CN114103375A - 一种具有储热性能的碳纤维复合电热木板及其制备方法 - Google Patents

一种具有储热性能的碳纤维复合电热木板及其制备方法 Download PDF

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CN114103375A
CN114103375A CN202111424771.XA CN202111424771A CN114103375A CN 114103375 A CN114103375 A CN 114103375A CN 202111424771 A CN202111424771 A CN 202111424771A CN 114103375 A CN114103375 A CN 114103375A
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layer
carbon fiber
heat
electric heating
heat storage
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石文标
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MtTitlis Beijing Control Technology Co ltd
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Abstract

本发明提供了一种具有储热性能的碳纤维复合电热木板及其制备方法，碳纤维复合电热木板包括由下至上依次设置的底部基材层、隔热层、碳纤维纸电热层、蓄热层、面层，上下两层之间设置有粘接剂层，碳纤维纸电热层由碳纤维纸层与铜箔通过导电复合胶粘结而成，铜箔表面设有若干个微米级孔。本发明中的碳纤维纸电热层中碳纤维电热纸与铜箔电极通过铜丝缝制、微米级孔和导电复合胶粘接，即采用化学及物理方式将铜箔与碳纤维电热纸双重固定，即使发生导电复合胶成分挥发或产品受潮的现象，铜箔电极也不会与发热体脱离或发生离弧现象，而且不影响电极引线的焊接。

Description

一种具有储热性能的碳纤维复合电热木板及其制备方法
技术领域
本发明创造属于复合材料功能性木板技术领域，尤其是涉及一种具有储热性能的碳纤维复合电热木板及其制备方法。
背景技术
木材在我们实际生活中具多种用途，自古就被人类广泛使用，并一直沿用到现代文明社会。提质增效是驱动我国木材加工行业转型升级的重要途径，木质功能复合材料恰在此战略问题上具有优势，促使木质复合材料功能化，如导电、吸声隔声及阻燃防火等，扩大应用领域，是当下实现木制品增值的技术创新之举。其中，赋予木质复合材料均匀、高效的电热功能，可应用于室内采暖，如墙暖、地暖、桌椅、床等家具，还可用于红外杀菌、防霉；采用电取暖，清洁卫生，舒适，节能，易安装维护，潜热性能好，还具有远红外保健功能。木质电热复合材料作为采暖和木材加工行业的新型材料和制品，具有广阔的产业化和市场前景。
电采暖系统较热水采暖系统节能，且热水采暖系统安装成本高、复杂。与瓷砖、水泥板等覆面材料对比，采用木质板材时温度适宜且分布比较均匀；此外，采用电热膜采暖，以热辐射为主，舒适，室内温度分布均匀，与热水、热风散热器等对流散热方式相比，无需配置锅炉、热水管道，具有干净卫生、节约能源等独特优点，是未来节能、环保型采暖技术发展的主流方向。
