CN114633529A - 一种航空用薄膜复合材料 - Google Patents
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Abstract
本发明提供了一种航空用薄膜复合材料，包括从上而下依次设置的乙烯‑三氟氯乙烯共聚物(ECTFE)薄膜层、粘剂层和增强纤维网格层，所述航空用薄膜复合材料的水汽透过率为0.1g/m2·24h～4g/m2·24h，剥离强度为2N/m～6N/m。本发明所述航空用薄膜复合材料具有质轻、优异的阻隔、阻燃、低烟雾释放、耐磨、耐冲击、耐老化、耐化学腐蚀等性能。
Description
技术领域
本发明涉及一种航空材料，特别涉及一种航空用薄膜复合材料。
背景技术
飞机机舱内所有的加压部位，从鼻坠部到尾部，都会安装隔音/隔热绝缘材料。这些隔音隔热绝缘材料是飞机上用量最大的复合材料，其除了重量、体积、隔音、隔热、减振、防腐蚀等要求外，还要求兼有耐高低温、水汽阻隔、阻燃等性能。因此，航空用隔音/隔热材料都必须复合一层包覆膜对其进行功能性保护。
包覆膜是由聚合物膜、阻隔层、粘合剂和支撑层组成的薄膜复合结构，主要起到防尘、阻燃、减少水汽透过的作用。目前，聚合物膜主要有聚氟乙烯(PVF)、聚酰亚胺(PI))、聚醚醚酮(PEEK)等。PVF薄膜的阻燃等级为HB，PEEK和PI更加耐燃，然而其抗压强度低，断裂韧性差，耐损伤性低以及加工性能不佳。
中国专利ZL201721635249.5公开了一种航空内饰用薄膜复合材料，包含材料层、铝箔层和网格层，材料层的材料为PVDF、PVF或PEEK中的一种或几种的组合，材料层的厚度为18～25微米，铝箔层的厚度为6.5～12微米。PVDF和PVF薄膜的阻燃性有限，必须通过使用微米级别的铝箔来提升，导致复合材料面密度相对较高，还存在断裂韧性差等问题。
发明内容
为了解决上述技术问题，本发明提出了一种具有质轻、优异的阻隔、阻燃、低烟雾释放、耐冲击、耐老化、耐化学腐蚀等性能航空用薄膜复合材料。
本发明的目的是通过以下技术方案实现的：
一种航空用薄膜复合材料，包括从上而下依次设置的乙烯-三氟氯乙烯共聚物(ECTFE)薄膜层、粘剂层和增强纤维网格层，所述航空用薄膜复合材料的水汽透过率为0.1g/m2·24h～4g/m2·24h，剥离强度为2N/m～6N/m。
优选地，所述航空用薄膜复合材料的水汽透过率为0.5g/m2·24h～2g/m2·24h。
所述航空用薄膜复合材料的面密度为20g/m2～60g/m2，优选为34g/m2～50g/m2。
所述航空用薄膜复合材料的顶破强度为100kPa～250kPa，优选为150kPa～250kPa。
由于ECTFE分子中的氟、氯原子均有疏水性，不会形成氢键；同时分子结构中的C-Cl键增强了分子极性、刚性和耐蠕变性，降低了分子链段的自由运动。综合以上原因，导致气体分子和水分子很难在ECTFE分子中移动，从而使其具有优良的水气阻隔性能。采用ECTFE薄膜制备复合材料可以省去阻隔层，以此有效降低薄膜复合材料的面密度。
所述ECTFE薄膜是以ECTFE树脂为基材，通过挤出机、过滤器、熔体计量泵、流延模具后流延收卷或者进一步双向拉伸，得到ECTFE薄膜。
优选地，所述ECTFE薄膜先进行表面处理，以有效提高表面张力。所述ECTFE薄膜表面处理方法可以是酸性刻蚀法、钠-萘络合物化学处理、火焰处理、等离子体处理或电晕处理中的至少一种。表面处理后的ECTFE薄膜的表面张力为40mN/m～56mN/m，能够很好地与增强纤维网格层复合，满足剥离强度的要求。
所述ECTFE薄膜厚度为8μm～60μm，优选为10μm～30μm，更有选为15μm～25μm。
所述粘剂层厚度为3μm～5μm。所述粘剂选自酯溶性聚氨酯、醇溶性聚氨酯或水性双组分复合胶中的至少一种。
所述增强纤维网格层是由纤维丝束编织而成。所述纤维选自芳纶纤维、聚酯纤维和尼龙纤维中的至少一种。每股纱线纤度为100D～250D，网格间距为2mm～5mm；优选地，纱线纤度150D～200D、网格间距为2.5mm～3mm。
具体地，所述航空用薄膜复合材料包括从上而下依次设置的ECTFE薄膜层、镀氧化铝层、粘剂层和增强纤维网格层，所述航空用薄膜复合材料的水汽透过率为0.5g/m2·24h～2g/m2·24h，剥离强度为2N/m～6N/m。
