CN114851640A - 一种起圈增韧泡沫双夹层复合材料及其制备方法 - Google Patents

一种起圈增韧泡沫双夹层复合材料及其制备方法 Download PDF

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CN114851640A
CN114851640A CN202210340526.9A CN202210340526A CN114851640A CN 114851640 A CN114851640 A CN 114851640A CN 202210340526 A CN202210340526 A CN 202210340526A CN 114851640 A CN114851640 A CN 114851640A
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double
layer
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foam
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邵明扬
蔡登安
周光明
于启航
李闯
胡方田
匡宁
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Nanjing University of Aeronautics and Astronautics
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
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    • B32B2260/046—Synthetic resin
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Abstract

本发明公开了一种起圈增韧泡沫双夹层复合材料结构及其制备方法，属于夹层增韧结构技术领域，本发明的起圈增韧泡沫双夹层复合材料包括面层、增韧层、芯层。所述面层由平纹布组成；增韧层由单面起圈织物和双面起圈织物组成；芯层由聚氨酯泡沫组成。本发明首先是将平纹布依次用手糊的方法将其铺在模具表面；在面层最顶层铺上单面起圈布；再将双面起圈布用浸润树脂胶后，将其夹在上下模具中间，并且拉紧避免褶皱；最后将配好的泡沫发泡剂倒入模具中，并密封模具，固化成型后脱模即可成型得到起圈增韧泡沫双夹层复合材料。通过该方法制得的起圈增韧泡沫双夹层复合材料具有抗分层、弯曲模量高、层间韧性好的特点。

