CN113583426B - Preparation method of carbon fiber/polyether ketone composite material - Google Patents
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Abstract
The invention relates to a preparation method of a carbon fiber/polyether ketone composite material, which comprises the following steps: (1) Dissolving polyether ketone in a solvent at room temperature to obtain a uniform polyether ketone solution; the polyether ketone in the polyether ketone solution can be fully dissolved; (2) Putting the polyetherketoneketone solution obtained in the step (1) into a sealed dipping tank, and drawing the carbon fiber bundles to be fully dipped in the polyetherketoneketone solution to obtain uniformly dipped carbon fiber/polyetherketoneketone pre-dipped bundles; (3) Completely removing residual solvent on the carbon fiber/polyether ketone prepreg obtained in the step (2) by adopting a heating mode; (4) And (4) preheating the carbon fiber/polyether ketone pre-impregnated bundle obtained in the step (3), and then carrying out hot press molding to obtain the carbon fiber/polyether ketone composite material. In the carbon fiber/polyether ketone composite material, the thickness of polyether ketone between carbon fibers is in the range of 1-3 mu m, and the utilization rate of the tensile strength of the carbon fibers is more than 95 percent.
Description
Technical Field
The invention belongs to the technical field of polyether ketone composite materials, and relates to a preparation method of a carbon fiber/polyether ketone composite material.
Background
In recent years, carbon fiber/polyether ketone composite materials are widely applied to the fields of aerospace, automobiles, wind power blades, medical treatment and health, 3D printing and the like.
Due to the polyaryletherketone polymers to which polyetherketoneketones belong, it is generally difficult to dissolve in conventional solvents, such as polyetheretherketone only at high temperatures (e.g. above 150 ℃ or close to the boiling point of the solvent) in concentrated sulfuric acid, diphenylsulfone, hydrofluoric acid, and the resulting solution is not a strict solution, but a suspension of polyetheretherketone particles with a size above 100 nm. Also based on the above, the current preparation of carbon fiber/polyetheretherketone or carbon fiber/polyetherketoneketone composite materials is mainly based on a lamination method of carbon fiber cloth and polyetheretherketone or polyetherketoneketone, and a wet impregnation method after sulfonation modification.
For example: patent CN201510111874.9 discloses a preparation method of a carbon fiber fabric reinforced polyetheretherketone composite material, which comprises the steps of adding polyetheretherketone powder into chloroform or N, N-dimethylformamide of polyarylsulfone to obtain a suspension, pouring the suspension on a carbon fiber fabric, and promoting the polyetheretherketone powder to permeate into fiber bundles by adopting a low-pressure suction filtration method. However, the process uses a suspension of polyetheretherketone, which can only be impregnated on the surface layer of the carbon fiber fabric, and the polyetheretherketone cannot be effectively impregnated into the fabric. Patent CN201711429254.5 prepares sulfonated polyether ether ketone by chemical reaction, and dissolves it in N, N-dimethylformamide, and then puts the carbon fiber fabric into polymer solution for soaking, and then prepares composite material by hot press molding; the sulfonated polyetheretherketone is dissolved in the process, but the polyetheretherketone cannot be dissolved, so that the obtained composite material is inferior to a carbon fiber/polyetheretherketone composite material in force and thermal properties. Patents CN202010419567.8, CN202010419576.7 and CN202010420330.1 disclose methods for preparing carbon fiber/polyetheretherketone composite materials by laminating and compounding modified carbon fiber cloth with polyetheretherketone films, non-woven fabric felts, powders or fibers, and the like, and such direct compounding methods also cannot achieve impregnation of polyetheretherketone in the carbon fiber cloth, and cannot obtain carbon fiber/polyetheretherketone composite materials with uniform compounding.
Therefore, the above composite structures generally have insufficient and uneven impregnation, and the carbon fibers are difficult to be fully coated by the resin matrix, so that the excellent mechanical properties of the carbon fibers are difficult to be fully utilized in the molded composite material, and interlayer fracture is easy to occur.
Therefore, the research on the carbon fiber/polyether ketone composite material with simple development process, good wettability and excellent mechanical property has very important significance.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a preparation method of a carbon fiber/polyether ketone composite material; the method specifically comprises the steps of dissolving polyether ketone by using a fluorine-based polar solvent and/or a chlorine-based polar solvent at room temperature (solving the problem of solubility of polyether ketone), then placing a polyether ketone solution in a sealed impregnation tank, drawing a carbon fiber bundle to be fully impregnated in the solution to obtain a uniformly impregnated strip-shaped carbon fiber/polyether ketone prepreg, then placing the carbon fiber/polyether ketone prepreg in an oven to be heated to fully remove residual solvent, finally laying the carbon fiber/polyether ketone prepreg, placing the carbon fiber/polyether ketone prepreg in a muffle furnace to be preheated, and then placing the carbon fiber/polyether ketone prepreg in a hot press to be subjected to hot press molding to obtain the carbon fiber/polyether ketone composite material.
