CN114701212B - 一种竹纤维复合毡及其制备方法和异型曲面复合毡 - Google Patents
一种竹纤维复合毡及其制备方法和异型曲面复合毡 Download PDFInfo
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- CN114701212B CN114701212B CN202210270165.5A CN202210270165A CN114701212B CN 114701212 B CN114701212 B CN 114701212B CN 202210270165 A CN202210270165 A CN 202210270165A CN 114701212 B CN114701212 B CN 114701212B
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Abstract
本发明属于竹纤维复合材料技术领域,提供了一种竹纤维复合毡,包括交替设置的竹纤维毡层和聚合物基体层;竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维;竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种。本发明提供的竹纤维复合毡通过将竹纤维毡层和聚合物基体层进行交替设置,解决了目前纤维复合毡界面结合不稳定的问题,有利于提升复合毡的强度;并且,竹纤维材料绿色、环保、可生物降解,有利于减少复合材料中树脂的含量,减轻环境压力。实施例的结果显示,本发明提供的竹纤维复合毡的断裂强力为50~100N,拉伸模量为10~200MPa,弯曲模量为50~500MPa。
Description
技术领域
本发明涉及竹纤维复合材料技术领域,尤其涉及一种竹纤维复合毡及其制备方法和异型曲面复合毡。
背景技术
用聚氯乙烯、聚乙烯、聚丙烯、聚苯乙烯以及其他树脂制成的塑料薄膜,由于其具有方便、干净、透明等的优点而广泛用于食品、办公用品、生活用具、医药、化工等领域。然而,塑料制品在为人类生活提供便利的同时由于自身难以降解也对环境产生了灾难性的影响,促使多国颁布“限塑令”、“禁塑令”。基于此,有必要寻找一种能够取代塑料制品或者可以有效减少树脂使用的材料。
竹纤维,是从自然生长的竹子中提取出的纤维素纤维,具有良好的透气性、瞬间吸水性、较强的耐磨性和良好的染色性等特性。并且,竹材资源丰富、可生物降解。因而,有望用竹纤维制品代替塑料制品。然而,现有的纤维复合毡存在界面结合不稳定的问题而影响纤维复合毡的强度。因此,如何制备结构稳定、强度高的竹纤维复合毡成为了本领域亟需解决的问题。
发明内容
本发明的目的在于一种竹纤维复合毡及其制备方法和异型曲面复合毡,本发明提供的竹纤维复合毡结构稳定,强度高。
为了实现上述发明目的,本发明提供了以下技术方案:
本发明提供了一种竹纤维复合毡,包括交替设置的竹纤维毡层和聚合物基体层;所述竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维;所述竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种。
优选地,所述竹短纤维的细度为20~200μm,长度为5~200mm;所述连续竹纤维的细度为0.5~5mm;所述竹篾的厚度为0.05~1.5mm,长度为 100~1500mm;所述竹丝的直径为0.01~0.5mm。
