CN117246021A - 一种树脂桁架结构增强泡沫吸波材料及其制备方法 - Google Patents
一种树脂桁架结构增强泡沫吸波材料及其制备方法 Download PDFInfo
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Abstract
本发明提供一种树脂桁架结构增强泡沫吸波材料及其制备方法,该吸波材料包括玻璃钢面板、吸波泡沫芯材、吸波树脂柱、碳纤维底板,上层为玻璃钢面板,下层为碳纤维底板,中间层设有吸波泡沫芯材,呈空间桁架结构形式的吸波树脂柱分布于吸波泡沫芯材中。本发明通过真空导入固化形成空间桁架结构的吸波树脂柱,对空间桁架结构的吸波树脂柱的尺寸参数和在吸波泡沫芯材中的空间分布参数进行电磁设计,在增强吸波泡沫芯材层间强度和抗压能力的同时,实现了泡沫夹层吸波材料薄型化和低频宽频吸波的兼容,能够解决现有结构型吸波材料在厚度受限条件下,对低、中、高频电磁波有效吸收难以兼顾的技术问题。本发明的制造工艺简单,易于控制,适合大规模生产。
Description
技术领域
本发明涉及吸波材料技术领域,具体涉及一种树脂桁架结构增强泡沫吸波材料及其制备方法。
背景技术
结构吸波材料是在先进复合材料基础上发展起来的既能承载又能吸波的多功能复合材料,按其结构形式可分为层板型、蜂窝夹层型和泡沫夹层型,其中,泡沫夹层吸波材料作为典型的轻质结构材料,由吸波泡沫芯材、透波面板和反射底板组成,透波面板和反射底板分别通过胶黏剂贴敷于吸波泡沫芯材上、下表面而成为整体,为获得频段更宽的吸波性能,现有技术手段是依据电磁波阻抗匹配和谐振损耗原理将吸波泡沫芯材设计为多个单层吸波泡沫层叠粘接的结构形式,但是,随着单层吸波泡沫层数增加,由于泡沫内聚力的原因其夹层吸波材料内部层间粘接强度较低,导致在工程应用时内部层间脱粘的风险升高,影响泡沫夹层吸波材料的使用可靠性,为增强泡沫夹层复合材料的层间强度,现有技术如专利CN116423936提供的一种结构吸波复合材料及其制备方法,是通过在泡沫芯材的上、下表面开槽和沿厚度方向于表面槽的交汇处开通孔,然后通过真空导入工艺将树脂导入至开设的槽和孔中,树脂固化后在泡沫芯材厚度方向形成树脂柱,从而对泡沫夹层复合材料进行增强。
如上所述,采用树脂柱增强的技术手段能够解决由多个单层吸波泡沫层叠粘接的夹层结构的层间粘接强度弱和平压强度欠佳的问题,但是现有技术将吸波泡沫芯材设计为多个单层吸波泡沫层叠的结构形式,仍然难以有效解决在材料厚度受限时宽频雷达吸波的问题,尤其是在中、高频吸波的同时难以兼顾对低频电磁波的有效吸收。
发明内容
本发明的主要目的在于提供一种树脂桁架结构增强泡沫吸波材料及其制备方法,解决现有泡沫夹层型吸波材料在厚度受限条件下,低、中、高频有效吸波难以兼顾的技术问题,并且增强泡沫夹层型吸波材料的层间强度和抗压能力。
为解决上述技术问题,本发明所采用的技术方案是:一种树脂桁架结构增强泡沫吸波材料,包括玻璃钢面板、吸波泡沫芯材、吸波树脂柱、碳纤维底板,上层为玻璃钢面板,下层为碳纤维底板,中间层设有吸波泡沫芯材,呈空间桁架结构形式的吸波树脂柱分布于吸波泡沫芯材中。
优选方案中,吸波泡沫芯材由2-10个单泡沫层复合叠加而成,总厚度为10-100mm,所述单泡沫层为聚甲基丙烯酰亚胺泡沫、聚氨酯泡沫、环氧树脂泡沫中的任意一种。
