CN115635705A - Waste textile fiber reinforced composite material prepared from waste textiles and phenolic resin and preparation method thereof - Google Patents
Waste textile fiber reinforced composite material prepared from waste textiles and phenolic resin and preparation method thereof Download PDFInfo
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- CN115635705A CN115635705A CN202211310794.2A CN202211310794A CN115635705A CN 115635705 A CN115635705 A CN 115635705A CN 202211310794 A CN202211310794 A CN 202211310794A CN 115635705 A CN115635705 A CN 115635705A
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- 239000004753 textile Substances 0.000 title claims abstract description 131
- 239000002699 waste material Substances 0.000 title claims abstract description 122
- 239000005011 phenolic resin Substances 0.000 title claims abstract description 47
- 229920001568 phenolic resin Polymers 0.000 title claims abstract description 47
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 title claims abstract description 45
- 239000003733 fiber-reinforced composite Substances 0.000 title claims abstract description 37
- 239000000463 material Substances 0.000 title claims abstract description 29
- 238000002360 preparation method Methods 0.000 title claims abstract description 15
- 239000000835 fiber Substances 0.000 claims abstract description 133
- 239000004744 fabric Substances 0.000 claims abstract description 110
- 238000000034 method Methods 0.000 claims abstract description 68
- 238000009958 sewing Methods 0.000 claims abstract description 29
- 239000012943 hotmelt Substances 0.000 claims abstract description 26
- 238000007731 hot pressing Methods 0.000 claims abstract description 20
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- 239000012535 impurity Substances 0.000 claims abstract description 10
- 238000002156 mixing Methods 0.000 claims abstract description 10
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 10
- 238000010030 laminating Methods 0.000 claims abstract description 5
- 239000002131 composite material Substances 0.000 claims description 35
- 239000011165 3D composite Substances 0.000 claims description 16
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 26
- 229920000049 Carbon (fiber) Polymers 0.000 description 9
- 229920006231 aramid fiber Polymers 0.000 description 9
- 239000004917 carbon fiber Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 9
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 9
- 238000004064 recycling Methods 0.000 description 8
- 229920000742 Cotton Polymers 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
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- 238000010586 diagram Methods 0.000 description 4
- 239000011208 reinforced composite material Substances 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 238000009787 hand lay-up Methods 0.000 description 3
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- 239000002689 soil Substances 0.000 description 3
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- 239000000975 dye Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
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Abstract
The invention discloses a waste textile fiber reinforced composite material prepared by waste textiles and phenolic resin and a preparation method thereof, wherein the preparation method comprises the following steps: s1, paving waste textile fabrics and opening the waste textile fabrics into fiber battings; s2, removing impurities from waste textile fabric fibers, uniformly mixing the waste textile fabric fibers into a single fiber shape, and carding the single fiber shape into a thin net; s3, cross-folding the thin net to prepare a fiber film; s4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 1-4mm and the cohesive force of 5-20N; s5, laying a plurality of layers of the needled felt obtained in the step S4 together, and laminating the fabric or the fiber fabric with the customized patterns on the upper surface and the lower surface; using hot-melt yarns as stitches, and sewing a plurality of layers of needled felts and fabric layers attached to the upper surface and the lower surface into a three-dimensional integral structure by using a blind stitch process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 1-24 mm; and S6, infiltrating the prefabricated member obtained in the step S5 with phenolic resin, and carrying out hot pressing until the required thickness is achieved, and curing.
Description
Technical Field
The invention relates to the field of textile fibers, in particular to a waste textile fiber reinforced composite material prepared by waste textiles and phenolic resin and a preparation method thereof.
Background
The exhaustion of fossil resources and the continuous deterioration of the environment promote the high-quality economic mode of sustainable and circular development of countries in the world. At present, although the recycling of waste textiles is increased all over the world, the quantity of the waste textiles is huge, and no effective treatment method exists in all countries of the world. At present, the treatment means of the waste textiles is mainly incineration or burial. Burn and can pollute atmospheric environment to a large amount of toxic gases of air discharge, bury and can let dyestuff and chemical substance on the old and useless fabrics release in the soil, cause soil pollution and then cause water pollution, and a lot of chemical fibre fabrics bury and be difficult to decompose in soil, cause the injury that is difficult to restore to the ecological environment.