优选地,所述聚合物基体层的材质包括PET、PU、PP、PE、PA、PS、 PVC、ABS、PHB和PLA中的一种或几种。
优选地,所述竹纤维毡层的层数为2~5,每层竹纤维毡层的厚度为 5~25mm;所述聚合物基体层的层数为1~4,每层聚合物基体层的厚度为 0.1~1mm。
优选地,所述竹纤维毡层和/或聚合物基层中还含有助剂和填料。
优选地,所述助剂包括耐磨剂、防霉剂、阻燃剂、界面相容剂、颜料、光屏蔽剂、抗氧剂和生物灭杀剂中的一种或几种;所述填料包括玻璃微珠。
优选地,所述助剂或填料在竹纤维毡层或聚合物基层中的质量含量独立地为0~10%。
本发明提供了上述技术方案所述竹纤维复合毡的制备方法,包括以下步骤:
(1)将纤维材料进行机械梳理和/或气流铺装,再进行针刺,得到竹纤维毡层;
(2)将所述步骤(1)得到的竹纤维毡层和聚合物原料交替铺设在模具内,再进行热压,得到竹纤维复合毡。
优选地,所述步骤(2)中热压的温度为140~250℃,热压的压力为 0.5~2.0MPa,热压的时间为1~30min。
本发明还提供了一种异型曲面复合毡,包括表层和芯层,所述表层设置于所述芯层的两个表面上,所述表层材料为上述竹纤维复合毡或上述制备方法制备的竹纤维复合毡,所述芯层包括泡沫、瓦楞纸和蜂窝板中的一种或几种。
本发明提供了一种竹纤维复合毡,包括交替设置的竹纤维毡层和聚合物基体层;所述竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维;所述竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种。本发明提供的竹纤维复合毡通过将竹纤维毡层和聚合物基体层进行交替设置,解决了目前纤维复合毡界面结合不稳定的问题,有利于提升复合毡的强度;并且,竹纤维材料绿色、环保、可生物降解,有利于减少复合材料中树脂的含量,减轻环境压力。实施例的结果显示,本发明提供的竹纤维复合毡的断裂强力为50~100N,拉伸强度为5~10MPa,拉伸模量为10~200MPa,弯曲强度为1~20MPa,弯曲模量为50~500MPa;采用本发明提供的竹纤维复合毡制备的异型曲面复合毡的断裂强力为120~200N,拉伸强度为10~15MPa,拉伸模量为300~500MPa,弯曲强度为25~50MPa,弯曲模量为1000~2000MPa。
本发明提供的竹纤维复合毡的制备方法操作简单,并且解决了目前纤维复合毡不均匀的问题,同时提高了复合毡的性能。
附图说明
图1为本发明实施例3中竹纤维复合毡和实施例5~8中异型曲面复合毡的制备方法的流程图;
其中,T为温度;F为压力。
具体实施方式
本发明提供了一种竹纤维复合毡,包括交替设置的竹纤维毡层和聚合物基体层;所述竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维;所述竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种。
本发明提供的竹纤维复合毡包括交替设置的竹纤维毡层和聚合物基体层。本发明通过将竹纤维毡层和聚合物基体层进行交替设置,解决了目前纤维复合毡界面结合不稳定的问题,有利于提升复合毡的强度。在本发明中,所述竹纤维复合毡层与聚合物基体层根据产品需要进行自由复配。
