CN114921093A - 一种纤维增强复合材料及其制备方法 - Google Patents

一种纤维增强复合材料及其制备方法 Download PDF

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CN114921093A
CN114921093A CN202210473578.3A CN202210473578A CN114921093A CN 114921093 A CN114921093 A CN 114921093A CN 202210473578 A CN202210473578 A CN 202210473578A CN 114921093 A CN114921093 A CN 114921093A
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刘淑辉
陈增军
黄雷
马海丰
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Shanghai Pincheng Holding Group Co ltd
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Abstract

本发明涉及一种纤维增强复合材料及其制备方法，所述复合材料包括20‑60vol％增强纤维和40％‑80vol％热塑性树脂；其中，所述增强纤维包括单纤维和纤维束，单纤维占总增强纤维的比例为5‑20wt％。本发明增强纤维中的单纤维和纤维束比例可控，具有高的纤维体积含量，兼具优良加工性能及机械强度特点，具有良好的市场应用前景。

Description

一种纤维增强复合材料及其制备方法
技术领域
本发明属于复合材料领域，特别涉及一种纤维增强复合材料及其制备方法。
背景技术
热固性树脂作为基质的纤维增强复合材料，一般所需成型时间很长，例如通过热压罐对预浸料坯进行加热加压2小时以上来获得纤维增强复合材料。近年来，RTM方法已经实现了成型时间的显著缩短，然而，即使在采用RTM方法的情况下，一个部件的成型也必需10分钟以上的时间。用热塑性树脂代替常规热固性树脂作为基质的复合材料，能显著缩短成型时间，且可100％回收利用，已吸引了极多的开发和研究注意。
使用热塑性树脂作为基质的纤维增强复合材料，有将用热塑性树脂预先浸渍的短切纤维加热至熔点以上，并加压模制，使纤维和树脂能够在模具中流动从而获得制品的形状、随后冷却并且成型的方法。通过使用预先以树脂浸渍的纤维，该方法能够在约1分钟的短时间内执行成型。在这样的热塑性冲压成型中，纤维和树脂在模具中流体化，因此，存在不能生产薄壁制品、纤维定向混乱、以及难以控制等问题。
通过将纤维束与热塑性树脂共同铺展并涂覆，形成无序纤维毡再行加压模制，可实现各项同性机械特性，且保证高的纤维体积含量。这个技术存在的问题为：纤维束堆叠中的单纤维无法完全实现理论增强效果，强度较低。而若将纤维束均匀地分散为单纤维形式，以提高纤维增强复合材料的各向同性和机械特性，则存在以下问题：由于纤维被完全分散为单纤维形式，树脂流动性差，且无法提高纤维体积含量，存在极限强度。
发明内容
本发明所要解决的技术问题是提供一种纤维增强复合材料及其制备方法，增强纤维中的单纤维和纤维束比例可控，具有高的纤维体积含量，兼具优良加工性能及机械强度特点，具有良好的市场应用前景。
本发明提供了一种纤维增强复合材料，所述复合材料包括20-60vol％增强纤维和40％-80vol％热塑性树脂；其中，所述增强纤维包括单纤维和纤维束，单纤维占增强纤维的比例为5-20wt％；
所述纤维束定义为：单纤维数：150根～1000根；单纤维间距<1.5D；D为单纤维直径，单位μm；纤维束断面尺寸：W/t＝5～40；W为纤维束平均束宽度，单位mm，t为纤维束平均束厚度，单位μm。
所述增强纤维为碳纤维、玻璃纤维、芳纶纤维中的一种或几种，长度为3-100mm。
所述热塑性树脂为聚酰胺PA、聚丙烯PP、聚乙烯PE、聚甲基丙烯酸甲酯PMMA、聚碳酸酯PC、聚对苯二甲酸丁二醇酯PBT、聚苯硫醚PPS、聚醚醚酮PEEK中的一种或几种。
所述热塑性树脂为纤维、颗粒、薄膜或者液体。
本发明还提供了一种纤维增强复合材料的制备方法，包括如下步骤：
(1)切割增强纤维形成单纤维和纤维束；
(2)将切割的增强纤维与热塑性树脂一起铺展并同时抽吸，并且喷撒和涂布；将所述热塑性树脂在压力下熔化，随后浸渍在增强纤维的单纤维和纤维束之间的空间中，冷却，得到纤维增强复合材料。
所述步骤(2)中得到的纤维增强复合材料通过冷压加工或热压加工制得制品。
所述冷压加工方法：将所述纤维增强复合材料加热至热塑性树脂的熔点以上或玻璃化转变点以上，使纤维增强复合材料的形状与待获得的成形制品的形状相匹配，并将纤维增强复合材料导入到维持在低于热塑性树脂的熔点或低于其玻璃化转变点下的模具中，随后压制，然后冷却，形成制品。
所述热压加工方法：将纤维增强复合材料导入模具中，将温度升高至热塑性树脂的熔点以上或玻璃化转变点以上的同时进行压力模制，并将模具冷却至低于热塑性树脂的熔点或低于其玻璃化转变点，形成制品。
有益效果
(1)本发明增强纤维中单纤维可提高纤维强度贡献率，产品具有高强度特点；同时，纤维束可保证纤维的浸润性良好，加工性良好；控制纤维束断面尺寸，可进一步控制纤维的浸润性和加工性；
(2)本发明增强纤维中的单纤维和纤维束比例可控，具有高的纤维体积含量，兼具优良加工性能及机械强度特点，具有良好的市场应用前景。
具体实施方式
下面结合具体实施例，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
实施例和对比例中所采用的原料如下：
增强纤维：T700，来源于日本东丽。
玻璃纤维市售。
热塑型树脂：PA6，来源于BASF Ultramid B。
PC，来源于科思创3117。
实施例和对比例的制备方法如下：
(1)切割增强纤维形成单纤维和纤维束；
(2)将切割的增强纤维与热塑性树脂一起铺展并同时抽吸，并且喷撒和涂布；将所述热塑性树脂在压力下熔化，随后浸渍在增强纤维的单纤维和纤维束之间的空间中，冷却，得到纤维增强复合材料。
性能测试标准如下：
拉伸强度-ASTM D 3039；
浸润效果-利用超声波检测成像设备，以5MHz的检测器频率和2.0mm×2.0mm的扫描间距执行超声波检测，来评价纤维增强复合材料的浸渍程度。在超声波检测中，具有高反射波强度(反射波强度为70％以上)的部分面积的比率越高，复合材料的内部越密实。相反的话，则复合材料的内部出现细孔，复合材料中存在许多未浸渍的部分。超声波检测观察到的反射波强度为70％以上的部位的比率为60％以上，定义为浸润效果好；＜60％，定义为浸润效果差。
加工性-切割250mm×250mm大小的样品，用加热装置加热至特定温度(聚酰胺6加热温度290℃；在聚碳酸脂加热至300℃)。将样品置于设定为150℃并且具有400mm×400mm×2.6mm间隙的模具的下模中，模具的上模下降后以在20MPa冷压样品1分钟，制备扁平的压制成型制品。
比较压制成型制品与压制成型前从碳纤维增强树脂复合材料切割的250mm×250mm大小的样品，测量冷压期间的流动距离。计算在各边(4边×4点的16个点)测量的流动长度的平均值，平均值>20mm，定义为加工性好，<20mm则定义为加工性差。
实施例和对比例的原料配比以及测试结果
Figure BDA0003624157770000031
Figure BDA0003624157770000041
由上述结果可知，实施例1-6的纤维增强复合材料兼具了高强度和加工流动性，具备优异的综合性能。当增强纤维中单纤维含量超过20％时，加工流动性会变差。当增强纤维中单纤维含量不足5％时，强度没有明显提升。
对比例3和实施例7为玻纤应用，可见单纤维含量会明显影响产品强度。