优选方案中,吸波树脂柱由树脂和吸收剂混合均匀后固化而成,所述树脂为乙烯基树脂、不饱和树脂、环氧树脂中的任意一种,所述吸收剂为短切碳纤维、炭黑、石墨烯中的任意一种或多种的复合,吸收剂添加量为树脂和吸收剂总质量的0.05-3%。
优选方案中,所述吸波树脂柱空间桁架结构,吸波树脂柱在三平面正交交汇处沿三个正交方向分别贯穿于吸波泡沫芯材,所述三平面包含吸波泡沫芯材的上表面或下表面所在的平面;吸波树脂柱斜交贯穿于吸波泡沫芯材内部形成正四棱锥结构,所述斜交起点为吸波树脂柱在吸波泡沫芯材上表面正交交汇处,即为正四棱锥结构的锥顶,所述斜交终点分别位于吸波树脂柱在吸波泡沫芯材下表面的4个正交交汇处,即为正四棱锥结构底面正方形的4个顶点,形成吸波树脂柱空间桁架结构。
优选方案中,玻璃钢面板厚度为0.2-1mm,由纤维织物增强树脂复合材料构成,所述纤维织物为玻璃纤维织物、石英纤维织物、芳纶纤维织物中的任意一种,所述树脂为环氧树脂、氰酸酯树脂中的任意一种。
优选方案中,碳纤维底板厚度为0.2-1mm,由碳纤维织物增强树脂复合材料构成,所述树脂为环氧树脂。
优选方案中,包括以下步骤:
S1、在吸波泡沫芯材的上、下表面开正交分布的槽,并且分别在上、下表面正交槽的交汇处沿厚度方向开通孔,在吸波泡沫芯材下表面正交槽的四个正交交汇处向上斜交,汇于上表面正交槽的一个正交交汇处并开四个通孔,使吸波泡沫芯材内部斜交的孔道呈正四棱柱结构,得到开槽开孔的吸波泡沫芯材;
S2、向树脂中加入适量吸收剂和固化剂,搅拌均匀,得到吸波树脂;
S3、在平板模具上依次铺放开槽开孔的吸波泡沫芯材、脱模布、导流网,并铺设树脂管和真空管,然后用真空袋膜将其密封,采用树脂真空导入工艺将吸波树脂注入吸波泡沫芯材的槽和孔中,保持抽真空状态完成吸波树脂柱预固化,预固化完成后升温进行后固化,降至室温后脱模,得到树脂桁架结构增强的吸波泡沫芯材;
S4、在平板模具上依次铺放碳纤维底板、树脂桁架结构增强的吸波泡沫芯材和玻璃钢面板,层间涂覆环氧树脂胶黏剂形成坯料,对坯料进行模压成型得到树脂桁架结构增强泡沫夹层吸波材料。
优选方案中,开槽宽度为1-5mm,开槽深度1-5mm,开孔直径为1-5mm,槽孔间距为16-75mm。
优选方案中,吸波树脂粘度控制在150~800mPa·s。
本发明提供了一种树脂桁架结构增强泡沫吸波材料及其制备方法,其有益效果在于:(1)本发明通过对用于真空导入工艺增强泡沫夹层材料的树脂进行改进设计和对真空导入固化形成的吸波树脂柱的尺寸参数和在吸波泡沫芯材中的空间分布参数进行电磁设计,在增强吸波泡沫芯材层间强度的同时,实现了泡沫夹层吸波材料薄型化和低频宽频吸波的兼容;(2)本发明的制造工艺简单,易于控制,适合大规模生产;(3)利用空间桁架结构增强泡沫吸波材料,可适应结构内部的弯矩和剪力分布,不仅使泡沫吸波材料拥有更强结构稳定性和抗压能力,而且能够增强夹层吸波材料内部层间粘接强度。
附图说明
下面结合附图和实施例对本发明作进一步说明:
图1是本发明树脂桁架结构增强泡沫吸波材料的一实施例的正视图;
图2是本发明树脂桁架结构增强泡沫吸波材料的一实施例的俯视图;
图3是本发明树脂桁架结构增强泡沫吸波材料的吸波树脂柱空间桁架胞元结构图;
图4是本发明树脂桁架结构增强泡沫吸波材料的吸波树脂柱空间桁架胞元正视图;