目前，国内相关木质发热材料应用主要有发热地板，采用木质地板与PET发热膜或者电热碳纤维发热线及电热金属丝压合在一起，制作成复合发热地板的工艺。此类产品普遍存在发热不均匀，局部过热，电热效应不稳定的问题，通电时发热，断电时快速降温，供热时对电能消耗较大、且应用场景单一。
发明内容
有鉴于此，本发明旨在克服现有技术中的缺陷，提出一种具有储热性能的碳纤维复合电热木板及其制备方法。
为达到上述目的，本发明的技术方案是这样实现的：
一种具有储热性能的碳纤维复合电热木板，包括由下至上依次设置的底部基材层、隔热层、碳纤维纸电热层、蓄热层、面层，上下两层之间设置有粘接剂层，碳纤维纸电热层由通过铜丝将铜箔缝制于碳纤维纸层表面形成，碳纤维纸层与铜箔之间涂覆有导电胶黏剂层，碳纤维纸电热层上设有若干个微米级孔。
优选的，铜线的直径为0.05-0.07mm。
优选的，铜线缝制的针脚距离铜箔两侧边缘1-2mm，相邻两个针脚之间的距离为8-10mm。
优选的，所述铜箔铜线采用Z字形缝制于碳纤维纸层表面。
优选的，相邻两个微米级孔的距离为1mm。
优选的，碳纤维纸层的厚度0.1-0.15mm，体积电阻率为 2.5-4Ω·cm。
优选的，铜箔的材质为紫铜，宽度为9-12mm，厚度为0.03-0.05mm。
优选的，碳纤维纸电热层的上表面和下表面均设有浸胶玻纤布层作为绝缘复合层。
优选的，浸胶玻纤布层由玻璃纤维布浸入绝缘树脂复合胶中进行浸胶操作后烘干制得，绝缘树脂复合胶由如下重量份数的组分制备而得：100-120份环氧树脂、40-50份稀释剂、25-30份固化剂、3-5份添加剂、1-2份导电填料。
优选的，固化剂为热固性固化剂。
优选的，稀释剂为质量百分比为90％以上的乙醇溶液。
优选的，添加剂优选为抗氧化剂、抗静电剂、阻燃剂中的一种或多种，其中，抗氧化剂优选烷基酚或烯基双酚；抗静电剂优选乙氧化胺类；阻燃剂优选无机阻燃剂如氢氧化镁；导电填料优选为二氧化硅粉和/或锌粉。
优选的，上述浸胶玻纤布层的制备方法包括如下步骤：
步骤1：将环氧树脂到入反应釜中加温至45-55℃，将稀释剂倒入反应釜对环氧树脂进行稀释，再将固化剂到入反应釜中，继续搅拌 30-40min后将添加剂及填料依次倒入反应釜继续保温搅拌2-2.5h，将搅拌混合后的环氧树脂复合胶胶液倒入浸胶池中，并保持温度在 30-40℃；
步骤2：将玻璃纤维布挂到浸胶导辊上并经导轨引入浸胶池，在浸液中浸泡5-8min后再经过挤压辊使胶液与玻璃纤维布充分复合；
步骤3：将浸润有浸胶液的玻璃纤维布经牵引导辊进入烘干通道，经过烘干通道后，经裁板机按要求裁好备用。
优选的，步骤3中的烘干通道分为上层烘干通道和下层烘干通道，上层烘干通道温度为80-90℃，下层烘干通道为120-130℃，上层烘干通道和下层烘干通道长度均为10-15m，烘干速率为6-7m/min，烘干通道整体维持负压。
优选的，蓄热层为多层胶合板，多层胶合板的表面设有若干凹槽，凹槽内填充有混合导热填料，混合导热填料由包括熔融态的石蜡与导热填料按照20:1的质量比混合而成。
优选的，导热填料为铜粉、硅粉、微纳米石墨碳材料、不锈钢丝带中的一种或多种的混合物。
优选的，多层胶合板的厚度为5-6mm，凹槽的槽深为3-4mm，槽宽为12-15mm。
优选的，隔热层为木丝水泥板、膨胀珍珠岩粉体板、泡沫石棉板或泡沫玻璃混凝土板聚氨酯板。
优选的，底部基材层为木质板材层，更优选为实木板材、刨花板、大芯板或抗倍特板，厚度为8-10mm。
优选的，底部基材层的下表面喷涂双层底漆和双层面漆。
本发明还提供一种上述碳纤维复合电热木板的制备工艺，包括如下步骤：将底部基材层、隔热层、碳纤维纸电热层、蓄热层、面层依次采用粘结剂通过热压机压合成型。