Claims (8)

1.一种纤维增强复合材料，其特征在于：所述复合材料包括20-60vol％增强纤维和40％-80vol％热塑性树脂；其中，所述增强纤维包括单纤维和纤维束，单纤维占总增强纤维的比例为wt％；
所述纤维束的定义为：
单纤维数：150根～1000根；
单纤维间距<1.5D；D为单纤维直径，单位μm；
纤维束断面尺寸：W/t＝5～40；W为纤维束平均束宽度，单位mm，t为纤维束平均束厚度，单位μm。
2.根据权利要求1所述的复合材料，其特征在于：所述增强纤维为碳纤维、玻璃纤维、芳纶纤维中的一种或几种，长度尺寸为3-100mm。
3.根据权利要求1所述的复合材料，其特征在于：所述热塑性树脂为聚酰胺PA、聚丙烯PP、聚乙烯PE、聚甲基丙烯酸甲酯PMMA、聚碳酸酯PC、聚对苯二甲酸丁二醇酯PBT、聚苯硫醚PPS、聚醚醚酮PEEK中的一种或几种。
4.根据权利要求1所述的复合材料，其特征在于：所述热塑性树脂为纤维、颗粒、薄膜或者液体。
5.一种如权利要求1所述的纤维增强复合材料的制备方法，包括如下步骤：
(1)切割增强纤维形成单纤维和纤维束；
(2)将切割的增强纤维与热塑性树脂一起铺展并同时抽吸，并且喷撒和涂布；将所述热塑性树脂在压力下熔化，随后浸渍在增强纤维的单纤维和纤维束之间的空间中，冷却，得到纤维增强复合材料。
6.根据权利要求5所述的制备方法，其特征在于：所述步骤(2)中得到的纤维增强复合材料通过冷压加工或热压加工制得制品。
7.根据权利要求6所述的制备方法，其特征在于：所述冷压加工方法：将所述纤维增强复合材料加热至热塑性树脂的熔点以上或玻璃化转变点以上，使纤维增强复合材料的形状与待获得的成形制品的形状相匹配，并将纤维增强复合材料导入到维持在低于热塑性树脂的熔点或低于其玻璃化转变点下的模具中，随后压制，然后冷却，形成制品。
8.根据权利要求7所述的制备方法，其特征在于：所述热压加工方法：将纤维增强复合材料导入模具中，将温度升高至热塑性树脂的熔点以上或玻璃化转变点以上的同时进行压力模制，并将模具冷却至低于热塑性树脂的熔点或低于其玻璃化转变点，形成制品。
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