在本发明中,所述竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维,优选为竹纤维材料和其它天然植物纤维。本发明以竹纤维为主要原料来制备复合毡,竹纤维材料绿色、环保、可生物降解,有利于减少复合材料中树脂的含量,减轻环境压力。
在本发明中,当所述竹纤维毡层中的纤维材料为竹纤维材料和其它天然植物纤维时,所述竹纤维材料的含量优选为竹纤维毡层质量的60~80%,更优选为70~80%。
在本发明中,所述竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种,更优选为竹短纤维、连续竹纤维、竹篾和竹丝。
在本发明中,所述竹短纤维的细度优选为20~200μm,更优选为 100~200μm;所述竹短纤维的长度优选为5~200mm,更优选为50~150mm。在本发明中,所述竹短纤维优选为竹材经化学或机械加工制得的包含单个纤维细胞或多纤维细胞集合体的束状、丝状或絮状单元。本发明对所述竹短纤维的制备方法没有特殊的限定,采用本领域技术人员熟知的短纤维的制备方法即可。
在本发明中,所述连续竹纤维的细度优选为0.5~5mm,更优选为2~4mm。在本发明中,所述连续竹纤维的制备方法优选为:将竹材制成网纹状竹纤维带;将所述网纹状竹纤维带进行加捻,得到纤维状竹片;将所述纤维状竹片进行解纤,得到蓬松絮状竹纤维;将所述蓬松絮状竹纤维进行拉伸,得到竹纤维毡;将所述竹纤维毡进行加捻,得到连续竹纤维。
在本发明中,所述网纹状竹纤维带的厚度优选为1~7mm;所述纤维状竹片的厚度优选为1~5mm;所述加捻的方式优选为罗拉加捻。
在本发明中,所述竹篾的厚度优选为0.05~1.5mm,更优选为0.5~1.5mm;所述竹篾的长度优选为100~1500mm,更优选为500~1500mm。本发明对所述竹篾的制备方法没有特殊的限定,采用本领域技术人员熟知的竹篾的制备方法即可。
在本发明中,所述竹丝的直径优选为0.01~0.5mm,更优选为0.1~0.5mm。在本发明中,所述竹丝优选为单根竹片或竹篾加工制成的横截面宽厚相近的细长条状单元。本发明对所述竹丝的制备方法没有特殊的限定,采用本领域技术人员熟知的制备竹丝的技术方案即可。
在本发明中,所述其它天然植物纤维优选包括棉纤维和/或麻纤维。本发明对所述其它天然植物纤维的来源没有特殊的限定,采用本领域技术人员熟知的市售产品即可。
在本发明中,所述竹纤维毡层的层数优选为2~5,更优选为2~3;每层竹纤维毡层的厚度优选为5~25mm,更优选为8~20mm。
在本发明中,所述聚合物基体层的材质优选包括PET、PU、PP、PE、 PA、PS、PVC、ABS、PHB和PLA中的一种或几种,更优选为PET、PU、 PP和PA中的一种或几种。在本发明中,所述聚合物基体层材质的形态优选包括树脂或纤维。本发明对所述聚合物基体层的材质的来源没有特殊的限定,采用本领域技术人员熟知市售产品即可。
在本发明中,所述聚合物基体层的层数优选为1~4,更优选为1~2;每层聚合物基体层的厚度优选为0.1~1mm,更优选为0.5~0.8mm。
在本发明中,所述竹纤维毡层和/或聚合物基层中优选还含有助剂和填料。本发明优选在竹纤维毡层和/或聚合物基层中添加助剂和填料来增加复合毡的功能性。
在本发明中,所述助剂优选包括耐磨剂、防霉剂、阻燃剂、界面相容剂、颜料、光屏蔽剂、抗氧剂和生物灭杀剂中的一种或几种,更优选为耐磨剂、防霉剂和阻燃剂中的一种或几种。在本发明中,所述耐磨剂优选包括超细高硬度陶瓷粉和/或EVA耐磨剂;所述防霉剂优选包括天然芥子萃取物和/或艾蒿;所述阻燃剂优选包括聚磷酸铵和/或三磷酸酯。本发明对所述助剂的来源没有特殊的限定,采用本领域技术人员熟知的市售产品即可。