However, the composite material is reinforced mainly by manually laying fabric fibers at present, and the uniform laying is difficult, so that the volume content of the fibers of the composite material cannot be accurately controlled, and the composite material has large performance difference and cannot be used as a structural member.
However, the above-described technique has the following problems in reinforcing a composite material:
(1) The surface density of the waste clothing cloth is not uniformly distributed, the density of some parts is high, the fluidity of resin in the waste clothing cloth is blocked, the density of some parts is low, the resin is easy to enrich, and the resin transfer molding process (RTM) or vacuum bag forming process is difficult to produce the composite material;
(2) Burning the waste textiles can discharge a large amount of toxic gas into the air to pollute the atmospheric environment, and burying can release dyes and chemical substances on the waste textiles into soil to cause soil pollution and further water pollution;
(3) Waste textiles are difficult to lay uniformly, so that the volume content of composite material fibers cannot be accurately controlled, the performance difference of the composite material is large, the composite material cannot be used as a structural member, and the efficiency is influenced.
Therefore, there is a need for an improvement of the preparation method in the prior art to solve the above problems.
Disclosure of Invention
The invention overcomes the defects of the prior art and provides a waste textile fiber reinforced composite material prepared by waste textiles and phenolic resin and a preparation method thereof. The technical problem solved comprises: the method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin is characterized in that a non-woven needling process is combined with a blind stitch process to prepare a multi-layer sewn waste textile fiber needled felt, hot melt yarns are used as stitches, and the multi-layer needled felt is sewn into a three-dimensional integral structure by the stitches penetrating along the thickness direction, so that the problems that the needled felt is thin in thickness in the prior art, and the reinforced composite material directly prepared from the waste textile fibers in the prior art is not attractive, uneven in mechanical property and poor in interlayer mechanical property are solved, the utilization rate of the waste textiles is improved, and huge ecological environment pressure brought by the waste textiles is reduced.
In order to achieve the purpose, the invention adopts the technical scheme that: a waste textile fiber reinforced composite material prepared by waste textiles and phenolic resin and a preparation method thereof comprise the following steps:
a preparation method for preparing a waste textile fiber reinforced composite material by using waste textiles and phenolic resin is characterized by comprising the following steps:
s1, paving waste textile fabrics and opening the waste textile fabrics into fiber battings;
s2, removing impurities from waste textile fabric fibers, uniformly mixing the waste textile fabric fibers into a single fiber shape, and carding the single fiber shape into a thin net;
s3, cross-folding the thin net to prepare a fiber film;
s4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 1-4mm and the cohesive force of 5-20N;
s5, laying a plurality of layers of the needled felt obtained in the step S4 together, adhering and printing fabrics or fiber fabrics with customized patterns on the upper and lower surfaces, and using hot-melt yarns as stitches; sewing the three-dimensional integral structure by using a blind stitch process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 1-24 mm;
and S6, infiltrating the prefabricated member obtained in the step S5 with phenolic resin, and carrying out hot pressing until the required thickness is achieved, and curing.
In a preferred embodiment of the present invention, in the step S1, the fiber length of the waste textile fiber batt obtained after opening is 20-140mm.
In a preferred embodiment of the present invention, in the step S5, the melting temperature of the hot-melt yarn is 80 ℃ to 130 ℃.
In a preferred embodiment of the present invention, in the step S6, the temperature of the hot pressing and curing is 100-150 ℃, the pressure is 1-10MPa, and the time is 5-30min.
In a preferred embodiment of the present invention, in the step S6, the fiber volume content of the composite material obtained by curing is 40-80%.
A waste textile fiber reinforced composite material prepared by waste textiles and phenolic resin is prepared by the preparation method, and comprises a three-dimensional composite structure: the three-dimensional composite structure comprises a plurality of needled felts and fabric layers attached to the upper surfaces and the lower surfaces of the needled felts; the number of layers of the needled felt is not less than 2, and the three-dimensional composite structure is penetrated by a plurality of stitches along the thickness direction; each needled felt is formed by needling a fiber film, and the fiber film is formed by crosswise folding a plurality of waste textile single fibers; the fabric layer is a fabric or a fiber fabric with a customized pattern; the three-dimensional composite structure is embedded with phenolic resin.
In a preferred embodiment of the invention, the stitch density of the needled felt is 1-25 stitches.