优选的，粘接剂为三聚氰胺改性脲醛胶、三聚氰胺胶、白乳胶中的一种或多种的混合物。
优选的，上述碳纤维复合电热木板的制备工艺，具体包括如下步骤：
S1、在工作台面上依次铺装冷轧钢板模具；
S2、铺装底部基材层，并在底部基材层上表面涂抹粘结剂；
S3、铺装隔热层，并在隔热层上表面涂抹粘结剂；
S4、铺装聚酯膜后铺装一层或多层浸胶玻纤布层；
S5、铺装碳纤维纸电热层；
S6、铺装一层或多层浸胶玻纤布层；
S7、铺装聚酯膜，并在该层聚酯膜表面涂抹粘接剂；
S8、铺装蓄热层，蓄热层的槽口向下；
S9、在蓄热层上方涂抹粘结剂；
S10、铺装面层；
S11、铺装冷轧钢板模具；
S12、将铺装好的冷轧钢板模具送入热压机后进行第一次加温加压操作，温度为120-130℃，压力为6-8MPa/cm2，保温保压30-40min 以后进行第二次加温加压操作，温度升至160℃-170℃，压力升至 9-10MPa/cm2，保温保压50-60min后降温，当温度降到40-45℃时，泄压，开启模具，出模，将压合成型的产品取出即得碳纤维复合电热木板。
本发明的有益效果：
(1)本发明中的碳纤维纸电热层中碳纤维电热纸与铜箔电极通过铜丝缝制、微米级孔和导电复合胶粘接，即采用化学及物理方式将铜箔与碳纤维电热纸双重固定，即使发生导电复合胶成分挥发或产品受潮的现象，铜箔电极也不会与发热体脱离或发生离弧现象，而且不影响电极引线的焊接，上述双重固定的方式是用铜网做的电极或完全依靠导电胶粘接的电极无法相比的。
(2)本发明中的蓄热层采用多层胶合板与石蜡及导热填料复合而成，石蜡与导热填料复配可以有效强化石蜡的导热性能，能提高蓄热器的蓄热和放热能力。另外，石蜡相变潜热高、几乎没有过冷现象、熔化时蒸气压力低、不易发生化学反应且化学稳定性较好、在多次吸放热后相变温度和相变潜热变化很小、自成核、没有相分离和腐蚀性。同时石蜡作为大宗化工原料，其来源丰富，种类繁多且价格低廉。
附图说明
图1为本发明的碳纤维复合电热木板的结构示意图；
图2为图1中A部的局部放大图；
图3为本发明的碳纤维复合电热木板中的蓄热层的结构示意图；
图4为本发明的碳纤维纸电热层的结构示意图。
图中：
1、底部基材层；2、隔热层；20、多层胶合板；21、凹槽；3、碳纤维纸电热层；30、浸胶玻纤布层；4、蓄热层；5、面层；6、粘接剂层；7、铜线；8、微米级孔。
具体实施方式
除有定义外，以下实施例中所用的技术术语具有与本发明创造所属领域技术人员普遍理解的相同含义。以下实施例中所用的试验试剂，如无特殊说明，均为常规生化试剂；所述实验方法，如无特殊说明，均为常规方法。
实施例
本实施例提供一种具有储热性能的碳纤维复合电热木板，如图1 所示，从底部到顶部依次包含底部基材层5、隔热层4、碳纤维纸电热层3、蓄热层2、面层1，各层之间设有粘接剂层6，粘接剂层的材质为E1级别的三聚氰胺改性脲醛胶、三聚氰胺胶、白乳胶中的一种或几种粘结剂的混合物，各层通过粘接剂层粘接后通过热压机压合成型。
在本实施例中，底部基材层采用实木芯材。具体地，在本发明的具体实施方式中，可选用实木板材、刨花板、大芯板、抗倍特板等板材，厚度在8-10mm，在底部基材层的表面喷涂双层底漆及双层面漆，确保复合电热木板防水防潮。底部基材层表面喷漆的具体操作步骤为：
步骤1：将底部基材层的表面经除尘机将板面细粉尘吸附后，由输送带送至水性底漆机辊涂水性漆，接着过毛刷快速将表面打均匀；
步骤2：经10m长红外灯流频，将于前道工序的水性底漆表层水份挥发完全，红外灯温度设定在55℃-65℃，通过速度在40m/min，以确保产品板面温度控制在35℃-45℃；