在本发明中,所述填料优选包括玻璃微珠。本发明对所述填料的来源没有特殊的限定,采用本领域技术人员熟知的市售产品即可。
在本发明中,所述助剂或填料在竹纤维毡层或聚合物基层中的质量含量独立地优选为0~10%,更优选为3~7%。
本发明提供的竹纤维复合毡通过将竹纤维毡层和聚合物基体层进行交替设置,解决了目前纤维复合毡界面结合不稳定的问题,有利于提升复合毡的强度;并且,竹纤维材料绿色、环保、可生物降解,有利于减少复合材料中树脂的含量,减轻环境压力。
本发明提供了上述技术方案所述竹纤维复合毡的制备方法,包括以下步骤:
(1)将纤维材料进行机械梳理和/或气流铺装,再进行针刺,得到竹纤维毡层;
(2)将所述步骤(1)得到的竹纤维毡层和聚合物原料交替铺设在模具内,再进行热压,得到竹纤维复合毡。
本发明将纤维材料进行机械梳理和/或气流铺装,再进行针刺,得到竹纤维毡层。本发明采用机械梳理、气流铺装和针刺工艺,有利于得到长细纤维在表层、短粗纤维在芯层的均匀纤维毡,解决目前纤维毡不均匀的问题,同时提高纤维毡性能。
在本发明中,所述机械梳理所用梳理机的结构组成优选为:自动喂毛机→双罗拉喂入梳针式刺辊→罗拉开松梳理→盖板梳理→自动换筒圈条器。
在本发明中,所述机械梳理的工艺参数优选为:机器幅宽1020mm;主锡林直径1290mm;出条定量3~8g/m;产量10~45kg/h。
在本发明中,所述气流铺装所用气流铺装机的结构组成优选为:计量料仓→均布下料器→计量耙→计量带装置→拨料辊→均布下料器→气流铺装箱→风力系统→风栅→振动筛→回风装置。
在本发明中,所述气流铺装的工艺参数优选为:风栅截面管方形 25*25mm,间距L=30mm,流射扩散角度α为28°,铺装宽度方向上喷气管的间距S为90mm,射流过渡区距离T为12mm,每组风栅垂直上下喷气管间距为110mm,气流铺装箱内水平方向速度为0.5~1m/s。
在本发明中,所述针刺的工艺参数优选为:针刺道数4~9道;针刺密度 300~800刺/cm3;针刺深度5~20mm。
当所述竹纤维毡层中含有助剂和填料时,本发明优选将纤维材料和助剂、填料依次进行机械梳理、气流铺装和针刺,得到竹纤维毡层。
得到竹纤维毡层后,本发明将所述竹纤维毡层和聚合物原料交替铺设在模具内,再进行热压,得到竹纤维复合毡。
在本发明中,所述热压的温度优选为140~250℃,更优选为180~200℃。在本发明中,所述热压的温度影响复合材料成型的快慢,取决于聚合物基体层所用材质的熔点。
在本发明中,所述热压的压力优选为0.5~2.0MPa,更优选为0.7~1.0MPa。本发明优选将所述热压的压力控制在上述范围内,热压的压力影响复合材料的力学性能,压力过低不能完全成型,压力过高导致压溃。
在本发明中,所述热压的时间优选为1~30min,更优选为5~20min。本发明优选将所述热压的时间控制在上述范围内,热压时间影响复合材料的结构稳定性。
当所述聚合物基体层中含有助剂和填料时,本发明优选将聚合物原料和助剂、填料混合后,再与竹纤维毡层进行交替铺设。
本发明提供的竹纤维复合毡的制备方法操作简单,并且解决了目前纤维复合毡不均匀的问题,同时提高了复合毡的性能。
本发明还提供了一种异型曲面复合毡,包括表层和芯层,所述表层设置于所述芯层的两个表面上,所述表层材料为上述竹纤维复合毡或上述制备方法制备的竹纤维复合毡,所述芯层包括泡沫、瓦楞纸和蜂窝板中的一种或几种。
