CN114438797B - 一种复合材料拉挤型材脱模布制备方法 - Google Patents

一种复合材料拉挤型材脱模布制备方法 Download PDF

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CN114438797B
CN114438797B CN202111636733.0A CN202111636733A CN114438797B CN 114438797 B CN114438797 B CN 114438797B CN 202111636733 A CN202111636733 A CN 202111636733A CN 114438797 B CN114438797 B CN 114438797B
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fabric
release cloth
nylon
coating
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CN114438797A (zh
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潘宝庆
范爱荣
邹本书
候圣伟
徐理伟
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Zhejiang Youwei New Materials Co ltd
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Abstract

本发明公开了一种复合材料拉挤型材脱模布制备方法，S1面料制备：采用尼龙66、尼龙6、尼龙56、聚酯纤维中的一种或者两种混编，一种作为经向，一种作为纬向，再经过整经、穿纹、织造、清洗、烘干定型制得所需面料；S2面料的分切：将面料采用激光、超声或者机械刀具等方式进行切割、分条，获得所要宽度的基体面料；S3功能溶液的制备。S4涂覆。S5烘干。本发明制备方法制得了具有挺度、耐高温、具有润滑性的高性能脱模布。

Description

一种复合材料拉挤型材脱模布制备方法
技术领域
本发明涉及脱模布技术领域，具体涉及一种复合材料拉挤型材脱模布制备方法。
背景技术
拉挤作为一种复合材料成型工艺，因高自动化、高产品良率以及高原材料利用率，倍受复材界瞩目。近年来由于风电行业迅猛发展，叶片大梁板的大规模应用，使得拉挤型材市场火热。在需要二次成型，粘接或者装配时，需要型材表面粗糙化，这样才能使得与其他材料结合牢固。
具体的拉挤型材工艺：纤维在纱盘退绕后，经过纱板集束、浸胶之后，上下表面覆盖脱模布。之后进入模具，经高温固化后被牵引出模具，形成产品。在使用前将上下表面的脱模布撕除掉，这样拉挤型材的上下表面就形成乐粗糙的表面。
目前脱模布大概可以分成三类：目前市场上最为常用的是以尼龙、聚酯等纤维为原料，经过整经、穿纹、织造、清洗、烘干定型等工序制得脱模布。这种脱模布最为常见，为了提升性能有人在此基础上做了发明、创造，由此产生了另外两种脱模布。
另外一类为多层结构，例如专利《一种适用于拉挤脱模布》(申请202020502831.X)中所述脱模布包括面料本体、编织层、增强尼龙抗压层、上面料基层和下面料基层。面料本体内部的中心位置处设有编织层，且编织层上方的面料本体内部设有上面料基层，并且编织层远离上面料基层一侧的面料本体内部设有下面料基层，所述上面料基层上方的面料本体内部设有增强尼龙抗压层，且增强尼龙抗压层的内部设有抗压结构，下面料基层远离编织层一侧的面料本体内部设有涤棉耐温层，并且涤棉耐温层以及增强尼龙抗压层远离编织层一侧的面料本体内部皆设有异氰酸酯防渗层。该专利不仅降低了脱模布使用时产生侵蚀的现象，延长了脱模布的使用寿命，而且提高了脱模布的适用范围，但是结构比较复杂制造成本上升，质量也很难把控。
还有一类为涂覆型，例如专利《一种新型防粘连脱模布》(申请201621191995.5)。该专利公开了一种新型防粘连脱模布，包括脱模布本体(1)，其特征在于，所述脱模布本体(1)采用聚酯纤维编制而成，所述脱模布本体(1)表面设置有硅油层(2)。本实用新型用于风力发电风机叶片的成型，防止在脱模时脱模布粘连在表面，提高制品的质量与脱模布的利用率。这种脱模布在真空灌注、热压罐成型工艺还好，在拉挤型材方面，并未解决，脱模布的收缩、褶皱等问题。
综上所述，现有技术下述缺陷：
1、在拉挤过程中脱模布容易跑偏、边缘褶皱，造成型材不良。
2、脱模布在宽度方向上的收缩，致使拉挤板材有一部分没有覆盖到，不能形成粗粗表面，影响产品质量。
3、脱模布边缘的纱线，在撕离的过程中容易残留于拉挤型材的表面。
4、耐温性差，在拉挤高温固化过程中会有失效状态，拉挤型材表面呈现印记，造成制品不良。
发明内容
本发明要解决的技术问题是：研制开发一种复合材料拉挤型材脱模布及其制备方法，该复合材料拉挤型材脱模布采用涂覆的方式，将石墨烯功能溶液与脱模布基体复合，形成具有一定挺度、耐高温、具有润滑性的高性能脱模布，进而解决现有脱模布的褶皱、收缩、残丝以及耐温性差等缺陷。
为了达到上述目的，本发明采用了以下技术方案：
一种复合材料拉挤型材脱模布制备方法，
S1面料制备：采用尼龙66、尼龙6、尼龙56、聚酯纤维中的一种或者两种混编，一种作为经向，一种作为纬向，再经过整经、穿纹、织造、清洗、烘干定型制得所需面料；
S2面料的分切：将面料采用激光、超声或者机械刀具等方式进行切割、分条，获得所要宽度的基体面料；
S3功能溶液的制备：
(1)按重量取100份的去离子水放入0.1-3份的石墨烯，0.01-0.1份的2，4-己二烯酸钾，加热至85℃；
(2)放入0.05-5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min；
(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.01～0.05mm。
S4烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到所需产品。
作为本方案的进一步改进，S1中面料为经向为聚酯纤维、纬向为尼龙56。
作为本方案的进一步改进，S1中面料为经向为聚酯纤维、纬向为聚酯纤维。
作为本方案的进一步改进，S1中面料为经向为尼龙56、纬向为尼龙56。
作为本方案的进一步改进，S1中制得的所需面料克重为60-150g/m2。
与现有技术相比，本发明具备下述有益效果：
1)本发明通过将石墨烯与聚乙烯醇复配于水溶液中，形成功能溶液，石墨烯具有耐高温和润滑的特性，聚乙烯醇能够粘附石墨烯并且提高脱模布基体的硬挺度，避免褶皱的出现，也使得脱模布不因张力过大而被拉扯变形；
2)石墨烯的润滑作用减小与模具之间的摩擦，降低拉挤设备的牵引力，也有利于脱模布的撕离，避免脱模布基体边缘纱线的残留，同时它也能够提高脱模布的耐温性，避免高温烙印；
3)通过功能溶液处理后，不仅提高了脱模布基体的耐温性和硬挺度，而且也减小了热收缩。
具体实施方式
为了使本发明的目的、技术方案和优点更加清楚，以下结合实施例对本发明作进一步说明：
实施例1：
S1面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
S2面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