步骤3：经输送带送至底漆机，辊涂UV附着底漆，油漆涂布量控制在20g/㎡-25g/㎡，经4m长红外灯流频，设定温度控制在35℃恒温，流水线速度在28-30m/min，让表层油漆在板面上均匀流平、结膜，后经固化机半固化；
步骤4：使用320#砂布的油砂机对底部基材层的表层进行油砂，使底部基材层的背面平整。
在本实施例中，隔热层采用木丝水泥板、膨胀珍珠岩粉体板、泡沫石棉板、泡沫玻璃混凝土板聚氨酯板其中的一种，优选使用木丝水泥板，厚度在4mm-5mm。
在本实施例中，碳纤维纸电热层采用碳纤维电热纸与电极复合而成，具体制备工艺如下：
碳纤维电热纸采用东丽碳纤维纸，厚度为0.1mm，体积电阻率为 3.67Ω·cm。电极采用紫铜材质的压延铜箔，宽度9mm，厚度0.03mm，在碳纤维电热纸两侧距离边缘15mm附近涂抹导电复合胶，将铜箔贴合在涂胶位置，铜箔长度两侧各超出碳碳纤维电热纸长度25mm，再将铜箔缝制在碳纤维发热纸上，具体地，铜箔使用直径为0.05-0.07mm 铜丝7采用采用Z字形缝制于碳纤维纸层表面，铜线缝制的针脚距离铜箔两侧边缘的距离1-2mm，相邻两个针脚之间的距离为8-10mm。
为了便于导电复合胶与碳纤维纸牢固的粘接，使铜箔更好地与碳纤维发热纸粘合，在铜箔与碳纤维纸粘接的位置洞穿小孔，在电极上形成有序排列的很多个微米级孔8。相邻两个微米级孔的间距约为 1mm。
另外，作为本实施例的优选实施方式，在碳纤维纸电热层的上表面和下表面均设有浸胶玻纤布层30作为绝缘复合层。浸胶玻纤布层采用如下制备工艺制备而得：
步骤1：制备绝缘树脂复合胶
绝缘树脂复合胶按照环氧树脂100份、稀释剂40份、固化剂25 份、添加剂5份、填料1份质量配比进行配置。
将环氧树脂到入反应釜中加温到45℃，将40份稀释剂倒入反应釜对环氧树脂进行稀释，再将固化剂到入反应釜中。继续搅拌30min 后将添加剂及填料到入反应釜继续保温搅拌两小时。将搅拌混合后的环氧树脂液体倒入玻璃纤维布浸胶机的浸胶池中，并保持温度在30℃ -40℃。
步骤2：玻璃纤维布浸胶复合
将玻璃纤维布挂到浸胶导辊上并经导轨引入浸胶池，在浸液中浸泡5min后再经过挤压辊使浸胶液充分均匀的与玻璃纤维布复合。
步骤3：将浸润有浸胶液的玻璃纤维布经牵引导辊进入烘干通道，烘干通道设计为分层分段式烘干，即分为上层烘干通道和下层烘干通道，上层烘干通道温度为80℃，目的是进行预热，下层烘干通道温度为130℃，目的是进行排湿排气，上层烘干通道和下层烘干通道长度均为10m，烘干速率为7m/min，烘干系统整体维持负压，并配VOC 处理系统，防止挥发出的物质污染空气。经过烘干通道后，经裁板机将浸胶烘干后的玻璃纤维布按要求裁好备用。
在本实施例中，玻璃纤维布采用无碱无蜡玻纤布，玻纤布长宽尺寸规格各超出碳纤维纸30mm。绝缘树脂复合胶中的环氧树脂选用 E44型环氧树脂。固化剂选用热固性固化剂，具体为714酰胺基胺固化剂。稀释剂选用质量百分比为90％乙醇溶液。填料选用二氧化硅粉，添加填料的目的为加强绝缘复合层的导热性能。添加剂选用氢氧化镁。
在本实施例中，蓄热层采用多层胶合板20与石蜡及导热填料复合而成。其中，多层胶合板选用5mm厚的多层胶合板，在多层胶合板表面铣有若干个凹槽21，凹槽的深度为3mm，宽度为15mm，将石蜡在容器中充分加热至完全熔融状态，将导热填料与石蜡按20:1 的质量比混合并用搅拌器充分搅拌30min，将混合有导热填料的熔融状态石蜡均匀填充在多层胶合板的凹槽内部，直至与多层胶合板的表面齐平，并在室温下使石蜡凝固。