Description

一种起圈增韧泡沫双夹层复合材料及其制备方法
技术领域
本发明属于泡沫夹层增韧技术领域，具体涉及起圈增韧泡沫双夹层复合材料结构及其制备方法。
背景技术
近年来，随着航空航天和高速列车等领域对轻质高强材料的需求越来越大，夹层结构由于其能在质量增加较小的情况下大幅度提高结构刚度而受到关注。夹层结构是先进复合材料的一种，一般由两块面板与密度较低的芯材（蜂窝、泡沫、皱褶纸等）粘合而成。夹层结构传载的方式与工字梁相似，上下面板主要承受面内应力，而芯材主要承受剪应力且对面板起到支撑作用。根据芯材的不同，夹层结构可以分为蜂窝夹层结构与泡沫夹层结构。传统的蜂窝夹层结构由于昂贵的维修护理费用、低的抗潮湿性能而收到很大使用限制。闭孔硬质泡沫可以避免蜂窝夹层结构的以上缺陷，且具有良好的热稳定性、耐腐蚀性，因此被广泛用作夹层结构的芯材。
中国发明专利CN109648939A，《一种碳纤维复合材料泡沫夹层结构及其成型工艺方法》提出了将碳纤维表皮与PVC泡沫芯材用增强纤维和环氧树脂胶粘到一起，再使用热压机层压工艺加热加压成型。该工艺的缺点是成型工艺复杂，需要多个步骤成型，并且层板与芯层之间无增韧层，抗分层性能较差。中国发明专利CN204869850U，《一种高性能泡沫夹层板》，提出了将空心微球填充到有机树脂基体材料中制备得到的合成泡沫材料，然后与表层板使用环氧树脂胶粘结在一起成型。该工艺的缺点是成型的泡沫夹层板质量大，不符合减重效果，而且泡沫球在成型过程中有可能分布不均与，导致泡沫夹层内部有缺陷。
传统泡沫夹层结构的主要缺点是Z向性能较弱，面板与泡沫芯连接强度低，从而造成剪切刚度和强度均低于相同密度的蜂窝夹层结构。在受冲击载荷、弯曲载荷或剪切载荷作用时，面板与泡沫很容易出现脱粘；较弱的芯材在Z向载荷作下容易塌陷；在湿热环境条件下，夹层结构会发生水浸，引起面板起泡等现象，工程应用中泡沫夹层结构出现上述损伤一般难于修理，从而影响制品质量和成本。
发明内容
本发明针对传统的泡沫夹层复合材料中存在的问题，公开了一种起圈增韧泡沫双夹层复合材料，本发明通过在成型过程中将单面起圈增韧层和双面起圈增韧层的毛圈嵌入到泡沫中去，解决了泡沫夹层复合材料抗冲击性能差、面层与芯层易脱粘分层的缺点，提高了面板与芯层的连接强度。
本发明是这样实现的：
一种起圈增韧泡沫双夹层复合材料，其特征在于，所述的复合材料包括面层、单面起圈增韧层、芯层、双面起圈增韧层；所述的双面起圈增韧层为正中间层，单面起圈增韧层位于双面起圈增韧层的上下两侧，单面起圈增韧层以及双面起圈增韧层之间的为芯层；面层位于单面起圈增韧层的外围两侧。
所述的面层为平纹布，所述的单面起圈增韧层为单面起圈织物，单面起圈织物的结构为在二维平面布的基础上，在面向芯层的单侧面设置立体绒经纱；所述的双面起圈增韧层为双面起圈织物，双面起圈织物的结构为在二维平面布的基础上，在两侧面增加立体绒经纱；所述芯层为手工发泡聚氨酯泡沫，在发泡过程中将双面起圈增韧层双面起圈织物的毛圈可以嵌入泡沫中去，增加泡沫与织物之间的连接强度。
本发明中的增韧层分为两种，位于所述面层和所述芯层之间的为单面起圈增韧层；另一种是位于所述芯层中间的双面起圈增韧层。
进一步，所述芯层为手工发泡聚氨酯泡沫，在成型过程中，有利于毛圈嵌入芯层。所述双面起圈增韧层位于所述芯层中间，增加了所述芯层的抗变形能力。
本发明还公开了一种起圈增韧泡沫双夹层复合材料的制备方法，其特征在于，步骤如下：
1）清理模具，在模具上贴上脱模布，并将气泡挤出；
2）根据模具尺寸剪裁平纹布和起圈布；
3）按比例配比环氧树脂；
4）按照设定的铺层一层一层放入模具中，并用毛刷将环氧树脂均匀渗透纤维布，并将浸透环氧树脂的双面起圈增韧层夹在模具中间；
5）配制聚氨酯泡沫发泡剂，并倒入模具中，封闭模具；
6）将合模后的模具放入恒温箱内保持65℃恒温150min，进行熟化处理；
7）将模具从恒温箱中取出，保持室温，24h后起模，去掉毛边后。
进一步，所述的设定的铺层具体为：最外的两层面层，双面起圈增韧层位于模具中间，面层、双面起圈增韧层之间为芯层，位于面层和芯层之间的为单面起圈增韧层；位于芯层中间的双面起圈增韧层。
本发明与现有技术的有益效果在于：
本发明中的起圈织物泡沫双加层结构，面板与芯层之间有一层单面起圈织物，毛圈可以嵌入到泡沫中去，使面板与泡沫芯层连接强度更高，面层与芯层不易脱粘，提高了夹层复合材料的冲击性能。
本发明在芯层中间添加了一层双面起圈布，双面起圈布在成型过程中，双面毛圈会嵌入到泡沫中去，提高了芯层的弯曲刚度，降低了夹层复合材料在承压时的绕曲变形。
本发明采用手工发泡成型工艺，可以随意控制芯层泡沫密度，成型工艺简单、效率高。
附图说明
图1为本发明起圈增韧泡沫双夹层复合材料结构示意图。
其中，1-面层，2-单面起圈增韧层，3-芯层，4-双面起圈增韧层。
具体实施方式
为了将本发明的目的、技术方案以及增韧机理描述的更加清楚，以下举例对本发明进一步详细描述。应当指出此处所描述的具体实施仅用以解释本发明，并不用于限定本发明。
如图1所示，本发明的一种起圈增韧泡沫双夹层复合材料，主要以平纹布、单面起圈布、双面起圈布和聚氨酯泡沫以及环氧树脂胶为主体材料设计制作的泡沫双夹层复合材料。具体而言，本发明的一种起圈增韧泡沫双夹层复合材料包括：面层1、单面起圈增韧层2、芯层3、双面起圈增韧层4；面层1位于夹层复合材料最顶部和最底部，在面层1顶部铺上一层单面起圈织物2，在夹层中间部位，铺设一层双面起圈织物4，芯层3位于双面起圈织物4和单面起圈增韧层2中间。
本发明的起圈增韧泡沫双夹层复合材料中所述面层1由平纹布组成；本发明的增韧层包括单面起圈增韧层2以及双面起圈增韧层4；芯层由聚氨酯泡沫组成。本发明首先是将平纹布依次用手糊的方法将其铺在模具表面；在面层最顶层铺上单面起圈布；再将双面起圈布用浸润树脂胶后，将其夹在上下模具中间，并且拉紧避免褶皱；最后将配好的泡沫发泡剂倒入模具中，并密封模具，固化成型后脱模即可成型得到起圈增韧泡沫双夹层复合材料。通过该方法制得的起圈增韧泡沫双夹层复合材料具有抗分层、弯曲模量高、层间韧性好的特点。
具体的，本发明的一种起圈增韧泡沫双夹层复合材料，其制备过程包括以下步骤：
1）清理模具，在模具上贴上脱模布，并将气泡挤出；
2）根据模具尺寸剪裁平纹布和起圈布；
3）按比例配比环氧树脂；
4）按照设定的铺层一层一层放入模具中，并用毛刷将环氧树脂均匀渗透纤维布，并将浸透环氧树脂的双面起圈增韧层4夹在模具中间；
5）配制聚氨酯泡沫发泡剂，并倒入模具中，封闭模具；
6）将合模后的模具放入恒温箱内保持65℃恒温150min，进行熟化处理；
7）将模具从恒温箱中取出，保持室温，24h后起模，去掉毛边后。
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，这些改进也应视为本发明的保护范围。