In a preferred embodiment of the invention, the needle punching density of the needle punching felt is 1-14 punches.
In a preferred embodiment of the invention, the thickness of the three-dimensional composite structure is 2-16mm.
In a preferred embodiment of the invention, the thickness of a plurality of the needle felt is 1-4mm.
The invention solves the defects in the background technology, and has the following beneficial effects:
(1) Compared with the prior art, the method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin abandons the traditional thought of manually laying the fiber reinforced composite material, adopts a non-woven needling process combined with a blind seam process to prepare the multilayer sewn waste textile fiber needled felt, and adopts a vacuum bag forming process combined with hot pressing and curing to prepare the waste fiber reinforced composite material.
(2) The invention combs disordered fibers into a very uniform fiber net firstly, so that the uniformity of each layer of fabric on the horizontal plane is ensured, and then the hidden seam process is used, so that the stitches can ensure that the multilayer fabric is compact along the thickness direction of the multilayer fabric, the gaps of each layer of fabric in the thickness direction are equal, and the uniformity of the fabrics in the vertical direction is realized; and finally, the prefabricated part is added into the phenolic resin for infiltration, so that the prefabricated part is embedded more uniformly in the horizontal and vertical directions when the phenolic resin is embedded into the prefabricated part, the integrity of the composite material is improved, and the mechanical property of the composite material is better.
(3) The invention adopts the blind stitch process on the basis of the non-woven needling process, and solves the problem that the high-thickness needled felt cannot be produced by using the non-woven needling process alone. The sewing process brings fibers in a part of surfaces into the thickness direction, the performance between layers of needled felts is improved, meanwhile, stitches can sew the multiple layers of needled felts into a three-dimensional overall structure, the sewn multiple layers of needled felts are high in integrity and thickness, the prepared composite material meets various thickness requirements, the mechanical performance between layers is excellent, the traditional rivet-adopting mode is solved, the cost is saved, and meanwhile, the product weight is reduced.
(4) According to the invention, the hot-melt sewing yarns are adopted in the blind stitch process, the hot-melt yarns are melted in the curing process, the multi-layer needled felt can be bonded into a three-dimensional integral structure, the prepared reinforced composite material has uniform mechanical properties, and the interlaminar and intrafacial mechanical properties are high. Meanwhile, after the hot-melt suture line is melted, marks cannot be left on the surface of the composite material which is attached and printed with the fabric with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or the high-performance fiber fabric (carbon fiber fabric or aramid fiber fabric), so that the attractiveness of the composite material is improved.
(5) The preparation method of the invention abandons the traditional direct hand lay-up forming, hot press forming or vacuum bag forming process of the waste fabric, adopts the vacuum bag hot press forming process, and after the multilayer sewing needle punched felt is completely soaked with resin in the vacuum bag, the composite material is hot pressed to the required thickness, the fiber volume content of the prepared composite material reaches 40-80 percent, the fiber volume content is improved, and the volume content of the phenolic resin is reduced. The production cost of the composite material can be effectively reduced by greatly reducing the content of the phenolic resin.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description of the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts;
FIG. 1 is a flow diagram of a process for preparing a multi-layer needled felt of waste textile fibers according to a preferred embodiment of the present invention;
fig. 2 is a blind stitch process diagram a and a blind stitch diagram b of a multi-layer waste textile fiber needled felt according to a preferred embodiment of the invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described herein, and therefore the scope of the present invention is not limited by the specific embodiments disclosed below.
As shown in fig. 1, the present invention provides a preparation flow chart of a waste textile fiber reinforced composite material prepared by using waste textiles and phenolic resins, which comprises the following steps:
s1, paving waste textile fabrics and opening the waste textile fabrics into fiber battings;
s2, removing impurities from waste textile fabric fibers, uniformly mixing the waste textile fabric fibers into a single fiber shape, and carding the single fiber shape into a thin net;
s3, cross-folding the thin net to prepare a fiber film;
s4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 1-4mm and the cohesive force of 5-20N;
s5, laying a plurality of layers of the needled felt obtained in the step S4 together, adhering and printing fabrics or fiber fabrics with customized patterns on the upper and lower surfaces, and using hot-melt yarns as stitches; sewing the three-dimensional integral structure by using a blind stitch process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 1-24 mm; as shown in fig. 2.a, it is a hidden seam process diagram of the multi-layer waste textile fiber needle felt of the present invention; as shown in fig. 2.b, it is a schematic view of a multilayer waste textile fiber needle felt blind stitch in the present invention;
and S6, infiltrating the prefabricated part obtained in the step S5 with phenolic resin, and carrying out hot pressing until the required thickness is achieved, and curing.