石蜡由于相变潜热高、几乎没有过冷现象、熔化时蒸气压力低、不易发生化学反应且化学稳定性较好、在多次吸放热后相变温度和相变潜热变化很小、自成核、没有相分离和腐蚀性。导热填料的目的为了有效强化石蜡的导热性能，提高蓄热器的蓄热和放热能力。在本实施例中，石蜡选用石蜡6499牌号，相变温度为62℃～68℃，相变潜热为189-252J/g，比热为2.12kJ/(kg·℃)比重为0.88～0.91。导热填料选用铜粉、硅粉、微纳米石墨碳材料或不锈钢丝带导热材料。
在本实施例中，面层采用防火板，厚度为1.2mm。
上述具有储热性能的碳纤维复合电热木板的压制工序为：
(1)在工作台面上依次铺装冷轧钢板模具的下模；
(2)铺底部底部基材层，并在底部基材层上表面涂抹粘结剂；
(3)铺装隔热层，并在隔热层上表面涂抹粘结剂；
(4)铺装聚酯膜后铺装一层或多层浸胶玻纤布层；
(5)铺装碳纤维纸电热层；
(6)铺装一层或多层浸胶玻纤布层；
(7)铺装聚酯膜，并在该层聚酯膜表面涂抹粘接剂；
(8)铺装蓄热层，蓄热层铣槽的槽口向下设置；
(9)在蓄热层上表面涂抹粘结剂；
(10)铺装面层；
(11)铺装冷轧钢板模具的上模；
(12)将铺装好的冷轧钢板模具送入热压机，进行第一次加温、加压，温度为130℃压力为6MPa/cm2，保温保压30min以后进行二次加温、加压，温度升至160℃-170℃，压力升至9-10MPa/cm2，保温保压50min后降温，当温度降至45℃时，泄压，开启模具，出模，将压合成型的产品取出，整理、裁板、测试、检验、成品入库。
以上所述仅为本发明创造的较佳实施例而已，并不用以限制本发明创造，凡在本发明创造的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明创造的保护范围之内。

Claims (10)

1.一种具有储热性能的碳纤维复合电热木板，其特征在于：包括由下至上依次设置的底部基材层、隔热层、碳纤维纸电热层、蓄热层、面层，上下两层之间设置有粘接剂层，碳纤维纸电热层由通过铜丝将铜箔缝制于碳纤维纸层表面形成，碳纤维纸层与铜箔之间涂覆有导电胶黏剂层，碳纤维纸电热层上设有若干个微米级孔。
2.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：铜线的直径为0.05-0.07mm；优选的，铜线缝制的针脚距离铜箔两侧边缘1-2mm，相邻两个针脚之间的距离为8-10mm；优选的，所述铜箔铜线采用Z字形缝制于碳纤维纸层表面；优选的，相邻两个微米级孔的距离为1mm。
3.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：碳纤维纸层的厚度0.1-0.15mm，体积电阻率为2.5-3Ω·cm；优选的，铜箔的材质为紫铜，宽度为9-12mm，厚度为0.03-0.05mm。
4.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：碳纤维纸电热层的上表面和下表面均设有浸胶玻纤布层作为绝缘复合层；优选的，浸胶玻纤布层由玻璃纤维布浸入绝缘树脂复合胶中进行浸胶操作后烘干制得，绝缘树脂复合胶由如下重量份数的组分制备而得：100-120份环氧树脂、40-50份稀释剂、25-30份固化剂、3-5份添加剂、1-2份导电填料；固化剂优选为热固性固化剂；稀释剂优选为质量百分比为90％以上的乙醇溶液；添加剂优选为抗氧化剂、抗静电剂、阻燃剂中的一种或多种，抗氧化剂优选烷基酚或烯基双酚类抗氧剂；抗静电剂优选乙氧化胺类抗静电剂；阻燃剂优选无机阻燃剂如氢氧化镁；导电填料优选为二氧化硅粉和/或锌粉。