所述镀氧化铝层厚度为0～100nm，优选为20nm～60nm，更优选为20nm～40nm。所述镀氧化铝层厚度仅为普通铝箔厚度的1/1000，具有优良的耐折性和柔韧性，相比于表面光滑的铝箔，镀氧化铝层更有利于与增强尼龙网格层的复合，通过粘剂层进行复合，能够有效提升航空用薄膜复合材料的剥离强度。
所述镀氧化铝层是采用真空镀膜工艺镀在ECTFE薄膜层表面，具体包括以下步骤：在高真空状态下，通过高温将氧化铝气化蒸发沉淀到ECTFE薄膜表面上，从而得到镀氧化铝ECTFE薄膜。
上述步骤中，所述氧化铝的纯度为99.9％及以上，气化温度为1100℃～1200℃。
再与纳米级别的镀氧化铝复合，水汽阻隔率得到进一步地增强。
本发明还提供上述任一所述航空用薄膜复合材料的制备方法，具体步骤如下：
先在ECTFE薄膜表面涂覆一层粘剂，再通过复合机与增强纤维网格布进行复合，得到薄膜复合材料。
根据上述航空用薄膜复合材料的制备方法，优选地，所述复合机的复合辊温度为60℃～110℃，复合时间为3min～10min。
当所述航空用薄膜复合材料增加一层镀氧化铝层时，将所述镀氧化铝层镀在ECTFE薄膜层表面后，再在镀氧化铝层涂上一层粘剂，通过复合机与增强纤维网格布进行复合，得到航空用薄膜复合材料。
本发明所述航空用薄膜复合材料可以用作航空隔音隔热材料包覆膜。
与现有技术相比，本发明具有的有益效果为：
1、本发明采用的ECTFE薄膜具有优异的水汽阻隔性、耐高低温性和机械性能，所制备的航空用薄膜复合材料可以省去阻隔层，且具有更宽的温度适用范围，更好的加工性能、抗压强度、断裂韧性和耐损伤性等。
2、本发明所述航空用薄膜复合材料具有质轻、优异的阻隔、阻燃、低烟雾释放、耐冲击、耐老化、耐化学腐蚀等性能。
具体实施方式
下面结合具体实施例来对本发明进行进一步说明，但并不将本发明局限于这些具体实施方式。本领域技术人员应该认识到，本发明涵盖了权利要求书范围内所可能包括的所有备选方案、改进方案和等效方案。
实施例1
将100份ECTFE树脂通过双螺杆挤出机、过滤器、熔体计量泵、模具挤出到流延辊冷却定型，得到25μm厚的ECTFE流延薄膜，表面张力为32mN/m。再将ECTFE流延薄膜进行电晕处理，制得的ECTFE流延薄膜的表面张力为56mN/m。
使用复合机将ECTFE薄膜的表面涂覆一层10μm的酯溶性双组份聚氨酯，再与增强尼龙网格材料(2#网格层)复合，复合温度为95℃，复合时间为4.0min，最终形成增强型ECTFE复合薄膜。
实施例2
将100份ECTFE树脂通过双螺杆挤出机、过滤器、熔体计量泵、模具挤出到流延辊冷却定型，得到10μm厚的ECTFE流延薄膜，表面张力为32mN/m。再将ECTFE流延薄膜进行电晕处理，制得的ECTFE流延薄膜的表面张力为46mN/m。
在高真空状态下，通过高温将氧化铝融化蒸发沉淀到移动的ECTFE薄膜表面上，得到镀氧化铝ECTFE薄膜，镀氧化铝的厚度为50nm。
使用复合机将ECTFE薄膜镀氧化铝层表面涂敷一层8μm的醇溶性双组份聚氨酯，再与增强尼龙网格材料(3#网格层)复合，复合温度为80℃，复合时间为4.0min，最终形成增强型ECTFE复合薄膜。
ECTFE薄膜镀氧化铝层与增强尼龙网格之间的剥离强度(T剥离)为2.8N/m。
实施例3
将100份ECTFE树脂通过双螺杆挤出机、过滤器、熔体计量泵、模具挤出到流延辊冷却定型，得到20μm厚的ECTFE流延薄膜，表面张力为32mN/m。再将ECTFE流延薄膜进行电晕处理，制得的ECTFE流延薄膜的表面张力为50mN/m。
在高真空状态下，通过高温将氧化铝融化蒸发沉淀到移动的ECTFE薄膜表面上，从而得到镀氧化铝ECTFE薄膜。镀氧化铝的厚度为25nm。
使用复合机将ECTFE薄膜镀氧化铝层表面涂覆一层12μm的醇溶性双组份聚氨酯，再与增强尼龙网格材料(1#网格层)复合，复合温度为100℃，复合时间为3.0min，最终形成增强型ECTFE复合薄膜。
ECTFE薄膜镀氧化铝层与增强尼龙网格之间的剥离强度(T剥离)为3.5N/m。
实施例4
