CN113149683A

CN113149683A - Carbon or carbon ceramic composite material short fiber preform, product and preparation method thereof

Info

Publication number: CN113149683A
Application number: CN202110471234.4A
Authority: CN
Inventors: 申富强; 申富胜
Original assignee: Q Carbon Material Co ltd
Current assignee: Q Carbon Material Co ltd
Priority date: 2021-04-29
Filing date: 2021-04-29
Publication date: 2021-07-23

Abstract

The invention relates to a carbon or carbon ceramic composite material short fiber preform, a product and a preparation method thereof, which are characterized in that the core of the preparation method is to extrude and mold short carbon fibers by an extruder to realize a continuous molded product; the chopped carbon fiber preform obtained by the preparation method is adopted; and obtaining the carbon-carbon or carbon-ceramic composite material product by vapor deposition or liquid deposition or a combination method of the two. The invention has the beneficial effects that: the chopped carbon fiber composite material product is prepared from pure short fibers, the raw material cost is low, the preparation method is simple in process, continuous production can be realized, the production efficiency is high, the product can be directly molded according to the shape of the final product, the machining allowance is reduced, the grinding waste is reduced, the preparation period is greatly shortened, and the cost is reduced; by adopting the annular cutting process, the edge material and the core material do not need to be removed, so that the waste of the carbon-carbon composite material brake disc preform material can be reduced.

Description

Carbon or carbon ceramic composite material short fiber preform, product and preparation method thereof

Technical Field

The invention relates to the technical field of carbon or carbon ceramic composite materials, in particular to a carbon or carbon ceramic composite material short fiber preform, a product and a preparation method thereof.

Background

The brake component is a brake component which is required to be equipped for airplanes, trains, automobiles, motorcycles and the like, and the use safety of vehicles and equipment is directly influenced by the quality of the performance of the brake component.

In the process of manufacturing the brake component, the vehicle which does not move at high speed is generally manufactured by adopting a powder metallurgy process; the high-speed vehicle adopts a preform preparation process, raw materials for preparing the preform are generally used for a carbon-carbon composite material, and the carbon-carbon composite material is a high-performance composite material of a carbon fiber reinforced carbon matrix and has the characteristics of high strength, corrosion resistance, strong designability and the like.

The brake material prefabricated body prepared by the prior art has the following problems:

firstly, the manufacturing period is long;

secondly, the process steps are complicated, the prior art generally adopts a multilayer composite needling or multilayer mould pressing process, wastes time and labor and cannot realize continuous production;

third, with high costs, generally make into the positive direction panel earlier at present, then go the angle and draw the core and obtain the preform, lead to a large amount of materials extravagant like this.

And fourthly, the structural strength is low, and the interlayer shearing force is not enough and easy to delaminate due to the currently adopted process, so that the overall strength is not enough.

The scheme provides a novel carbon-carbon composite material prefabricated body, a product and a preparation method thereof. By developing new thermal structure composite materials, the application of the thermal structure composite materials is not limited to brake discs, and the thermal structure composite materials can be further expanded to vehicles in other fields, such as trains, heavy trucks, passenger cars, buses, sports cars and the like.

Disclosure of Invention

The invention provides a carbon-carbon or carbon-ceramic composite material short fiber preform, a product and a preparation method thereof, which solve the technical problems.

In order to solve the technical problems, the invention is realized by the following technical scheme:

the invention provides a preparation method of a chopped carbon fiber preform for manufacturing a carbon or carbon ceramic composite material. The method specifically comprises the following steps:

s1, molding, namely extruding and molding the chopped carbon fibers by an extruder to obtain a continuous molded product;

and S2, cutting, namely cutting the solidified preform blank into a multi-section preform according to the thickness of the final product.

Further, the forming shape of the preform is determined according to the selected core mold according to different requirements.

Furthermore, the chopped carbon fibers are prepared from chopped carbon fibers with the length of 2mm-10mm or any mixture of multiple groups of chopped carbon fibers in proportion.

And further comprising S3, and carrying out needle punching compounding on the obtained multi-section prefabricated body thin sheet and at least one layer of graphite paper or carbon cloth.

Further, the carbon cloth is made of special carbon cloth which is woven cloth or unidirectional cloth.

Furthermore, the woven cloth is woven by fiber bundles or prepreg tapes, and the thickness of the fiber bundles or tapes is 0.01-0.20 mm, preferably 0.01-0.05 mm.