S3功能溶液的制备：(1)按重量取100份的去离子水放入0.1份的石墨烯，0.01份的2，4-己二烯酸钾，加热至85℃。(2)放入0.05份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min。(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.01mm。
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到复合材料拉挤型材脱模布产品。
实施例2：
S1面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
S2面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
S3功能溶液的制备：(1)按重量取100份的去离子水放入0.8份的石墨烯，0.03份的2，4-己二烯酸钾，加热至85℃。(2)放入1.5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min。(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.02mm。
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到复合材料拉挤型材脱模布产品。
实施例3：
S1面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
S2面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
S3功能溶液的制备：(1)按重量取100份的去离子水放入1.5份的石墨烯，0.05份的2，4-己二烯酸钾，加热至85℃。(2)放入2.5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min。(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.03mm。
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到复合材料拉挤型材脱模布产品。
实施例4：
S1面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
S2面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
S3功能溶液的制备：(1)按重量取100份的去离子水放入2.3份的石墨烯，0.08份的2，4-己二烯酸钾，加热至85℃。(2)放入3.5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min。(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.04mm。
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到复合材料拉挤型材脱模布产品。
实施例5：
S1面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
S2面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
S3功能溶液的制备：(1)按重量取100份的去离子水放入3份的石墨烯，0.1份的2，4-己二烯酸钾，加热至85℃。(2)放入5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min。(3)使用真空泵将溶液中气饱脱出，等待使用。
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0.5mm。
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到复合材料拉挤型材脱模布产品。
对比例：
1、面料制备：采用尼龙6，经过整经、穿纹、织造、清洗、烘干定型制得克重为80g/m2的面料。
2、面料的分切：将面料采用激光切割、分条，获得宽度为118mm的基体面料。
一、硬挺度测试：
对实施例1～实施例5及对比例进行硬挺度测试。织物的弯曲长度是表征材料抵抗弯曲变形的特性指标之一，反映了织物的硬挺程度。
采用标准GB/T 18318-2001《纺织品织物弯曲长度的测定》。试样宽度为(25±1)mmX(250±1)mm,所有样品都在同等条件下处理。试样长轴与测试平台长轴平行，沿平台长轴方向推进试样，使其伸出平台并在自重下弯曲。伸出部分端悬空，由尺子压住仍在平台上的试样另一端。当试样的头端通过平台的前缘达到与水平线呈41.5°倾角的斜面上时，伸出长度等于弯曲长的的两倍。
测试结果如表1所示：
表1实施例1～5及对比例弯曲长度测试结果
备注：弯曲长度越长说明材料的硬挺度越大。
二、应用测试：
将上述对实施例1—实施例5及对比例脱模布进行拉挤，拉挤同样长度。拉挤复合材料为玻纤/环氧树脂(玻纤体积含量在60％)，上、下覆盖脱模布，制备宽度为120mm的拉挤板材。使用千分尺测量脱模布宽度方向的收缩情况；对拉挤后的型材表面进行目测，统计脱模布褶皱情况；之后进行脱模布的撕离，目测脱模布纱线残留状况以及是否有高温烙印。
表2实施例1～5及对比例的应用测试结果
实施例1 实施例2 实施例3 实施例4 实施例5 对比例
收缩(mm) 2.0 1.6 0.5 2.1 0.5 6.7
褶皱 无 无 无 无 无 有
残丝 无 无 无 无 无 有
烙印 无 无 无 无 无 略有
通过上述数据对比，本专利提供一种复合材料拉挤型材脱模布，不因张力过大而被拉扯变形，耐温性及硬挺度提高，同时热收缩减小。
本配方组成中的成分聚乙烯醇是通过醋酸乙烯酯聚合制得聚醋酸乙烯酯，然后再醇解或者水解得到。聚乙烯醇分子中存在两种化学结构，即1,3和1,2乙二醇结构，但主要的结构是1,3乙二醇，即“头-尾”结构。聚乙烯醇的大分子链分子主链构型为伸长的直链。其分子链直径小、分子间作用力强、极性大，其理论强度和模量分别可达200cN/dtex和2000eN/dtex。由于分子链上含有大量的侧基-羟基，因此聚乙烯醇具有很好的吸水性，同时还有很好的成膜性，粘结力，对脱模布的湿度有很好的保持作用，同时聚乙烯醇粘着力强、成膜性好，皮膜强度高。可提高脱模布的耐磨、耐折，能够提高脱模布的硬挺度。避免拉挤型材因为脱模布硬挺度不够引起的褶皱不良。
本配方组成中的成分2,4-己二烯酸钾能够与微生物酶系统的巯基结合从而破坏许多酶系统的作用，可以有效抑制霉菌，好氧性细菌以及酵母菌活性，还可以防止葡萄球菌、肉毒杆菌以及沙门氏菌等微生物的繁殖，防止涂覆聚乙烯醇脱模布长期储存后的霉变。
本配方组成中的成分石墨烯是一种以sp2杂化连接的碳原子紧密堆积成单层二维蜂窝状晶格结构的新材料，每个碳原子周围有3个碳原子成键，键角120°，具有独特的晶粒取向。在石墨烯中，碳原子在不停的振动，振动的幅度有可能超多其厚度。石墨烯的晶格振动使得其热性能及其优异，平面内具有150-1500W/m-K范围内的超高导热性能，熔点在5000K左右具有极高的耐热性能。这可以大大提高脱模布的耐高温性能，防止脱模布熔融、粘附在拉挤型材表面。减少脱模布的收缩，提高有效覆盖面积。
以上所述仅为本发明的优选实施方式，并非因此限制本发明的专利范围，凡是利用本发明所作的等效变换，均在本发明的专利保护范围内。