Claims (3)

1.一种起圈增韧泡沫双夹层复合材料，其特征在于，所述的复合材料包括面层（1）、单面起圈增韧层（2）、芯层（3）、双面起圈增韧层（4）；所述的双面起圈增韧层（4）为正中间层，单面起圈增韧层（2）位于双面起圈增韧层（4）的上下两侧，单面起圈增韧层（2）以及双面起圈增韧层（4）之间的为芯层（3）；面层（1）位于单面起圈增韧层（2）的外围两侧；
所述的面层（1）为平纹布，所述的单面起圈增韧层（2）为单面起圈织物，单面起圈织物的结构为在二维平面布的基础上，在面向芯层（3）的单侧面设置立体绒经纱；
所述的双面起圈增韧层（4）为双面起圈织物，双面起圈织物的结构为在二维平面布的基础上，在两侧面增加立体绒经纱；
所述芯层（3）为手工发泡聚氨酯泡沫，在发泡过程中将双面起圈增韧层（4）双面起圈织物的毛圈可以嵌入泡沫中去，增加泡沫与织物之间的连接强度。
2.一种起圈增韧泡沫双夹层复合材料的制备方法，其特征在于，步骤如下：
1）清理模具，在模具上贴上脱模布，并将气泡挤出；
2）根据模具尺寸剪裁平纹布和起圈布；
3）按比例配比环氧树脂；
4）按照设定的铺层一层一层放入模具中，并用毛刷将环氧树脂胶均匀渗透纤维布，并将浸透环氧树脂胶的双面起圈增韧层（4）夹在模具中间；
5）配制聚氨酯泡沫发泡剂，并倒入模具中，封闭模具；
6）将合模后的模具放入恒温箱内保持65℃恒温150min，进行熟化处理；
7）将模具从恒温箱中取出，保持室温，24h后起模，去掉毛边后。
3.根据权利要求2所述的一种起圈增韧泡沫双夹层复合材料的制备方法，其特征在于，所述的设定的铺层具体为：最外的两层面层（1），双面起圈增韧层（4）位于模具中间，面层（1）、双面起圈增韧层（4）之间为芯层（3），位于面层（1）和芯层（3）之间的为单面起圈增韧层；位于芯层（3）中间的双面起圈增韧层（4）。
CN202210340526.9A 2022-03-31 2022-03-31 一种起圈增韧泡沫双夹层复合材料及其制备方法 Pending CN114851640A (zh)

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CN202138019U (zh) * 2011-03-17 2012-02-08 任翠 一种泡沫夹芯三维增强复合材料
CN103373014A (zh) * 2012-04-25 2013-10-30 浙江昱辉阳光能源有限公司 一种保温材料及其制备方法
CN105442811A (zh) * 2015-12-02 2016-03-30 中材科技股份有限公司 一种保温装饰板及其制备方法
CN108544809A (zh) * 2018-03-29 2018-09-18 江苏赛菲新材料有限公司 一种夹芯结构复合材料及其制备方法
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Publication number Priority date Publication date Assignee Title
CN202138019U (zh) * 2011-03-17 2012-02-08 任翠 一种泡沫夹芯三维增强复合材料
CN103373014A (zh) * 2012-04-25 2013-10-30 浙江昱辉阳光能源有限公司 一种保温材料及其制备方法
CN105442811A (zh) * 2015-12-02 2016-03-30 中材科技股份有限公司 一种保温装饰板及其制备方法
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