Polyether ketone ketones have a higher molecular polarity and thus a better solubility than other poly (aryl ether ketones) in theory, but the literature (organic Preparation of PEKK Dispersion for Coating by Transfer from a chromatography stage Dispersion to an Aqueous stage Dispersion, by Emulsion/Solvent evaluation, J.Dispersion Sci.Technol.2016,37 (3), 360-365.) reports a method for promoting the Dispersion of polyether ketone particles in Aqueous solvents using surfactants. However, the average size of the polyetherketoneketone particles in the dispersion is still between 120 and 140nm, no Tyndall phenomenon is observed, and sedimentation occurs upon standing for a short time (e.g., 1 hour).
The invention uses fluorine-based polar solvent and/or chlorine-based polar solvent to realize high-concentration dissolution of polyether ketone at room temperature (the solvent can be used for high-concentration dissolution because the solvent is polar solvent and contains fluorine and chlorine polar terminals), and the obtained solution has viscosity of less than 2 x 10 3 And the size of the polyether ketone in the solution is less than 20nm (the size of the polyether ketone in the polyether ketone dispersion liquid is usually more than 100nm and even larger), so that the polyether ketone in the solution can be efficiently and uniformly impregnated into the middle of the carbon fiber bundle, and a new technology is provided for developing a carbon fiber/polyether ketone composite material with simple process, good wettability and excellent mechanical properties.
In order to achieve the purpose, the invention adopts the following scheme:
a preparation method of a carbon fiber/polyether ketone composite material comprises the following steps:
(1) Dissolving polyether ketone in a solvent at room temperature to obtain a uniform polyether ketone solution;
the solvent is one of fluorine-based polar solvent such as trifluoroacetic acid, 3-trifluoro-2, 2-dimethyl propionic acid, or chlorine-based polar solvent such as p-chlorophenol, dichloroacetic acid, dichloropropionic acid, etc.;
the solvent can also be a mixed solvent formed by one of the solvents and dichloroethane, wherein the mass content of the dichloroethane is 25-75%;
the polyether ketone in the polyether ketone solution can be fully dissolved, and the particle size of the dissolved polyether ketone is lower than 20nm by using a dynamic light scattering method; the mass ratio of the polyether ketone to the solvent in the polyether ketone solution is x (100-x), wherein x is 5-22; when x is 22, the solution is saturated.
(2) Putting the polyetherketoneketone solution obtained in the step (1) into a sealed dipping tank (sealing to prevent solvent from volatilizing), and drawing the carbon fiber bundles to be fully dipped in the polyetherketoneketone solution to obtain uniformly dipped carbon fiber/polyetherketoneketone pre-dipping bundles;
(3) Completely removing residual solvent on the carbon fiber/polyether ketone prepreg obtained in the step (2) by adopting a heating mode (if the carbon fiber/polyether ketone prepreg is placed in an oven for heating fully);
the temperature of the heating does not exceed the boiling point of the solvent; operating above its boiling point, the results are extremely poor;
(4) And (4) preheating the carbon fiber/polyether ketone pre-impregnated bundle obtained in the step (3), and then carrying out hot press molding to obtain the carbon fiber/polyether ketone composite material.
As a preferable scheme:
in the preparation method of the carbon fiber/polyether ketone composite material, in the step (1), a high-speed stirring mode is adopted for dissolution, the high-speed stirring speed is 1200-1800 rpm, and the stirring time is 6-12 h.
A method for preparing a carbon fiber/polyetherketoneketone composite material as described above, wherein the polyetherketoneketone is prepared from a mixture of 50, 60, 70, 30, 80 or 100 parts by mass of terephthaloyl monomers and isophthaloyl monomers.
In the method for preparing the carbon fiber/polyether ketone composite material, the solvent can be one of trifluoroacetic acid, 3-trifluoro-2, 2-dimethyl propionic acid, p-chlorophenol, dichloroacetic acid, dichloropropionic acid and the like, or a mixed solvent of the solvent and dichloroethane, and the concentration of the polyether ketone in the polyether ketone solution is preferably 8 to 15wt%.