The second aspect of the invention provides a preparation method of a chopped carbon fiber preform for carbon or carbon ceramic composite material preparation, which is technically characterized by comprising the step of extruding and molding chopped carbon fibers by an extruder to realize a continuous molded product. The method specifically comprises the following steps:

s1, uniformly mixing the chopped carbon fibers and the resin according to a certain proportion;

s2, molding, namely extruding and molding the short carbon fiber prepreg through an extruder to realize a continuous molded product;

s3, curing, and heating to cure the resin;

and S4, cutting, namely cutting the solidified preform blank into a multi-section preform according to the thickness of the final product.

Further, the resin includes one or more of polyazosilanes, polycarbosilanes, epoxy resins, phenolic resins, urea-formaldehyde resins, and the like.

Furthermore, the soaking material adopts the mass percentage, and the resin content is 0.01-50%.

The invention provides a chopped carbon fiber preform, which is characterized by being obtained by any one of the preparation methods.

The invention provides a carbon or carbon ceramic composite material product obtained by the preparation method, which is characterized in that: the carbon or carbon ceramic composite material product is obtained by vapor deposition or liquid deposition or a combination method of the vapor deposition and the liquid deposition.

Further, the carbon-carbon or carbon-ceramic composite material product comprises a plate, a column, a cylinder, a sphere, a ring material and other special-shaped materials.

Further, the carbon-carbon or carbon-ceramic composite material product comprises a brake disc, a brake pad, a support rod, a tray, an electrode column, a support column, a material rack, a support plate, a crucible, a guide cylinder, a heat-insulating barrel, a cover plate, a support ring, a fastener, a rocket throat lining, an engine nozzle and an engine blade.

The invention has the beneficial effects that:

1. the prefabricated body of the short carbon fiber composite material type brake component is made of pure short fibers, the equipment space occupancy rate is small, and the preparation method is simple in process.

2. The raw materials are easy to obtain, and the cost is low;

3. continuous production can be realized, the production efficiency is high, and the preparation period is greatly shortened;

4. the forming machine can be directly formed according to the shape of a final product, reduces machining allowance, reduces grinding waste and reduces cost.

Specifically, the following advantages are also provided:

1) the addition of the graphite paper has a buffering effect, so that squeaking is reduced;

2) the addition of graphite paper has heat conduction radiating effect for outside brake disc core temperature conducts the dish fast, does benefit to the heat dissipation, promotes friction stability, improves the life of brake disc. (supplement contrast data, e.g. time to remove heat from core, e.g. 5s when not added and 3s when added)

3) The addition of the carbon cloth can weave the high-volume-density fiber cloth which can be woven only by weaving small-tow carbon fibers at the cost of large-tow carbon fibers, so that the cost is greatly reduced;

4) the addition of the carbon cloth can greatly improve the volume fraction of the composite material preform, so that the strength of the composite material is greatly improved;

5) the addition of the carbon cloth greatly shortens the deposition period of the carbon-carbon composite material, and further reduces the cost of the carbon-carbon composite material;

6) the carbon cloth is added, so that the carbon-carbon composite material achieves the same strength, the thickness of the prefabricated body can be reduced, and the cost is reduced;

7) the addition of the carbon cloth enables the carbon-carbon composite material to achieve the same strength under the condition of using the preforms with the same density, and the carbon-carbon composite material has low density and low cost.

8) The addition of the carbon cloth can greatly reduce the deformation of the carbon-carbon composite material and improve the structural strength.

9) Compared with the existing plate-type prefabricated body, the annular cutting process is adopted, so that the waste of the prefabricated body material of the brake disc can be reduced without removing rim charge and core material;

10) by adopting the annular cutting process, a plurality of disc-type prefabricated bodies can be manufactured at one time, and the manufacturing working hours can be reduced;

11) by adopting the annular cutting process, compared with the plate type needling preform in the prior art, the density of the disc type preform is more uniform, and the consistency of the preform is enhanced;

12) resin and filler are added into the prefabricated body, so that the period of vapor deposition can be effectively shortened, the functional requirements of buffering, shock absorption, heat dissipation, heat conduction and the like are met, and the problems of insufficient heat dissipation, vibration and oxidation resistance and the like of the conventional brake disc are solved.

13) And the resin is added into the prefabricated body, so that dust can be reduced, and pollution is reduced.

14) Compared with the existing needling plate type prefabricated body short fiber process, the short fiber process has the advantages of easily available raw materials and low cost.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.