图5是本发明树脂桁架结构增强泡沫吸波材料的吸波树脂柱空间桁架胞元俯视图;
图6是本发明实施方式中实施例1与对比例1的泡沫吸波材料的平板反射率曲线的对比图。
图中:玻璃钢面板1;吸波泡沫芯材2;吸波树脂柱3;碳纤维底板4。
具体实施方式
如图1~6所示,一种树脂桁架结构增强泡沫吸波材料,包括玻璃钢面板1、吸波泡沫芯材2、吸波树脂柱3、碳纤维底板4,上层为玻璃钢面板1,下层为碳纤维底板4,中间层设有吸波泡沫芯材2,呈空间桁架结构形式的吸波树脂柱3分布于吸波泡沫芯材2中。对真空导入固化形成的吸波树脂柱3的尺寸参数和在吸波泡沫芯材中的空间分布参数进行电磁优化设计,使镶嵌于吸波泡沫芯材2上、下表面的呈90°交错的吸波树脂柱3形成了一种有规律的周期排列结构单元,该吸波周期结构单元具有小于工作波长的尺寸,属于吸波超结构范畴,由吸波树脂柱3和吸波泡沫芯材2组成的周期超结构在保证组成单元产生相应吸收峰的同时,依靠单元间的耦合效应使得多个吸收峰产生叠加,同时单元层间由驻波引起的容性耦合效应使吸收峰往低频偏移,能够解决现有结构型吸波材料在厚度受限条件下,低、中、高频有效吸波难以兼顾的技术问题,并且空间桁架结构形式的吸波树脂柱3增强了泡沫吸波材料的结构稳定性。
优选方案中,吸波泡沫芯材2由2-10个单泡沫层复合叠加而成,总厚度为10-100mm,所述单泡沫层为聚甲基丙烯酰亚胺泡沫、聚氨酯泡沫、环氧树脂泡沫中的任意一种。聚甲基丙烯酰亚胺泡沫、聚氨酯泡沫、环氧树脂泡沫均为市售成熟产品,制造工艺成熟,性能稳定,种类丰富,可根据吸波性能要求进行选择,其中面层和底层单泡沫层为普通空白泡沫时,吸波性能更优。
优选方案中,吸波树脂柱3由树脂和吸收剂混合均匀后固化而成,所述树脂为乙烯基树脂、不饱和树脂、环氧树脂中的任意一种,所述吸收剂为短切碳纤维、炭黑、石墨烯中的任意一种或多种的复合,吸收剂添加量为树脂和吸收剂总质量的0.05-3%。对用于真空导入工艺增强泡沫夹层材料的树脂进行改进,加入轻质碳系吸收剂,调节树脂的电磁参数,成为具有吸波功能的树脂。
优选方案中,所述吸波树脂柱3空间桁架结构,吸波树脂柱3在三平面正交交汇处沿三个正交方向分别贯穿于吸波泡沫芯材2,所述三平面包含吸波泡沫芯材2的上表面或下表面所在的平面;吸波树脂柱3斜交贯穿于吸波泡沫芯材2内部形成正四棱锥结构,所述斜交起点为吸波树脂柱3在吸波泡沫芯材2上表面正交交汇处,所述斜交终点分别位于吸波树脂柱3在吸波泡沫芯材2下表面的4个正交交汇处,形成吸波树脂柱空间桁架结构。
吸波树脂柱3空间桁架结构,一方面可增强泡沫吸波材料的结构稳定性和抗压能力,另一方面可增强吸波材料内部层间粘接强度。
优选方案中,玻璃钢面板1厚度为0.2-1mm,由纤维织物增强树脂复合材料构成,所述纤维织物为玻璃纤维织物、石英纤维织物、芳纶纤维织物中的任意一种,所述树脂为环氧树脂、氰酸酯树脂中的任意一种。
优选方案中,碳纤维底板4厚度为0.2-1mm,由碳纤维织物增强树脂复合材料构成,所述树脂为环氧树脂。
优选方案中,包括以下步骤:
S1、在吸波泡沫芯材2的上、下表面开正交分布的槽,并且分别在上、下表面正交槽的交汇处沿厚度方向开通孔,在吸波泡沫芯材2下表面正交槽的四个正交交汇处向上斜交,汇于上表面正交槽的一个正交交汇处并开四个通孔,使吸波泡沫芯材2内部斜交的孔道呈正四棱柱结构,得到开槽开孔的吸波泡沫芯材2;