In the step (2), the carbon fiber bundle is pulled while being kept in a straight state during impregnation (5 to 9 guide rails may be arranged in the impregnation tank, the carbon fiber bundle is introduced into the impregnation tank, passes through the guide rails in sequence, is guided out of the impregnation tank after being sufficiently impregnated, and is rolled to form a strip-shaped carbon fiber/polyether ketone pre-impregnated bundle (the strip-shaped carbon fiber/polyether ketone pre-impregnated bundle is formed during the rolling process), the pulling speed of the carbon fiber bundle is 0.2 to 1m/min, preferably 0.5m/min, the impregnation time is 1 to 5min, and the temperature of the polyether ketone solution during impregnation is 25 to 30 ℃.
According to the preparation method of the carbon fiber/polyether ketone composite material, in the step (3), the heating temperature is 120-180 ℃, and the time is 2-4 h.
The preparation method of the carbon fiber/polyether ketone composite material comprises the following specific steps in the step (4):
(4.1) carrying out ply stacking (the number of layers can be 15-45 layers) on a plurality of layers of the carbon fiber/polyether ketone prepreg bundles obtained in the step (3) to obtain a laminar prepreg bundle with the thickness of 1-3 mm (1 mm is obtained by 15 layers and 2mm is obtained by 30 layers);
(4.2) keeping the laminated prepreg obtained in the step (4.1) in a compact state under the pressure lower than 0.05MPa, placing the laminated prepreg in a mould, and performing preheating treatment in a muffle furnace at the preheating temperature of 340-400 ℃ for 30-60 min;
(4.3) placing the mould filled with the laminar prepreg and obtained in the step (4.2) in a hot press heated to the same preheating temperature, and carrying out hot pressing treatment under the condition that the pressure of the laminar prepreg is 10-50 MPa for 60-120 min;
and (4.4) taking out the mold filled with the layered prepreg obtained in the step (4.3), placing the mold at room temperature for natural cooling, and opening the mold to obtain the carbon fiber/polyether ketone composite material.
In the carbon fiber/polyether ketone composite material, the polyether ketone is completely filled in the gaps of the carbon fiber bundles, and the thickness of the polyether ketone between the carbon fibers is within the range of 1-3 mu m;
the carbon fiber/polyether ketone composite material has a uniform composite structure and high-strength and high-modulus mechanical properties, and the utilization rate of the tensile strength of the carbon fiber in the carbon fiber/polyether ketone composite material reaches more than 95%.
The principle of the invention is as follows:
the invention solves the problem of dissolving the polyether ketone, so that the polyether ketone can form polyether ketone particles with the size of below 20nm in the solution, and can be more effectively impregnated into carbon fiber bundles in a dissolved state to obtain a high-efficiency and uniform impregnated composite structure, and the technical bottleneck that the partial impregnated composite of the polyether ketone can be only realized in the carbon fiber bundles or carbon fiber cloth in the prior art is broken through, so that the mechanical property of carbon fibers can be fully utilized in the formed composite material, and the mechanical property of the composite material is improved.
Advantageous effects
(1) The preparation method of the carbon fiber/polyether ketone composite material has the advantages of simple process, low cost and good wettability of resin and fiber;
(2) The carbon fiber reinforced thermoplastic resin composite material prepared by the invention has good comprehensive mechanical properties.
Drawings
FIG. 1 is a Tyndall effect diagram of the polyetherketoneketone solution of example 1 a;
FIG. 2 shows the results of dynamic light scattering for the particle size of polyetherketoneketone from example 1a after dissolution in trifluoroacetic acid;
FIG. 3 shows the results of dynamic light scattering of the particle size of polyetherketoneketone in example 1b after it has been dissolved in p-chlorophenol;
FIG. 4 is a schematic view showing the arrangement of a sealing and dipping tank and a guide rail used in example 2;
FIG. 5 shows the microstructure of the carbon fiber/polyetherketoneketone prepreg obtained in example 2 without autoclaving;
FIG. 6 is the microstructure of the carbon fiber/polyetherketoneketone composite obtained in example 3.
Detailed Description
The invention will be further illustrated with reference to specific embodiments. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention can be made by those skilled in the art after reading the teaching of the present invention, and these equivalents also fall within the scope of the claims appended to the present application.
Example 1a
12g of polyetherketoneketone (T/I ratio 50/50) was added to 88g of trifluoroacetic acid, and stirred with a magnetic stirrer at 1800rpm and 25 ℃ for 12 hours to give a polyetherketoneketone-dissolved solution of 12% by weight. By irradiating the solution with laser, a significant tyndall effect (as shown in fig. 1) was observed, confirming that the polyetherketoneketone was sufficiently dissolved. The polyether ketone solution does not settle after standing for more than 1 month at room temperature.