FIG. 1 is a first process flow chart of the preparation method of the carbon-carbon or carbon-ceramic composite short fiber preform according to the present invention;

FIG. 2 is a process flow chart of a preparation method of a carbon-carbon or carbon-ceramic composite short fiber preform according to the present invention;

FIG. 3 is a schematic structural diagram of a first preform of the brake material of the present invention;

FIG. 4 is a schematic structural diagram of a brake material preform according to the present invention;

FIG. 5 is a schematic structural diagram III of a brake material preform according to the present invention;

FIG. 6 is a fourth schematic structural diagram of a brake material preform according to the present invention;

FIG. 7 is a schematic structural diagram of a brake material preform according to the present invention;

FIG. 8 is a schematic diagram of the composite of the preform and graphite paper or carbon cloth by needling;

FIG. 9 is a schematic view of a woven cloth;

FIG. 10 is a schematic view of a sheet product of the present invention;

FIG. 11 is a schematic representation of a pillar article according to the present invention;

FIG. 12 is a schematic view of a cartridge article of the present invention;

FIG. 13 is a schematic representation of a spherical article according to the present invention;

the notation in the figure is:

1 is a short carbon fiber layer, 2 resin layers, 3 graphite paper or carbon cloth, and 4 is a plurality of carbon fiber pure short fibers.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

In the description of the present invention, it is to be understood that the directions or positional relationships are merely for convenience of description and simplicity of description, and are not intended to indicate or imply that the components or elements referred to must have a particular direction, be constructed and operated in a particular direction, and thus are not to be construed as limiting the present invention.

Example 1:

the invention provides a preparation method of a carbon-carbon or carbon-ceramic composite material short fiber preform, which is characterized by comprising the following steps as shown in figure 1:

s1, molding, namely extruding and molding the chopped carbon fibers; in order to form preforms of different shapes, it is possible to install a core mold on the fixed bed according to different requirements so as to manufacture preforms of different shapes, for example, a cylindrical core mold, for example, having a diameter of 280mm, and an inner cavity of an extruder die having a diameter of 420mm, and to form a hollow annular preform having an inner diameter of 280mm and an outer diameter of 420mm on the fixed bed; for example, a heart-shaped plate, a preform with a heart-shaped recess in the middle, typically in the form of a cake, can be formed in the fixed bed.

S2, cutting the solidified preform blank into a multi-section preform according to the thickness of the final product (for example, 30mm for a common airplane brake disc, 28mm for an automobile brake disc and 40-90 mm for a high-speed rail), wherein the volume density of fibers in the preform is controlled to be 0.1-0.7 g/cm³。

Example 2:

the invention provides a preparation method of a carbon-carbon or carbon-ceramic composite material short fiber preform, which is characterized by further comprising the following steps under the existing steps of example 1, as shown in figure 1:

and S3, needling and compounding the obtained multi-section prefabricated body slices and at least one layer of graphite paper or carbon cloth. The carbon cloth is made of special carbon cloth which is woven cloth or unidirectional cloth. The woven cloth is woven by fiber bundles or prepreg tapes. The thickness of the fiber bundle or the tape is 0.01 to 0.50mm, preferably 0.01 to 0.20mm, more preferably 0.01 to 0.05 mm.

Example 3:

the invention provides a preparation method of a carbon-carbon or carbon-ceramic composite material short fiber preform, which is characterized by comprising the following steps as shown in figure 2:

s1, uniformly mixing the chopped carbon fibers and the resin according to a certain proportion; the resin comprises one or more of polysilazane, polycarbosilane, epoxy resin, phenolic resin, urea resin and the like; the soaking material adopts the mass percentage, and the resin content is 0.01-50%; the chopped carbon fibers are prepared by mixing chopped carbon fibers with the length of 2mm-10mm or any multiple groups of chopped carbon fibers in proportion.

S2, molding, namely extruding and molding the short carbon fiber prepreg through an extruder to realize a continuous molded product; molding, namely extruding and molding the short carbon fiber prepreg; in order to form the prefabricated bodies with different shapes, a core mould can be arranged on the fixed bed according to different requirements so as to manufacture the prefabricated bodies with different shapes, such as a circular plate, and then a prefabricated body with a circular notch in the middle can be formed on the fixed bed; for example, a heart-shaped plate, a preform with a heart-shaped recess in the middle, typically in the form of a cake, can be formed in the fixed bed.