本发明对所述泡沫、瓦楞纸和蜂窝板的来源没有特殊限定,采用本领域技术人员熟知的市售产品即可。在本发明中,所述泡沫的材质优选包括聚氨酯、聚苯乙烯、PET、PP、PE、PMI和橡胶中的一种或几种。在本发明中,所述聚氨酯泡沫优选包括聚氨酯软泡、聚氨酯半硬泡或聚氨酯硬泡。
在本发明中,所述表层的厚度优选为10~50mm,更优选为10~30mm;所述芯层的厚度优选为5~25mm,更优选为10~20mm。
在本发明中,所述异型曲面复合毡的成型方式优选包括模压、真空浸渍 RTM、拉挤、缠绕、针刺或缝合,更优选为模压、真空浸渍RTM、拉挤或缠绕。本发明对所述模压、真空浸渍RTM、拉挤、缠绕、针刺和缝合的操作没有特殊的限定,采用本领域技术人员熟知的模压、真空浸渍RTM、拉挤、缠绕、针刺和缝合的技术方案即可。
在本发明中,所述模压的工艺参数优选为:温度135~170℃,压力 5~20MPa,时间30~300s。
在本发明中,所述真空浸渍RTM的工艺参数优选为:树脂粘度 0.5~1.5Pa·S,注射压力小于30psi,成型温度175~190℃,真空度0.1~0.25MPa;其中,1psi=68.95Pa。
在本发明中,所述拉挤的工艺参数优选为:预浸渍时间5~30min,加热温度120~190℃,固化时间5~15min,冷却温度-15~25℃,拉引速率5~15m/s。
在本发明中,所述缠绕的工艺参数优选为:张力10~55N;角度:环向缠绕85~90°,纵向缠绕小于25°;速度100~200m/min。
下面将结合本发明中的实施例,对本发明中的技术方案进行清楚、完整地描述。显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
竹纤维复合毡,由竹纤维毡层和聚合物基体层组成,竹纤维毡层和聚合物基体层中均含有超细高硬度陶瓷粉和玻璃微珠;竹纤维毡层中的纤维材料为竹短纤维、连续竹纤维、竹篾和竹丝,竹纤维毡层的层数为2层,每层厚度为5mm;聚合物基体层的材质为PET和PU,聚合物基体层的层数为1层,厚度为0.5mm;
原料:细度为100~200μm、长度为100~150mm的竹短纤维,细度为 2~4mm的连续竹纤维,厚度为1~1.5mm、长度为1000~1500mm的竹篾,直径为0.2~0.4mm的竹丝,PET,PU,超细高硬度陶瓷粉和玻璃微珠;
制备过程:
(1)将竹短纤维、连续竹纤维、竹篾、竹丝、超细高硬度陶瓷粉和玻璃微珠通过机械梳理、气流铺装和针刺形成厚度为5mm的竹纤维毡层;其中,竹短纤维、连续竹纤维、竹篾和竹丝的质量比为30%:30%:20%:20%,超细高硬度陶瓷粉和玻璃微珠分别占纤维材料总质量的2%;机械梳理的工艺参数为:机器幅宽1020mm,主锡林直径1290mm,出条定量8g/m,产量 45kg/h;气流铺装的工艺参数为:风栅截面管方形25*25mm,间距L=30mm,流射扩散角度α为28°,铺装宽度方向上喷气管的间距S为90mm,射流过渡区距离T为12mm,每组风栅垂直上下喷气管间距为110mm,气流铺装箱内水平方向速度为0.5m/s;针刺的工艺参数为:针刺道数5道,针刺密度500 刺/cm3,针刺深度10mm;
(2)将PET、PU、超细高硬度陶瓷粉和玻璃微珠混合,得到含超细高硬度陶瓷粉和玻璃微珠的聚合物原料;其中,PET和PU的质量比为1:1,超细高硬度陶瓷粉和玻璃微珠分别占PET和PU总质量的2%;