5.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：浸胶玻纤布层的制备方法包括如下步骤：
步骤1：将环氧树脂到入反应釜中加温至45-55℃，将稀释剂倒入反应釜对环氧树脂进行稀释，再将固化剂到入反应釜中，继续搅拌30-40min后将添加剂及填料依次倒入反应釜继续保温搅拌2-2.5h，将搅拌混合后的环氧树脂复合胶胶液倒入浸胶池中，并保持温度在30-40℃；
步骤2：将玻璃纤维布挂到浸胶导辊上并经导轨引入浸胶池，在浸液中浸泡5-8min后再经过挤压辊使胶液与玻璃纤维布充分复合；
步骤3：将浸润有浸胶液的玻璃纤维布经牵引导辊进入烘干通道，经过烘干通道后，经裁板机按要求裁好备用；
优选的，步骤3中的烘干通道分为上层烘干通道和下层烘干通道，上层烘干通道温度为80-90℃，下层烘干通道为120-130℃，上层烘干通道和下层烘干通道长度均为10-15m，烘干速率为6-7m/min，烘干通道整体维持负压。
6.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：蓄热层为多层胶合板，多层胶合板的表面设有若干凹槽，凹槽内填充有混合导热填料，混合导热填料由包括熔融态的石蜡与导热填料按照20:1的质量比混合而成；优选的，多层胶合板的厚度为5-6mm，凹槽的槽深为3-4mm，槽宽为12-15mm；优选的，导热填料为铜粉、硅粉、微纳米石墨碳材料、不锈钢丝带中的一种或多种的混合物。
7.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：隔热层为木丝水泥板、膨胀珍珠岩粉体板、泡沫石棉板或泡沫玻璃混凝土板聚氨酯板。
8.根据权利要求1所述的具有储热性能的碳纤维复合电热木板，其特征在于：底部基材层为木质板材层，更优选为实木板材、刨花板、大芯板或抗倍特板，厚度优选为8-10mm；优选的，底部基材层的下表面喷涂双层底漆和双层面漆；优选的，粘接剂层的材质为三聚氰胺改性脲醛胶、三聚氰胺胶、白乳胶中的一种或多种的混合物。
9.一种权利要求1-8中任一所述的碳纤维复合电热木板的制备方法，其特征在于：包括如下步骤：将底部基材层、隔热层、碳纤维纸电热层、蓄热层、面层依次采用粘结剂粘接成型后通过热压机压合成型。
10.根据权利要求9所述的碳纤维复合电热木板的制备方法，其特征在于：包括如下步骤：
S1、在热压机的工作台面上依次铺装冷轧钢板模具；
S2、铺装底部基材层，并在底部基材层上表面涂抹粘结剂层；
S3、铺装隔热层，并在隔热层上表面涂抹粘结剂层；
S4、铺装聚酯膜后铺装一层或多层浸胶玻纤布层；
S5、铺装碳纤维纸电热层；
S6、铺装一层或多层浸胶玻纤布层；
S7、铺装聚酯膜，并在该层聚酯膜表面涂抹粘接剂；
S8、铺装蓄热层，蓄热层的槽口向下；
S9、在蓄热层上方涂抹粘结剂层；
S10、铺装面层；
S11、铺装冷轧钢板模具；
S12、将铺装好的冷轧钢板模具送入热压机后进行第一次加温加压操作，温度为120-130℃，压力为6-8MPa/cm2，保温保压30-40min以后进行第二次加温加压操作，温度升至160℃-170℃，压力升至9-10MPa/cm2，保温保压50-60min后降温，当温度降到40-45℃时，泄压，开启模具，出模，将压合成型的产品取出即得碳纤维复合电热木板。
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