度3~15%半固化片;
步骤四、在半固化片表面叠置低粗糙度的离型膜和钢板,放入80℃~230℃,0.5~5Mpa平板压机内进行热压2~5h,最后拆解离型膜和钢板进而得到板材。对比例1~6的具体组份及其含量如下表2:
表2对比例1~6的组份及其含量
注:常规离型膜:粗糙度为Ra>0.06,Rz>0.6的PP、PET、PA、PTFE中的一种;常规钢板:Ra>0.1,Rz>1.0的钢板。
将上述的实施例1~5与对比例1~5进行性能对比,得到如下表3和表4:
表3实施例1~5的性能表征
表4对比例1~5的性能表征
实施例1与对比例1进行对比,配方的设计对于产品的无卤阻燃也有影响;
实施例1、对比例1、对比例2及对比例3进行对比,可以说明要实现不撕裂爆板要求的超薄玻纤板材,需对配方设计及玻纤处理同时进行,单一的配方进行设计或者单一的对玻纤进行处理,切割时依然会出现撕裂和爆板的情况;实施例1和对比例4进行对比,我们可以发现,在此条件下,使用低粗糙度的离型膜和钢板,可以得到低粗糙度(Ra≤0.1,Rz≤1.0)的板材;实施例1和对比例4进行对比,要实现超薄板切割时不撕裂爆板现象,玻纤的选用影响也比较大,目前只有使用1080/2116这种克重低于105g/m2的玻纤才可实现;实施例1~4及对比例5进行对比,我们可以得出,配方中含磷环氧和含磷酚醛,且所占树脂比重及树脂胶液配方各成分的设定对于板材的切割情况会有影响,同时影响板材的TG、卤素及是否阻燃。综上,在特定情况下对玻纤进行处理、对配方进行设计,可以保证薄板在切割加工时不出现撕裂和爆板的情况,而单一处理的情况下依旧有撕裂和爆板的情况出现;该配方设计得到高TG且无卤阻燃的玻纤板材;同时使用镜面钢板和低粗糙度的(Ra≤0.06,Rz≤0.6)的离型膜,可以得到低粗糙度(Ra≤0.1,Rz≤1.0)的板材。
Claims (9)
1.一种超薄无卤阻燃且具有低粗糙度的玻纤板材,其特征是:将树脂混合液浸渍在电子级玻璃纤维布上制得半固化片;所述电子级玻璃纤维布需预先在250-300℃下烘烤10-30min,待冷却后放入醇类处理剂与偶联剂的混合物中超声处理,自然干燥后在烘箱内进行烘干;所述电子级玻璃纤维布为1080电子布或者2116电子布;
所述半固化片的上下两侧叠置离型膜,同时,离型膜的外侧叠置钢板,然后放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材;所述离型膜的粗糙度Ra≤0.06、Rz≤0.6,所述钢板粗糙度Ra≤0.1、Rz≤1;
所述树脂混合液按重量份计包括树脂40~160份,橡胶1~30份,填料5~65份,固化剂1.0~20.0份,催化剂0.003~3.0份,溶剂10~60份;树脂为含磷环氧树脂、多官能团环氧树脂、含磷酚醛树脂和苯氧树脂;其中含磷环氧树脂、多官能团环氧树脂、含磷酚醛树脂、苯氧树脂的质量比为9:8:2:1、8:8:2:1或8:9:2:2;或者树脂为含磷环氧树脂、多官能团环氧树脂、含磷酚醛树脂=9:8:2。
2.根据权利要求1所述的超薄无卤阻燃且具有低粗糙度的玻纤板材,所述树脂混合液按重量份计包括树脂50~150份,橡胶1~20份,填料10~50份,固化剂1.0~10.0份,催化剂0.005~2.0份,溶剂20~50份。
3.一种如权利要求1或2所述的玻纤板材的制备方法,其特征是,包括如下步骤:
步骤一)、将电子级玻璃纤维布在250-300℃下烘烤10-30min,待冷却后放入醇类处理剂与偶联剂的混合物中超声处理,自然干燥后在烘箱内进行烘干;
步骤二)、将所需的树脂、橡胶、填料、固化剂、催化剂、溶剂进行混合,得到均匀的树脂混合液;
步骤三)、将树脂混合液浸渍到步骤一)中经处理后得到的电子级玻璃纤维布上,然后,放入烘箱烘烤得到半固化片;
步骤四)、在半固化片表面叠置离型膜和钢板,放入平板压机内进行热压,最后拆解离型膜和钢板进而得到玻纤板材。
4.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤一)中,所述醇类处理剂为甲醇、乙醇、丁醇、异丁醇中的一种或多种;所述偶联剂为KH550、KH560、KH570中的一种或多种。
5.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤二)中,所述橡胶为丁腈橡胶、核壳橡胶、聚氨酯橡胶、丁苯橡胶中的一种或多种。
6.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤二)中,所述填料为氢氧化铝、滑石粉、钛白粉、硅微粉中的一种或多种。
7.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤二)中,所述固化剂为电子级双氰胺、4,4-二氨基二苯砜中的一种或两种。
8.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤二)中,所述溶剂为二甲基甲酰胺、丁酮、甲苯中的一种或多种。
9.根据权利要求3所述的玻纤板材的制备方法,其特征是:步骤三)中,将树脂混合液浸渍到步骤一)中经处理后得到的电子级玻璃纤维布上,然后经烘箱140℃~200℃加热3-10min,冷却后得到半固化片。
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