(3)将步骤(1)得到的竹纤维毡层和步骤(2)得到的含超细高硬度陶瓷粉和玻璃微珠的聚合物原料按照竹纤维毡层+聚合物基体层+竹纤维毡层的方式交替铺设在模具内,然后进行热压,热压的温度为180℃,压力为 0.5MPa,10min后得到竹纤维复合毡,其中,聚合物基体层的厚度为0.5mm。
实施例2
竹纤维复合毡,由竹纤维毡层和聚合物基体层组成,竹纤维毡层中含有超细高硬度陶瓷粉,聚合物基体层中含有天然芥子萃取物和玻璃微珠;竹纤维毡层中的纤维材料为竹短纤维、连续竹纤维、竹篾和竹丝,竹纤维毡层的层数为2层,每层厚度为10mm;聚合物基体层的材质为PP和PA,聚合物基体层的层数为1层,厚度为1mm;
原料:细度为100~200μm、长度为100~150mm的竹短纤维,细度为2~4mm的连续竹纤维,厚度为1~1.5mm、长度为1000~1500mm的竹篾,直径为0.2~0.4mm的竹丝,PP,PA,超细高硬度陶瓷粉、天然芥子萃取物和玻璃微珠;
制备过程:
(1)将竹短纤维、连续竹纤维、竹篾、竹丝和超细高硬度陶瓷粉通过机械梳理、气流铺装和针刺形成厚度为10mm的竹纤维毡层;其中,竹短纤维、连续竹纤维、竹篾和竹丝的质量比为30%:30%:20%:20%,超细高硬度陶瓷粉占纤维材料总质量的2%;机械梳理的工艺参数为:机器幅宽1020mm,主锡林直径1290mm,出条定量8g/m,产量45kg/h;气流铺装的工艺参数为:风栅截面管方形25*25mm,间距L=30mm,流射扩散角度α为28°,铺装宽度方向上喷气管的间距S为90mm,射流过渡区距离T为12mm,每组风栅垂直上下喷气管间距为110mm,气流铺装箱内水平方向速度为0.5m/s;针刺的工艺参数为:针刺道数5道,针刺密度500刺/cm3,针刺深度10mm;
(2)将PP、PA、天然芥子萃取物和玻璃微珠混合,得到含天然芥子萃取物和玻璃微珠的聚合物原料;其中,PP和PA的质量比为1:1,天然芥子萃取物和玻璃微珠分别占PP和PA总质量的2%;
(3)将步骤(1)得到的竹纤维毡层和步骤(2)得到的含天然芥子萃取物的聚合物原料按照竹纤维毡层+聚合物基体层+竹纤维毡层的方式交替铺设在模具内,然后进行热压,热压的温度为185℃,压力为0.8MPa,8min 后得到竹纤维复合毡,其中,聚合物基体层的厚度为1mm。
实施例3
竹纤维复合毡,由竹纤维毡层和聚合物基体层组成,聚合物基体层中含有聚磷酸铵和玻璃微珠;竹纤维毡层中的纤维材料为竹短纤维、连续竹纤维、竹篾、竹丝和麻纤维,竹纤维毡层的层数为2层,每层厚度为20mm;聚合物基体层的材质为PET和PA,聚合物基体层的层数为1层,厚度为1mm;
原料:细度为100~200μm、长度为100~150mm的竹短纤维,细度为 2~4mm的连续竹纤维,厚度为1~1.5mm、长度为1000~1500mm的竹篾,直径为0.2~0.4mm的竹丝,麻纤维,PET,PA、聚磷酸铵和玻璃微珠;
制备过程:
(1)将竹短纤维、连续竹纤维、竹篾、竹丝和麻纤维通过机械梳理、气流铺装和针刺形成厚度为20mm的竹纤维毡层;其中,竹短纤维、连续竹纤维、竹篾和竹丝的质量比为30%:30%:20%:20%,竹纤维材料占纤维材料总质量的75%;机械梳理的工艺参数为:机器幅宽1020mm,主锡林直径 1290mm,出条定量8g/m,产量45kg/h;气流铺装的工艺参数为:风栅截面管方形25*25mm,间距L=30mm,流射扩散角度α为28°,铺装宽度方向上喷气管的间距S为90mm,射流过渡区距离T为12mm,每组风栅垂直上下喷气管间距为110mm,气流铺装箱内水平方向速度为0.5m/s;针刺的工艺参数为:针刺道数5道,针刺密度500刺/cm3,针刺深度10mm;
