CN114539603A - 一种酚醛树脂浸渍溶液、预浸料和复合板材 - Google Patents
一种酚醛树脂浸渍溶液、预浸料和复合板材 Download PDFInfo
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Abstract
本发明公开了一种酚醛树脂浸渍溶液、预浸料和复合板材，其内包含有由塑料制成的其内封闭有气体的微球，微球体积可随着内部气体的受热膨胀而增大，在酚醛树脂复合材料板材的制备过程中，随着温度的上升，微球内的空气受热膨胀，从而可以显著降低了酚醛树脂复合材料板材整体的密度，同时也意味着制备所需原材料损耗的减少。
Description
技术领域
一种用于铁路运输、汽车工业、造船和建筑领域的酚醛复合材料，特别涉及一种基于可溶性酚醛树脂的酚醛复合材料。
背景技术
酚醛树脂材料又名酚醛塑料，俗称电木粉，酚醛树脂复合材料具有良好的耐酸性能、力学性能、耐热性能，可用于广泛的行业。
特别在铁路内饰、船舶制造、汽车工业、建筑等领域，期望进一步提高酚醛树脂复合材料在轻质、隔音和高阻燃方面的性能。
发明内容
为实现上述目的，本发明在第一方面提供了所述的酚醛树脂浸渍溶液中包含塑料空心微球，其中，微球粒径在10-20μm之间，微球壁厚在1.2-2.0μm之间。
进一步地，酚醛树脂与微球的质量比在7:1-12:1之间。
进一步地，所述的酚醛树脂浸渍溶液中游离酚含量小于2%，游离甲醛含量小于0.5%；粘度为450 - 550mPa.s/ 25℃，固体含量为59.5 - 65.5%，pH为8.5-9.5；在150℃温度下，其固化时间为60 - 65秒。
本发明在第二方面提供了一种酚醛树脂预浸料，所述的酚醛树脂预浸料通过如下步骤制备而得：
（1）将非织造材料浸渍于如上述的酚醛树脂浸渍溶液中；
（2）将浸渍后的非织造材料烘干，使之部分固化。
进一步地，酚醛树脂浸渍溶液中还加入了氢氧化铝，且酚醛树脂与氢氧化铝的比例为14:1。
进一步地，非织造材料为碳纤维、等级为E和C的玻璃纤维、或作为氨基硅烷基油剂的玄武岩玻璃纤维无序排列于表面的增强型非织造材料。
进一步地，烘干过程包括80-90℃和105-115℃两个阶段，浸渍速度不超过10m/min。烘干后酚醛树脂塑料空心微球粒径在20-40μm之间，微球壁厚在0.1-1.2μm之间。
本发明在第三方面提供了一种酚醛树脂复合材料板材，所述的酚醛复合材料压合板由一组上述的酚醛树脂预浸料压制而成。
进一步地，压制的温度区间在于130-145℃，压力位于3-7Mpa之间，压制时间位于2-25分钟之间。
进一步地，压制后的板材的厚度范围为2mm至20mm，其密度范围在120kg/m2至600kg/m3。
本发明中酚醛树脂浸渍溶液、酚醛树脂预浸料和酚醛树脂复合材料板材中的微球通过随着温度的上升，微球内的空气受热膨胀，从而可以显著降低了酚醛树脂复合材料板材整体的密度，获得更加轻质的酚醛树脂复合材料，同时也意味着制备所需原材料损耗的减少。且通过控制浸渍溶液中微球的比例，可获得所需的板材密度。此外，微球的存在也可提高酚醛树脂复合材料的隔音性能。
以下将结合附图对本发明的构思、具体结构及产生的技术效果作进一步说明，以充分地了解本发明的目的、特征和效果。
附图说明
图1是根据本发明的一个具体实施例中的酚醛树脂复合材料中微球在加热前后膨胀的示意图。
具体实施方式
以下参考说明书附图介绍本发明的多个优选实施例，使其技术内容更加清楚和便于理解。本发明可以通过许多不同形式的实施例来得以体现，本发明的保护范围并非仅限于文中提到的实施例。
本发明首先制备了一种酚醛树脂浸渍溶液，在一个具体实施例中，该浸渍溶液中游离酚含量小于2%，游离甲醛含量小于0.5%；粘度为450 - 550mPa.s/ 25℃，固体含量为59.5 - 65.5%，pH为8.5-9.5；在150℃温度下，其固化时间为60 - 65秒。在该浸渍溶液中，还添加了一种由塑料制成的其内封闭有气体的微球，在一个具体实施例中，酚醛树脂与微球的质量比在7:1-12:1之间。微球体积可随着内部气体的受热膨胀而增大。微球是采用悬浮聚合法制备的，即利用机械搅拌将一个或多个单体在水中混合，同时进行单体聚合，从而形成球状的聚合物。
进一步地，本发明采用这种酚醛树脂浸渍溶液制备酚醛树脂预浸料，在酚醛树脂浸渍溶液中加入氢氧化铝以提高复合材料的防火性能参数，在一个具体实施例中，酚醛树脂与氢氧化铝的比例为14:1。将非织造材料置于该酚醛树脂浸渍溶液中浸渍得到酚醛树脂预浸料。在一个具体实施例中，非织造材料为碳纤维、等级为E和C的玻璃纤维、或作为氨基硅烷基油剂的玄武岩玻璃纤维等纤维无序排列于表面的增强型非织造材料。然后，将浸渍后的非织造材料烘干，使之部分固化。部分固化后的非织造材料的含水量处于6-8%。在一个具体实施例中，烘干过程包括80-90℃和105-115℃两个阶段，浸渍速度不超过10m/min。