In step S1 of the invention, the fiber length of the waste textile fiber wadding obtained after opening is 20-140mm.
The waste textile fiber recycling method has the advantages that various waste textiles are directly loosened and carded into the waste textile fibers, and the waste textiles are high in recycling rate, low in recycling cost and high in recycling efficiency.
In step S5 of the invention, the melting temperature of the hot-melt stitching yarn is 80-130 ℃.
It should be noted that the hot-melt sewing yarns are adopted in the blind stitching process, the hot-melt yarns are melted in the curing process, the multi-layer needled felt can be bonded into a three-dimensional integral structure, and the prepared reinforced composite material has uniform mechanical properties and high interlaminar and intrafacial mechanical properties. Meanwhile, after the hot-melt suture line is melted, no trace is left on the surface of the composite material which is adhered with the fabric with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or the high-performance fiber fabric (carbon fiber fabric or aramid fiber fabric), so that the aesthetic property of the composite material is improved, and a new method is provided for manufacturing the waste textile fiber composite material.
In step S6 of the invention, the temperature of hot pressing and curing is 100-150 ℃, the pressure is 1-10MPa, and the time is 5-30min.
In step S6 of the invention, the fiber volume content of the composite material obtained by curing is 40-80%.
The invention abandons the traditional direct hand-lay-up forming, hot-press forming or vacuum bag forming process of waste fabrics, adopts the vacuum bag hot-press forming process, and hot-presses the multilayer sewing needled felt to the required thickness after the multilayer sewing needled felt is completely soaked in the resin in the vacuum bag, so that the fiber volume content of the prepared composite material is up to 40-80 percent, and the increase of the fiber volume content means that the volume content of the phenolic resin is reduced. The production cost of the composite material can be effectively reduced by greatly reducing the content of the phenolic resin.
A waste textile fiber reinforced composite material prepared by using waste textiles and phenolic resin is prepared by any one of the preparation methods, comprises a three-dimensional composite structure, and is characterized in that: the three-dimensional composite structure comprises a plurality of needled felts and fabric layers attached to the upper surfaces and the lower surfaces of the needled felts; the layer number of the needled felt is not less than 2, and the three-dimensional composite structure is penetrated by a plurality of stitches along the thickness direction; each needled felt is formed by needling a fiber film, and the fiber film is formed by crosswise folding a plurality of waste textile single fibers; the fabric layer is a fabric or a fiber fabric with a customized pattern; phenolic resin is embedded in the three-dimensional composite structure.
The sewing density of the needled felt is 1-25 needles.
The needling density of the needled felt is 1-14.
The thickness of the three-dimensional composite structure is 2-16mm.
The thickness of the plurality of needled felts is 1-4mm.
When the invention is used, the decoration is removed firstly, the textile clothing cloth is loosened into fiber batting, and the fiber length of the waste textile fiber batting obtained after loosening is 20-80mm; the waste textiles utilized in the invention mainly comprise cotton fibers, polyester fibers and the like, the spinnability is good, the natural deflection of the cotton fibers enables the cotton fibers to have certain cohesive force, and the chemical fibers have excellent mechanical properties. Feeding the textile clothing fabric fiber batting into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing and uniformly forming single fibers, carding the single fibers into a fiber thin net, and manufacturing the fiber thin net into a fiber web film by using a cross folding lapping machine; then, needling is carried out on the fiber web film to obtain a needled felt, then the needled felt is laid together in a multi-layer mode, fabrics or fiber fabrics (carbon fiber fabrics or aramid fiber fabrics) with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) are attached to the upper surface and the lower surface, a blind seam process is used, hot-melt yarns are adopted as sewing threads to be sewn into a three-dimensional integral structure, and a three-dimensional composite structure of the textile fiber reinforced composite fabric is obtained; and finally, infiltrating the prefabricated part with phenolic resin by using a vacuum bag forming process, and placing the prefabricated part on a hot press for hot pressing and curing.