After the solutions were diluted to 0.05wt%, the particle size of polyetherketoneketone was measured by dynamic light scattering method, and a scattering peak was observed at 20nm (as shown in fig. 2), confirming that the polyetherketoneketone size was below 20nm, and further confirming that the obtained solutions were solutions of polyetherketoneketone.
Example 1b
The procedure for preparing a polyetherketoneketone solution was substantially the same as in example 1a, except that trifluoroacetic acid was replaced with p-chlorophenol, and the resulting polyetherketoneketone solution was irradiated with laser light to observe a significant tyndall effect, confirming that polyetherketoneketone was sufficiently dissolved. The polyether ketone solution does not settle after standing for more than 1 month at room temperature.
After the solution was diluted to 0.05wt%, the size of the polyetherketoneketone particles was measured by dynamic light scattering, and a scattering peak was observed at 20nm (as shown in fig. 3), confirming that the polyetherketoneketone size was below 20nm, and further confirming that the solution was obtained.
Example 1c
22g of polyetherketoneketone (T/I ratio of 60/40) was added to a mixed solvent of 78g of trifluoroacetic acid (39 g) and dichloroethane (39 g), and stirred for 6 hours at 1200rpm and 30 ℃ with a magnetic stirrer to obtain a polyetherketoneketone-dissolved solution having a solubility of 22 wt%. By irradiating the solution with laser, obvious Tyndall effect can be observed, which proves that the polyether ketone is fully dissolved. The polyether ketone solution does not settle after standing for more than 1 month at room temperature.
After the polyether ketone dissolving solution is respectively diluted to 0.05wt%, the particle size of the polyether ketone is detected by a dynamic light scattering method, a scattering peak is found under 20nm, the polyether ketone size is proved to be lower than 20nm, and the obtained polyether ketone dissolving solution is further proved.
Example 2
(1) Preparing a 12wt% polyetherketoneketone (T/I ratio of 50/50)/trifluoroacetic acid-dichloroethane solution:
the procedure is essentially the same as in example 1a, except that: replacing trifluoroacetic acid with a mixed solvent of trifluoroacetic acid and dichloroethane with the mass ratio of 1, and increasing the corresponding addition amount in equal proportion to prepare a solution of polyetherketoneketone with the volume of 500ml and the concentration of 12wt% (T/I ratio of 50/50)/trifluoroacetic acid-dichloroethane;
(2) 500ml of 12wt% polyetherketoneketone (T/I ratio of 50/50)/trifluoroacetic acid-dichloroethane solution (i.e., polyetherketoneketone solution) was placed in a sealed impregnation tank, and T300 carbon fiber bundle (12K) was introduced into the polyetherketoneketone solution using a guide rail, and the fiber bundle was kept in a stretched state in the solution using 7 guide rails arranged up and down, sufficiently impregnated at a speed of 0.5m/min (impregnation time was 2 min), and led out of the impregnation tank (the distribution schematic diagram of the sealed impregnation tank and the guide rails thereof is shown in FIG. 4). Placing the carbon fiber/polyether ketone pre-impregnated bundle which is subjected to solution impregnation in an oven for treatment at 120 ℃ for 4h to completely remove residual solvent to obtain a solvent-free carbon fiber/polyether ketone pre-impregnated bundle, the microscopic structure of the carbon fiber is shown in figure 5 by characterization and observation of an electron microscope, and the polyether ketone can be seen to be fully impregnated into the carbon fiber, aggregated into particles with the size of below 80nm and uniformly coated on the surface of the carbon fiber.
Example 3
The carbon fiber/polyetherketoneketone composite material was obtained by stacking 15 layers of the carbon fiber/polyetherketoneketone prepreg prepared in example 2 in a mold, placing the prepreg together with the mold in a muffle furnace, keeping the prepreg in a pressureless state (the pressure due to the self weight of the mold does not exceed 0.05 MPa), preheating at 360 ℃ for 60min, transferring to a hot press which had been heated to 360 ℃ in advance, hot-pressing at 360 ℃ and 50MPa for 120min, naturally cooling, and opening the mold.
In the carbon fiber/polyether ketone composite material, polyether ketone is completely filled in the gaps of the carbon fiber bundles, as shown in fig. 6, the thickness of the polyether ketone between the carbon fibers can be determined to be in the range of 1-3 mu m through a large amount of observation;
the carbon fiber/polyether ketone composite material has a uniform composite structure, and the utilization rate of the tensile strength of the carbon fiber in the carbon fiber/polyether ketone composite material reaches more than 95%.