进一步地，本发明采用得到的酚醛树脂预浸料制备酚醛树脂复合材料板材，通过将一组酚醛树脂预浸料压制而得酚醛树脂复合材料板材。在一个具体实施例中，压制的温度区间在于130-145℃，压力位于3-7Mpa之间，压制时间位于2-25分钟之间。压制后的板材的厚度范围为2mm至20mm，其密度范围在120kg/m2至600kg/m3。
如图1所示，在酚醛树脂复合材料板材的制备过程中，随着温度的上升，微球1内的空气受热膨胀，从而可以显著降低了酚醛树脂复合材料板材整体的密度，同时也意味着制备所需原材料损耗的减少。
以上详细描述了本发明的较佳具体实施例。应当理解，本领域的普通技术无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此，凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案，皆应在由权利要求书所确定的保护范围内。
Claims (10)
1.一种酚醛树脂浸渍溶液，其特征在于，所述的酚醛树脂浸渍溶液中包含塑料空心微球，其中，微球粒径在10-20μm之间，微球壁厚在1.2-2.0μm之间。
2.如权利要求1所述的酚醛树脂浸渍溶液，其中，酚醛树脂与微球的质量比在7:1-12:1之间。
3.如权利要求1所述的酚醛树脂浸渍溶液，其中，所述的酚醛树脂浸渍溶液中游离酚含量小于2%，游离甲醛含量小于0.5%；粘度为450 - 550mPa.s/ 25℃，固体含量为59.5 -65.5%，pH为8.5-9.5；在150℃温度下，其固化时间为60 - 65秒。
4.一种酚醛树脂预浸料，其特征在于，所述的酚醛树脂预浸料通过如下步骤制备而得：
（1）将非织造材料浸渍于如权利要求1-3中任意一项中的酚醛树脂浸渍溶液中；
（2）将浸渍后的非织造材料烘干，烘干后的非织造材料的含水量处于6-8%。
5.如权利要求4所述的酚醛树脂预浸料，其中，酚醛树脂浸渍溶液中还加入了氢氧化铝，且酚醛树脂与氢氧化铝的比例为14:1。
6.如权利要求4所述的酚醛树脂预浸料，其中，非织造材料为碳纤维、等级为E和C的玻璃纤维、或作为氨基硅烷基油剂的玄武岩玻璃纤维无序排列于表面的增强型非织造材料。
7.如权利要求4所述的酚醛树脂预浸料，其中，烘干过程包括80-90℃和105-115℃两个阶段，浸渍速度不超过10m/min，烘干后酚醛树脂塑料空心微球粒径在20-40μm之间，微球壁厚在0.1-1.2μm之间。
8.一种酚醛树脂复合材料板材，其特征在于，所述的酚醛复合材料板材由一组如权利要求4中的酚醛树脂预浸料压制而成。
9.如权利要求8所述的酚醛树脂复合板材，其中，压制的温度区间在于130-145℃，压力位于3-7Mpa之间，压制时间位于2-25分钟之间。
10.如权利要求8所述的酚醛树脂复合板材，其中，压制后的板材的厚度范围为2mm至20mm，其密度范围在120kg/m2至600kg/m3。
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| US4483889A (en) * | 1982-08-05 | 1984-11-20 | Kemanord Ab | Method for the production of fibre composite materials impregnated with resin |
| CN102731960A (zh) * | 2012-06-18 | 2012-10-17 | 航天材料及工艺研究所 | 一种高韧性阻燃酚醛预浸料复合材料及其制备方法和用途 |
| CN113896940A (zh) * | 2021-11-10 | 2022-01-07 | 株洲时代新材料科技股份有限公司 | 一种纤维增强酚醛发泡材料及其制备方法 |
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2022
- 2022-03-08 CN CN202210218250.7A patent/CN114539603A/zh active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4483889A (en) * | 1982-08-05 | 1984-11-20 | Kemanord Ab | Method for the production of fibre composite materials impregnated with resin |
| CN102731960A (zh) * | 2012-06-18 | 2012-10-17 | 航天材料及工艺研究所 | 一种高韧性阻燃酚醛预浸料复合材料及其制备方法和用途 |
| CN113896940A (zh) * | 2021-11-10 | 2022-01-07 | 株洲时代新材料科技股份有限公司 | 一种纤维增强酚醛发泡材料及其制备方法 |
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