Claims (5)

1.一种复合材料拉挤型材脱模布制备方法，其特征在于，
S1面料制备：采用尼龙66、尼龙6、尼龙56、聚酯纤维中的一种或者两种混编，一种作为经向，一种作为纬向，再经过整经、穿纹、织造、清洗、烘干定型制得所需面料；
S2面料的分切：将面料采用激光、超声或者机械刀具的方式进行切割、分条，获得所要宽度的基体面料；
S3功能溶液的制备：
(1)按重量取100份的去离子水放入0 .1~3份的石墨烯，0 .01~0 .1份的2，4~己二烯酸钾，加热至85℃；
(2)放入0 .05~5份的聚乙烯醇，搅拌1小时后停止加热，待聚乙烯醇全部溶解后，再静止30min；
(3)使用真空泵将溶液中气泡脱出，待使用；
S4涂覆：使用涂覆机，采用挤压辊的方式，将步骤3的功能溶液涂覆在脱模布表面，涂层厚度在0 .01～0 .05mm；
S5烘干：涂覆后在100℃的烘道中通过，将表面烘干，收卷得到所需产品。
2.根据权利要求1所述的复合材料拉挤型材脱模布制备方法，其特征在于，S1中面料为经向为聚酯纤维、纬向为尼龙56。
3.根据权利要求1所述的复合材料拉挤型材脱模布制备方法，其特征在于，S1中面料为经向为聚酯纤维、纬向为聚酯纤维。
4.根据权利要求1所述的复合材料拉挤型材脱模布制备方法，其特征在于，S1中面料为经向为尼龙56、纬向为尼龙56。
5.根据权利要求1所述的复合材料拉挤型材脱模布制备方法，其特征在于，S1中制得的所需面料克重为60~150g/m2。
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