Example 1
Step 1, removing ornaments on waste textiles, paving the waste textile fabrics, and opening the waste textile fabrics into fiber battings with the fiber length of 20mm by using a cloth opener;
step 2, feeding the waste textile fabric fiber batting into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing, uniformly forming single fibers, and carding the single fibers into a thin net;
step 3, preparing the thin web into a fiber film by using a cross-folding lapping machine;
step 4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 4mm and the cohesive force of 20N;
step 5, laying every two layers of the needled felt obtained in the step 4 together, laminating a fabric or a high-performance fiber fabric (a carbon fiber fabric or an aramid fiber fabric) with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) on the upper surface and the lower surface, selecting hot-melt yarns as sewing lines, and sewing the hot-melt yarns into a three-dimensional integral structure by using a blind sewing process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 8 mm;
and 6, infiltrating the prefabricated part obtained in the step 5 with phenolic resin by using a vacuum bag forming process, placing the prefabricated part on a hot press, and hot-pressing the prefabricated part until the prefabricated part is 5mm and cured, wherein the hot-pressing curing temperature is 135 ℃, the pressure is 2MPa, and the time is 15min.
Example 2
Step 1, removing ornaments on waste textiles, paving the waste textile fabrics, and opening the waste textile fabrics into fiber battings with the fiber length of 40mm by using a cloth opener;
step 2, feeding fiber batting of the waste textile fabrics into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing, uniformly forming single fibers, and carding the single fibers into a thin net;
step 3, preparing the thin web into a fiber film by using a cross-folding lapping machine;
step 4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 4mm and the cohesive force of 20N;
step 5, laying the needled felt obtained in the step 4 together in every three layers, laminating fabrics with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or high-performance fabrics (carbon fiber fabrics or aramid fiber fabrics) on the upper and lower surfaces, selecting hot-melt yarns as sewing threads, and sewing the hot-melt yarns into a three-dimensional integral structure by using a blind sewing process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 12 mm;
and 6, infiltrating the prefabricated part obtained in the step 5 with phenolic resin by using a vacuum bag forming process, placing the prefabricated part on a hot press, and hot-pressing the prefabricated part until the thickness is 8mm for solidification, wherein the hot-pressing solidification temperature is 135 ℃, the pressure is 3MPa, and the time is 15min.
Example 3
Step 1, removing ornaments on waste textiles, paving the waste textile fabrics, and opening the waste textile fabrics into fiber battings with the fiber length of 80mm by using a cloth opener;
step 2, feeding the waste textile fabric fiber batting into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing, uniformly forming single fibers, and carding the single fibers into a thin net;
step 3, preparing the thin web into a fiber film by using a cross-folding lapping machine;
step 4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 4mm and the cohesive force of 20N;
step 5, laying every four layers of the needled felts obtained in the step 4 together, attaching fabrics printed with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or high-performance fabrics (carbon fiber fabrics or aramid fiber fabrics) on the upper and lower surfaces, selecting hot-melt yarns as stitches, and sewing the stitches into a three-dimensional integral structure by using a blind stitch process to obtain a textile fiber reinforced composite material prefabricated part with the thickness of 16 mm;
and 6, infiltrating the prefabricated part obtained in the step 5 with phenolic resin by using a vacuum bag forming process, placing the prefabricated part on a hot press, and hot-pressing to 12mm for curing, wherein the hot-pressing curing temperature is 135 ℃, the pressure is 5MPa, and the time is 15min.
Example 4
Step 1, removing ornaments on waste textiles, paving waste textile fabrics, and opening the waste textile fabrics into fiber batts with the fiber length of 25mm by using a cloth opener;
step 2, feeding fiber batting of the waste textile fabrics into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing, uniformly forming single fibers, and carding the single fibers into a thin net;
step 3, making the thin net into a fiber film by using a cross-folding lapping machine;
step 4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 2mm and the cohesive force of 15N;
step 5, laying every four layers of the needled felt obtained in the step 4 together, laminating a fabric or a high-performance fiber fabric (a carbon fiber fabric or an aramid fiber fabric) with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) on the upper surface and the lower surface, selecting hot-melt yarns as sewing lines, and sewing the hot-melt yarns into a three-dimensional integral structure by using a blind sewing process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 8 mm;
and 6, infiltrating the prefabricated part obtained in the step 5 with phenolic resin by using a vacuum bag forming process, placing the prefabricated part on a hot press, and hot-pressing the prefabricated part until the thickness is 6mm for solidification, wherein the hot-pressing solidification temperature is 135 ℃, the pressure is 3MPa, and the time is 15min.