According to the composite rule of the composite material, the tensile strength of the ideal carbon fiber/polyether ketone composite material is sigma c ＝σ f v f +σ m v m Where σ is f And σ m Is the tensile strength, v, of carbon fibers and polyetherketoneketones f And v m ＝1-v f The volume ratio of the carbon fiber to the polyether ketone is shown. V is a value obtained when the diameter of carbon fibers is d =7 μm and the thickness of gaps between carbon fibers is δ =2 μm m =45%, insert into equation above to get σ c ＝0.55σ f +0.45σ m (ii) a Wherein sigma m =0.1GPa. When the carbon fiber used is T300, σ f =3.5GPa. So as to obtain the ideal strength sigma of the composite material c ＝1.97GPa。
The tensile strength of the T300 carbon fiber/polyether ketone composite material obtained by the method reaches 1.872-1.923 GPa, which is 95-97.6% of an ideal result, namely the utilization rate of the tensile strength of the carbon fiber reaches the same proportion.
Claims (6)
1. A preparation method of a carbon fiber/polyether ketone composite material is characterized by comprising the following steps:
(1) Dissolving polyether ketone in a solvent at room temperature to obtain a uniform polyether ketone solution;
the solvent is p-chlorophenol;
the polyether ketone in the polyether ketone solution can be fully dissolved, and the particle size of the dissolved polyether ketone is less than 20nm; and the mass ratio of the polyether ketone to the solvent in the polyether ketone solution isx:(100-x) WhereinxIs 5 to 22;
the polyether ketone is prepared from a terephthaloyl monomer and an isophthaloyl monomer with the monomer ratio of 50 or 60;
dissolving by adopting a high-speed stirring mode, wherein the high-speed stirring speed is 1200-1800 rpm, and the stirring time is 6-12h;
(2) Putting the polyetherketoneketone solution obtained in the step (1) into a sealed dipping tank, and drawing the carbon fiber bundles to be fully dipped in the polyetherketoneketone solution to obtain uniformly dipped carbon fiber/polyetherketoneketone pre-dipped bundles;
(3) Completely removing residual solvent on the carbon fiber/polyether ketone prepreg obtained in the step (2) by adopting a heating mode;
the temperature of the heating does not exceed the boiling point of the solvent;
(4) And (4) preheating the carbon fiber/polyether ketone pre-impregnated bundle obtained in the step (3), and then carrying out hot press molding to obtain the carbon fiber/polyether ketone composite material.
2. The preparation method of the carbon fiber/polyether ketone composite material as claimed in claim 1, wherein the concentration of polyether ketone in the polyether ketone solution is 8-15wt%.
3. The preparation method of the carbon fiber/polyether ketone composite material as claimed in claim 1, wherein in the step (2), the carbon fiber bundle is pulled in a straightened state during the impregnation, the pulling speed of the carbon fiber bundle is 0.2 to 1m/min, the impregnation time is 1 to 5min, and the temperature of the polyether ketone solution during the impregnation is 25 to 30 ℃.
4. The preparation method of the carbon fiber/polyether ketone composite material as claimed in claim 1, wherein in the step (3), the heating temperature is 120 to 180 ℃ and the heating time is 2 to 4h.
5. The preparation method of the carbon fiber/polyether ketone composite material as claimed in claim 1, wherein the step (4) comprises the following specific steps:
(4.1) layering and laminating a plurality of layers of the carbon fiber/polyether ketone prepreg obtained in the step (3) to obtain a layered prepreg with the thickness of 1-3mm;
(4.2) keeping the laminated prepreg obtained in the step (4.1) in a compaction state under the pressure lower than 0.05MPa, placing the laminated prepreg in a mold, and performing preheating treatment in a muffle furnace at the preheating temperature of 340-400 ℃ for 30-60min;
(4.3) placing the mould filled with the layered prepreg and obtained in the step (4.2) in a hot press heated to the same preheating temperature, and carrying out hot pressing treatment under the condition that the pressure of the layered prepreg is 10-50MPa for 60-120min;
and (4.4) taking out the mold filled with the layered prepreg obtained in the step (4.3), naturally cooling the mold at room temperature, and opening the mold to obtain the carbon fiber/polyether ketone composite material.
6. The method for preparing the carbon fiber/polyether ketone composite material as claimed in claim 1, wherein in the carbon fiber/polyether ketone composite material, polyether ketone is completely filled in gaps of carbon fiber bundles, and the thickness of the polyether ketone between carbon fibers is within a range of 1 to 3 μm;
the carbon fiber/polyether ketone composite material has a uniform composite structure, and the utilization rate of the tensile strength of the carbon fiber in the carbon fiber/polyether ketone composite material reaches more than 95%.
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