S3, curing, namely heating to cure the resin, wherein the curing temperature is different according to different resins;

s4, cutting, and feeding the solidified prefabricated blank according to the thickness of the final productLine-cutting into multi-section prefabricated body, and controlling the volume density of fiber in the prefabricated body to be 0.1-0.7 g/cm³。

Example 4:

the invention provides a preparation method of a chopped carbon fiber composite preform, which is characterized by comprising the following steps of:

s1, uniformly mixing the chopped carbon fibers and the resin according to a certain proportion; the resin comprises one or more of polysilazane, polycarbosilane, epoxy resin, phenolic resin, urea resin and the like; the soaking material adopts the mass percentage, and the resin content is 0.5 to 30 percent; the chopped carbon fibers are prepared by mixing chopped carbon fibers with the length of 2mm-10mm or any multiple groups of chopped carbon fibers in proportion.

S3, curing, and heating to cure the resin;

s4, slitting, namely slitting the cured preform blank into a multi-section preform according to the thickness of the final product, wherein the bulk density of fibers in the preform is controlled to be 0.1-0.7 g/cm³。

Example 5:

in addition to example 2, the thickness of the fiber bundle or tape is preferably 0.01 to 0.20mm, preferably 0.01 to 0.05mm, and for cost reduction, it is preferable to use a fiber yarn having a thickness of more than 12 k.

In the present embodiment, carbon fiber is taken as an example, the woven cloth in the present embodiment may be a general woven cloth, preferably a high bulk density woven cloth, and the parameters thereof can be referred to CN 201720691977.1. The width of the carbon fiber widening yarn is selected from 8 +/-0.5 mm, 10 +/-0.7 mm, 16 +/-1 mm, 20 +/-1 mm, 27 +/-2 mm or 34 +/-2.5 mm, and the density of the carbon fiber woven cloth is correspondingly selected from 200 +/-5 g/m2, 160 +/-5 g/m2, 100 +/-3 g/m2, 80 +/-3 g/m2, 60 +/-3 g/m2 or 48 +/-2 g/m 2.

The high bulk density woven fabric as referred to in the present application means that the smaller the grammage of the woven fabric is, the thinner the woven fabric is, that is, the higher the fiber content is, the greater the bulk density of the woven fabric with high bulk density is, by 15% to 30% as compared with the conventional woven fabric, and the high bulk density woven fabric means such a carbon fabric, in the case of the same distribution in the fiber plane.

Example 6:

on the basis of example 2, the film is directly cut according to the set thickness. And obtaining a short fiber preform.

Example 7:

in addition to example 2, if a carbon cloth is added, the carbon cloth is sliced and attached to a predetermined thickness. And obtaining a short fiber preform.

Example 8

In another aspect, the present invention provides a chopped carbon fiber composite article, including but not limited to brake material, characterized by being made using the preform as described in any of examples 1, 3, 5. The preparation method comprises vapor deposition or liquid deposition, and specifically comprises the following steps:

and S1, depositing, performing chemical vapor deposition, wherein the equipment adopts a vapor deposition furnace or a deposition system, carbon source gas is introduced into the deposition furnace from the bottom of the deposition furnace through a multi-path gas inlet pipe, the carbon source gas is directly introduced into the bottom of the deposition chamber in the furnace body at a certain flow and flow rate, and after pyrolysis, matrix carbon is formed and deposited in the interior or on the surface of the blank product.

The step may also be liquid deposition or gas-liquid mixed deposition, since the step is a well-known technique and detailed description thereof is omitted here.

S2, graphitizing;

and S3, fine machining, and performing precision machining forming on the prepared blank according to the requirements of the drawing to obtain the carbon brake disc.

On the basis of embodiment 6, in order to improve the wear resistance and corrosion resistance of the brake disc, modification steps such as siliconizing can be added according to different actual use scenes, and the modification steps are specifically as follows:

and (3) placing the prepared blank into a graphite crucible, placing the graphite crucible into a vacuum sintering furnace, heating to 1600-1650 ℃, preserving heat for 0.5-1 hour, and infiltrating molten Si or silane gas into a carbon brake disc for 12-20 min. And cooling and taking out the graphite crucible to prepare the carbon fiber reinforced SiC or CF matrix composite brake pad with the volume density of 1.95-2.16 g/cm 3.

The carbon or carbon ceramic composite material product comprises a plate, a column, a cylinder, a sphere, a ring material and other special-shaped materials.