(2)将PET、PA、聚磷酸铵和玻璃微珠混合,得到含聚磷酸铵和玻璃微珠的聚合物原料;其中,PET和PA的质量比为1:1,聚磷酸铵和玻璃微珠分别占PET和PA总质量的3%;
(3)将步骤(1)得到的竹纤维毡层和步骤(2)得到的含聚磷酸铵和玻璃微珠的聚合物原料按照竹纤维毡层+聚合物基体层+竹纤维毡层的方式交替铺设在模具内,然后进行热压,热压的温度为190℃,压力为0.7MPa, 5min后得到竹纤维复合毡,其中,聚合物基体层的厚度为1mm。
图1为本实施例中竹纤维复合毡的制备方法的流程图,先以竹短纤维、连续竹纤维、竹篾、竹丝、棉纤维、麻纤维为原料制得竹纤维毡层,作为增强相,然后与含有助剂和填料的聚合物基体层经过热压制成竹纤维复合毡。
实施例4
竹纤维复合毡,由竹纤维毡层和聚合物基体层组成,聚合物基体层中含有三磷酸酯和玻璃微珠;竹纤维毡层中的纤维材料为竹短纤维、连续竹纤维、竹篾、竹丝和棉纤维,竹纤维毡层的层数为2层,每层厚度为10mm;聚合物基体层的材质为4080低熔点PET纤维,聚合物基体层的层数为1层,厚度为1mm;
原料:细度为100~200μm、长度为100~150mm的竹短纤维,细度为 2~4mm的连续竹纤维,厚度为1~1.5mm、长度为1000~1500mm的竹篾,直径为0.2~0.4mm的竹丝,棉纤维,4080低熔点PET纤维、三磷酸酯和玻璃微珠;
制备过程:
(1)将竹短纤维、连续竹纤维、竹篾、竹丝和棉纤维通过机械梳理、气流铺装和针刺形成厚度为10mm的竹纤维毡层;其中,竹短纤维、连续竹纤维、竹篾和竹丝的质量比为30%:30%:20%:20%,竹纤维材料占纤维材料总质量的60%;机械梳理的工艺参数为:机器幅宽1020mm,主锡林直径 1290mm,出条定量8g/m,产量45kg/h;气流铺装的工艺参数为:风栅截面管方形25*25mm,间距L=30mm,流射扩散角度α为28°,铺装宽度方向上喷气管的间距S为90mm,射流过渡区距离T为12mm,每组风栅垂直上下喷气管间距为110mm,气流铺装箱内水平方向速度为0.5m/s;针刺的工艺参数为:针刺道数5道,针刺密度500刺/cm3,针刺深度10mm;
(2)将4080低熔点PET纤维、三磷酸酯和玻璃微珠混合,得到含三磷酸酯和玻璃微珠的聚合物原料;其中,三磷酸酯和玻璃微珠分别占4080低熔点PET纤维的质量的3%;
(3)将步骤(1)得到的竹纤维毡层和步骤(2)得到的含三磷酸酯和玻璃微珠的聚合物原料按照竹纤维毡层+聚合物基体层+竹纤维毡层的方式交替铺设在模具内,然后进行热压,热压的温度为190℃,压力为0.8MPa, 2min后得到竹纤维复合毡,其中,聚合物基体层的厚度为1mm。
实施例5
以聚苯乙烯泡沫为芯层,实施例1制备的竹纤维复合毡为表层,竹纤维复合毡设置于聚苯乙烯泡沫的两个表面上,然后采用模压成型工艺,制得密度为1500g/m2的异型曲面复合毡;其中,模压的工艺参数为:温度170℃,压力10MPa,时间100s;芯层的厚度为5mm,表层的厚度为10.5mm。
实施例6
以聚氨酯软泡为芯层,实施例2制备的竹纤维复合毡为表层,竹纤维复合毡设置于聚氨酯软泡的两个表面上,然后采用真空浸渍RTM成型工艺,制得密度为1800g/m2的异型曲面复合毡;其中,真空浸渍RTM的工艺参数为:树脂粘度0.8Pa·S,注射压力20psi,成型温度175℃,真空度0.2MPa;芯层的厚度为8mm,表层的厚度为21mm。
实施例7