Example 5
Step 1, removing ornaments on waste textiles, paving textile fabrics, and opening the textile fabrics into fiber battings with the fiber length of 40mm by using a cloth opener;
step 2, feeding the waste textile fabric fiber batting into a roller type carding machine, removing impurities through a cylinder, a doffer, a working roller and a stripping roller, mixing, uniformly forming single fibers, and carding the single fibers into a thin net;
step 3, making the thin net into a fiber film by using a cross-folding lapping machine;
step 4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 4mm and the cohesive force of 18N;
step 5, laying every six layers of the needled felts obtained in the step 4 together, attaching fabrics printed with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or high-performance fabrics (carbon fiber fabrics or aramid fiber fabrics) on the upper and lower surfaces, selecting hot-melt yarns as stitches, and sewing the stitches into a three-dimensional integral structure by using a blind stitch process to obtain a 24 mm-thick textile fiber reinforced composite material prefabricated part;
and 6, infiltrating the prefabricated part obtained in the step 5 with phenolic resin by using a vacuum bag forming process, placing the prefabricated part on a hot press, and hot-pressing the prefabricated part until the thickness of the prefabricated part is 20mm for solidification, wherein the hot-pressing solidification temperature is 135 ℃, the pressure is 5MPa, and the time is 15min.
The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin directly opens and combs various waste textiles into the waste textile fiber, and the waste textiles have the advantages of high recycling rate, low recycling cost and high recycling efficiency.
Compared with the prior art, the method abandons the traditional thought of manually laying the fiber reinforced composite material, adopts a non-woven needling process combined with a blind stitch process to prepare the multilayer sewn waste textile fiber needled felt, and adopts a vacuum bag forming process combined with hot pressing and curing to prepare the waste fiber reinforced composite material; the invention adopts the blind stitch process on the basis of the non-woven needling process, and solves the problem that the high-thickness needled felt cannot be produced by using the non-woven needling process alone. The blind sewing process brings partial in-plane fibers into the thickness direction, so that the interlayer performance of the needled felt is improved, meanwhile, the multilayer needled felt can be sewn into a three-dimensional integral structure by sewing threads, the integrity of the sewn multilayer needled felt is strong, the thickness of the sewn multilayer needled felt is high, the prepared composite material meets various thickness requirements, and the interlayer mechanical property is excellent.
The invention adopts hot-melt sewing yarns in the sewing process, the hot-melt yarns are melted in the curing process, the multi-layer needled felt can be bonded into a three-dimensional integral structure, and the prepared reinforced composite material has uniform mechanical properties and high interlaminar and intrafacial mechanical properties. Meanwhile, on the basis of a non-woven needling process, a sewing process is adopted to connect all parts of the composite material, special structural parts are prepared, and the parts are integrally formed according to product requirements, so that the traditional rivet mode is solved, the cost is saved, and the product weight is reduced. After the hot-melt suture line is melted, marks cannot be left on the surface of the composite material which is attached with the fabric with customized patterns (wood-like patterns, stone-like patterns, flower-like patterns and the like) or the high-performance fiber fabric (carbon fiber fabric or aramid fiber fabric), so that the attractiveness of the composite material is improved, and a new method is provided for manufacturing the waste textile fiber composite material.
The invention abandons the traditional direct hand-lay-up forming, hot-press forming or vacuum bag forming process of the waste fabrics, adopts the vacuum bag hot-press forming process, and hot-presses the multilayer blind stitch needled felt to the required thickness after the multilayer blind stitch needled felt is completely soaked in the resin in the vacuum bag, and the prepared composite material has the fiber volume content of 40-80 percent, and the fiber volume content is improved, which means that the volume content of the phenolic resin is reduced. The production cost of the composite material can be effectively reduced by greatly reducing the content of the phenolic resin; the matrix material selected by the invention is phenolic resin, has good mechanical property and short curing time, the curing time is only 15min at 135 ℃, the production efficiency is high, and the requirement of mass production in short time of enterprises is met.