The carbon-carbon or carbon-ceramic composite material product comprises a brake disc, a brake pad, a supporting rod, a tray, an electrode column, a supporting column, a material rack, a supporting plate, a crucible, a guide cylinder, a heat-insulating barrel, a cover plate, a supporting ring, a fastener, a rocket throat liner, an engine spray pipe and an engine blade.

Example 8

In another aspect, the present invention provides a chopped carbon fiber composite article, including but not limited to brake material, characterized by being made from the preform as described in any of examples 2 and 4. The preparation method comprises vapor deposition or liquid deposition, and specifically comprises the following steps:

s1, carbonizing, which is a known technology and is not described in detail;

and S2, depositing, performing chemical vapor deposition, wherein the equipment adopts a vapor deposition furnace or a deposition system, carbon source gas is introduced into the deposition furnace from the bottom of the deposition furnace through a multi-path gas inlet pipe, the carbon source gas is directly introduced into the bottom of the deposition chamber in the furnace body at a certain flow and flow rate, and after pyrolysis, matrix carbon is formed and deposited in the interior or on the surface of the blank product.

The step can also adopt liquid phase deposition or gas-liquid mixed deposition.

S3, graphitizing;

and S4, fine machining, and performing precision machining forming on the prepared blank according to the requirements of the drawing to obtain the carbon brake disc.

On the basis of embodiment 8, in order to improve the wear resistance and corrosion resistance of the brake disc, modification steps such as siliconizing can be added according to different actual use scenes, and the modification steps are specifically as follows:

The present application is illustrated with respect to brake discs in the carbon-carbon or carbon-ceramic composite field, but it should be understood that the present invention may also be used with other articles in the carbon-carbon or carbon-ceramic composite field, such as pallets, trays, crucibles, etc., while the present invention may also be used with articles in the non-carbon or carbon-ceramic composite field.

The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A preparation method of a short fiber preform for manufacturing carbon or carbon ceramic composite materials is characterized by comprising the step of extruding and molding short carbon fibers through an extruder to obtain a continuous molded product.

2. The method for preparing a short fiber preform for carbon-carbon or carbon-ceramic composite material manufacturing according to claim 1, comprising the following steps:

3. The method for preparing a short fiber preform for carbon-carbon or carbon-ceramic composite material manufacturing according to claim 1, comprising the following steps:

s3, curing, and heating to cure the resin;

4. A method of making a preform of staple fiber for carbon-carbon or carbon-ceramic composites as claimed in claim 3, wherein: the resin comprises one or more of polyazosilane, polycarbosilane, epoxy resin, phenolic resin, urea resin and the like.

5. A method of preparing a preform of staple fibres for carbon-carbon or carbon-ceramic composites, as claimed in claim 1, 2 or 3, wherein: the chopped carbon fibers are prepared by mixing chopped carbon fibers with the length of 2mm-10mm or any multiple groups of chopped carbon fibers in proportion.

6. A method of preparing a preform of staple fiber for carbon-carbon or carbon-ceramic composite fabrication as claimed in claim 2, wherein: and S3, carrying out needling compounding on the obtained multi-section prefabricated body thin sheet and at least one layer of graphite paper or carbon cloth.

7. A method of making a preform of staple fiber for carbon-carbon or carbon-ceramic composites as claimed in claim 8, wherein: the carbon cloth is made of special carbon cloth which is woven cloth or unidirectional cloth; the woven cloth is formed by weaving fiber bundles or prepreg tapes, and the thickness of the fiber bundles or tapes is 0.01-0.20 mm.

8. A short fiber preform for carbon-carbon or carbon-ceramic composite material production, which is obtained by the preparation method of any one of claims 1 to 7.

9. A carbon-carbon or carbon-ceramic composite article obtained by the preparation method according to any one of claims 1 to 7, characterized in that: the carbon or carbon ceramic composite material product is obtained by vapor deposition or liquid deposition or a combination method of the vapor deposition and the liquid deposition.

10. A carbon-carbon or carbon-ceramic composite article as claimed in claim 9, comprising plates, columns, cylinders, spheres, rings and other shaped materials.

11. The carbon-carbon or carbon-ceramic composite article of claim 10, comprising brake disks, brake pads, support rods, trays, electrode posts, support columns, stacks, support plates, crucibles, guide cylinders, holding tanks, cover plates, support rings, fasteners, rocket throat inserts, engine nozzles, engine blades.