以聚氨酯硬泡为芯层,实施例3制备的竹纤维复合毡为表层,竹纤维复合毡设置于聚氨酯硬泡的两个表面上,然后采用拉挤成型工艺,制得密度为 2200g/m2的异型曲面复合毡;其中,拉挤的工艺参数为:预浸渍时间10min,加热温度150℃,固化时间8min,冷却温度10℃,拉引速率10m/s;芯层的厚度为20mm,表层的厚度为41mm。
实施例8
以聚氨酯半硬泡为芯层,实施例4制备的竹纤维复合毡为表层,竹纤维复合毡设置于聚氨酯半硬泡的两个表面上,然后采用缠绕成型工艺,制得密度为2600g/m2的异型曲面复合毡;其中,缠绕的工艺参数为:张力35N;角度:环向缠绕85°,纵向缠绕15°;速度150m/min;芯层的厚度为15mm,表层的厚度为21mm。
图1为实施例5~8中异型曲面复合毡的制备方法的流程图,先将竹纤维复合毡与芯层叠合,然后经过模压、真空浸渍RTM、拉挤或缠绕形成不同结构的异型曲面复合毡。
表1实施例1~8制备的复合毡的性能
由以上实施例可以看出,本发明提供的竹纤维复合毡的断裂强力为 50~100N,拉伸强度为5~10MPa,拉伸模量为10~200MPa,弯曲强度为 1~20MPa,弯曲模量为50~500MPa;采用本发明提供的竹纤维复合毡制备的异型曲面复合毡的断裂强力为120~200N,拉伸强度为10~15MPa,拉伸模量为300~500MPa,弯曲强度为25~50MPa,弯曲模量为1000~2000MPa。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (6)
1.一种竹纤维复合毡,包括交替设置的竹纤维毡层和聚合物基体层;所述竹纤维毡层中的纤维材料为竹纤维材料,或者为竹纤维材料和其它天然植物纤维;所述竹纤维材料包括竹短纤维、连续竹纤维、竹篾和竹丝中的一种或几种;
所述竹短纤维的细度为20~200μm,长度为5~200mm;所述连续竹纤维的细度为0.5~5mm;所述竹篾的厚度为0.05~1.5mm,长度为100~1500mm;所述竹丝的直径为0.01~0.5mm;
所述竹纤维毡层的层数为2~5,每层竹纤维毡层的厚度为5~25mm;所述聚合物基体层的层数为1~4,每层聚合物基体层的厚度为0.1~1mm;
所述聚合物基体层的材质为4080低熔点PET;
所述竹纤维复合毡的制备方法,包括以下步骤:
(1)将纤维材料进行机械梳理和/或气流铺装,再进行针刺,得到竹纤维毡层;
(2)将所述步骤(1)得到的竹纤维毡层和聚合物原料交替铺设在模具内,再进行热压,得到竹纤维复合毡。
2.根据权利要求1所述的竹纤维复合毡,其特征在于,所述竹纤维毡层和/或聚合物基体层中还含有助剂和填料。
3.根据权利要求2所述的竹纤维复合毡,其特征在于,所述助剂包括耐磨剂、防霉剂、阻燃剂、界面相容剂、颜料、光屏蔽剂、抗氧剂和生物灭杀剂中的一种或几种;所述填料包括玻璃微珠。
4.根据权利要求2所述的竹纤维复合毡,其特征在于,所述助剂或填料在竹纤维毡层或聚合物基体层中的质量含量独立地为0~10%。
5.根据权利要求1所述的竹纤维复合毡,其特征在于,所述步骤(2)中热压的温度为140~250℃,热压的压力为0.5~2.0MPa,热压的时间为1~30min。
6.一种异型曲面复合毡,包括表层和芯层,所述表层设置于所述芯层的两个表面上,所述表层材料为权利要求1~5任一项所述竹纤维复合毡,所述芯层包括泡沫、瓦楞纸和蜂窝板中的一种或几种。
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