将100份ECTFE树脂通过双螺杆挤出机、过滤器、熔体计量泵、模具挤出到流延辊冷却定型，得到15μm厚的ECTFE流延薄膜，表面张力为32mN/m。再将ECTFE流延薄膜进行电晕处理，制得的ECTFE流延薄膜的表面张力为52mN/m。
在高真空状态下，通过高温将氧化铝融化蒸发沉淀到移动的ECTFE薄膜表面上，从而得到镀氧化铝ECTFE薄膜。镀氧化铝的厚度为40nm。
使用复合机将ECTFE薄膜镀氧化铝层表面涂覆一层10μm的酯溶性双组份聚氨酯，再与增强尼龙网格材料(4#网格层)复合，复合温度为90℃，复合时间为5.0min，最终形成增强型ECTFE复合薄膜。
ECTFE薄膜镀氧化铝层与网格布之间的剥离强度(T剥离)为3.4N/m。
对比例
将100份PVF树脂高速分散在200份γ-丁内酯中，所制得的PVF树脂分散体通过双螺杆挤出机、过滤器、熔体计量泵、流延模具，经过脱挥(脱出γ-丁内酯中)，得到20μm厚的PVF流延薄膜，表面张力为36mN/m，进一步将PVF流延薄膜进行电晕处理，得到PVF流延薄膜，表面张力为48mN/m。
使用复合机在PVF薄膜表面涂敷一层10μm的醇溶性双组份聚氨酯，再与厚度为10μm的铝箔层以及涂覆有醇溶性双组份聚氨酯的增强尼龙网格材料(3#网格层)复合，复合温度为90℃，复合时间为6.0min，最终形成增强型PVF复合薄膜。PVF薄膜与铝箔之间的剥离强(T剥离)为1.4N/m。
对实施例1～4和对比例制得的薄膜复合材料进行性能指标测试评价，具体性能指标测试方法如下：
(1)薄膜厚度按照GB/6672-2001测定；
(2)镀氧化铝层厚度按照GB/T15717-1995测定；
(3)顶破强度按照GB7742-2015测定；
(4)水蒸气透过率按照GB/T 1037-1988测定；
(5)表面张力按照GB/T 14216-2008测定；
(6)剥离强度按照GB/T 2791-1995测定；
(7)面密度按照HB 7736.2-2004第2部分测定。
表1实施例1～4和对比例制得薄膜复合材料的测试结果表
从表1可以看出，对比例选用PVF薄膜作为薄膜复合材料的聚合物膜，阻隔层是厚度为10μm的铝箔，虽然铝箔的使用能有效提升水汽阻隔性，但是会增加复合材料的面密度，导致复合材料的面密度过大，此外，铝箔与PVF薄膜的复合性能也较差，易剥离。
Claims (10)
1.一种航空用薄膜复合材料，其特征在于：包括从上而下依次设置的ECTFE薄膜层、粘剂层和增强纤维网格层，所述航空用薄膜复合材料的水汽透过率为0.1g/m2·24h～4g/m2·24h，剥离强度为2N/m～6N/m。
2.根据权利要求1所述的薄膜复合材料，其特征在于：所述航空用薄膜复合材料的面密度为20g/m2～60g/m2，顶破强度为100kPa～250kPa。
3.根据权利要求1所述的薄膜复合材料，其特征在于：所述ECTFE薄膜厚度为8μm～60μm，表面张力为40mN/m～56mN/m。
4.根据权利要求1所述的薄膜复合材料，其特征在于：所述粘剂层厚度为3μm～5μm，所述粘剂选自酯溶性聚氨酯、醇溶性聚氨酯或水性双组分复合胶中的至少一种。
5.根据权利要求1所述的薄膜复合材料，其特征在于：所述增强纤维网格层是由纤维丝束编织而成，网格间距为2mm～5mm。
6.根据权利要求1所述的薄膜复合材料，其特征在于：所述薄膜复合材料还包括镀氧化铝层，从上而下依次设置为ECTFE薄膜层、镀氧化铝层、粘剂层和增强纤维网格层。
7.根据权利要求6所述的薄膜复合材料，其特征在于：所述镀氧化铝层厚度为20nm～60nm。
8.根据权利要求6所述的薄膜复合材料，其特征在于：所述镀氧化铝层是采用真空镀膜工艺镀在ECTFE薄膜层表面。
9.权利要求1-6任一所述的薄膜复合材料的制备方法，其特征在于：所述制备方法包括：先在ECTFE薄膜或镀氧化铝ECTFE薄膜表面涂覆一层粘剂，再通过复合机与增强纤维网格布进行复合，得到薄膜复合材料，所述复合机的复合辊温度为60℃～110℃，复合时间为3min～10min。
10.权利要求1所述的薄膜复合材料的应用，其特征在于：所述薄膜复合材料用作航空隔音隔热材料的包覆膜。
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