The waste textiles utilized in the invention mainly comprise cotton fibers, polyester fibers and the like, the spinnability is good, the cotton fibers naturally bend to enable the cotton fibers to have certain cohesive force, and the chemical fibers have excellent mechanical properties. The phenolic resin has the characteristics of excellent chemical resistance and heat resistance, excellent rigidity, electric insulation, small density, corrosion resistance, moisture resistance, excellent dimensional stability, easy processing and forming and the like, and the composite material prepared from the waste textile fiber reinforced phenolic resin can simultaneously play the advantages of various components, so that the performance of the composite material is supplemented by the advantages of the components, and the composite material with excellent performance is formed. The fabric with customized patterns (wood-like texture, stone-like texture, flower-like pattern and the like) is attached to the upper surface and the lower surface of the multilayer blind stitch needled felt, the prepared textile fiber composite material can be directly used, subsequent surface treatment (such as film pasting, paint brushing and the like) is not needed, the subsequent processing cost is saved, and the multilayer blind stitch needled felt is green, environment-friendly and free of formaldehyde. The selected textile is textile waste, so that the waste of resources can be reduced, the utilization rate of the textile waste is improved, meanwhile, the pollution to the environment caused by the landfill and the combustion of the textile waste can be avoided, and the win-win situation of economic and social development and ecological environment protection is achieved.
In light of the foregoing description of the preferred embodiment of the present invention, it is to be understood that various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (10)
1. A preparation method for preparing a waste textile fiber reinforced composite material by using waste textiles and phenolic resin is characterized by comprising the following steps:
s1, paving waste textile fabrics and opening the waste textile fabrics into fiber battings;
s2, removing impurities from waste textile fabric fibers, uniformly mixing the fibers into a single fiber shape, and carding the single fiber shape into a thin net;
s3, cross-folding the thin net to prepare a fiber film;
s4, reinforcing the fiber film by repeated needling to obtain a needled felt with the thickness of 1-4mm and the cohesive force of 5-20N;
s5, laying a plurality of layers of the needled felt obtained in the step S4 together, and laminating the fabric or the fiber fabric with the customized patterns on the upper surface and the lower surface; using hot-melt yarns as stitches, and sewing a plurality of layers of needled felts and fabric layers attached to the upper surface and the lower surface into a three-dimensional integral structure by using a blind stitch process to obtain a textile fiber reinforced composite prefabricated part with the thickness of 1-24 mm;
and S6, infiltrating the prefabricated part obtained in the step S5 with phenolic resin, and carrying out hot pressing until the required thickness is achieved, and curing.
2. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 1, is characterized in that: in the step S1, the fiber length of the waste textile fiber batting obtained after opening is 20-140mm.
3. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 1 is characterized by comprising the following steps: in the step S5, the melting temperature of the hot-melt yarn is 80-130 ℃.
4. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 1, is characterized in that: in the step S6, the hot-pressing curing temperature is 100-150 ℃, the pressure is 1-10MPa, and the time is 5-30min.
5. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 1, is characterized in that: in the step S6, the fiber volume content of the composite material obtained by curing is 40-80%.
6. A waste textile fiber reinforced composite material prepared by using waste textiles and phenolic resins and prepared by the preparation method of any one of claims 1-5, which comprises a three-dimensional composite structure, and is characterized in that: the three-dimensional composite structure comprises a plurality of needled felts and fabric layers attached to the upper surfaces and the lower surfaces of the needled felts; the number of layers of the needled felt is not less than 2, and the three-dimensional composite structure is penetrated by a plurality of stitches along the thickness direction; each needled felt is formed by needling a fiber film, and the fiber film is formed by crosswise folding a plurality of waste textile single fibers; the fabric layer is a fabric or a fiber fabric with a customized pattern; the three-dimensional composite structure is embedded with phenolic resin.
7. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 6, is characterized in that: the sewing density of the needled felt is 1-25 needles/cm 2 。
8. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 6 is characterized in that: the needling density of the needled felt is 1-14 spines/cm 2 。
9. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 6, is characterized in that: the thickness of the three-dimensional composite structure is 2-16mm.
10. The method for preparing the waste textile fiber reinforced composite material by using the waste textiles and the phenolic resin according to claim 6, is characterized in that: the thickness of the plurality of needle punched felts is 1-4mm.
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