S2、向树脂中加入适量吸收剂和固化剂,搅拌均匀,得到吸波树脂;
S3、在平板模具上依次铺放开槽开孔的吸波泡沫芯材2、脱模布、导流网,并铺设树脂管和真空管,然后用真空袋膜将其密封,采用树脂真空导入工艺将吸波树脂注入吸波泡沫芯材的槽和孔中,保持抽真空状态完成吸波树脂柱3预固化,预固化完成后升温进行后固化,降至室温后脱模,得到树脂桁架结构增强的吸波泡沫芯材;
S4、在平板模具上依次铺放碳纤维底板4、树脂桁架结构增强的吸波泡沫芯材和玻璃钢面板1,层间涂覆环氧树脂胶黏剂形成坯料,对坯料进行模压成型得到树脂桁架结构增强泡沫夹层吸波材料。
优选方案中,开槽宽度为1-5mm,开槽深度1-5mm,开孔直径为1-5mm,槽孔间距为16-75mm。
优选方案中,吸波树脂粘度控制在150~800mPa·s。
实施例1
S1、选取由4个单泡沫层复合叠加粘接而成的聚甲基丙烯酰亚胺吸波泡沫平板芯材,上、下表面的单泡沫层为空白泡沫层,总厚度为25mm,在其上、下表面开正交分布的槽,并且在正交槽的交汇处沿厚度方向开通孔,在吸波泡沫芯材下表面正交槽的四个正交汇处向上斜交,汇于上表面正交槽的一个正交交汇处并开四个通孔,汇于上表面斜交交汇处并开通孔,使吸波泡沫芯材内部斜交的孔道呈正四棱柱结构,开槽宽度为3mm,开槽深度3mm,开孔直径为3mm,槽孔间距为75mm,得到开槽开孔的吸波泡沫平板芯材;
S2、向环氧树脂中加入质量分数为0.8%的短切碳纤维吸收剂和适量固化剂,搅拌均匀,得到粘度为600mPa·s的吸波树脂;
S3、在平板模具上依次铺放开槽开孔的聚甲基丙烯酰亚胺吸波泡沫平板芯材、脱模布、导流网,并铺设树脂管和真空管,然后用真空袋膜将其密封,采用树脂真空导入工艺将吸波树脂注入吸波泡沫芯材的槽和孔中,保持抽真空状态完成吸波树脂预固化,预固化完成后升温进行后固化,降至室温后脱模,得到树脂桁架结构增强的吸波泡沫芯材;
S4、在平板模具上依次铺放厚度为0.5mm的碳纤维底板、树脂桁架结构增强的吸波泡沫芯材和厚度为0.5mm石英纤维织物增强环氧树脂玻璃钢面板,层间涂覆环氧树脂胶黏剂,涂覆施胶量为250g/m2,形成坯料,对坯料进行模压成型得到树脂桁架结构增强泡沫夹层吸波材料。
经测试,制得的树脂桁架结构增强泡沫吸波材料平板反射率曲线如图6所示。
对比例1
与实施例1对比,采用现有技术,第S1步中,不在波泡沫芯材内部开斜交的通孔,第S2步中,不在环氧树脂中加入短切碳纤维吸收剂,其余条件和步骤与实施例1一致,得到层间力学增强的泡沫夹层吸波材料。
经测试,制得的层间力学增强的泡沫夹层吸波材料平板反射率曲线如图6所示。
将本对比例与实施例1的测试数据进行对比,列于表1中。
表1实施例1与对比例1测试数据对比
实施例2
S1、选取由5个单泡沫层复合叠加粘接而成的聚氨酯吸波泡沫平板芯材,总厚度为35mm,在其上、下表面开正交分布的槽,并且在正交槽的交汇处沿厚度方向开通孔,在吸波泡沫芯材下表面正交槽的四个正交汇处向上斜交,汇于上表面正交槽的一个正交交汇处并开四个通孔,汇于上表面斜交交汇处并开通孔,使吸波泡沫芯材内部斜交的孔道呈正四棱柱结构,开槽宽度为2mm,开槽深度2mm,开孔直径为2mm,槽孔间距为30mm,得到开槽开孔的吸波泡沫平板芯材;
S2、向乙烯基树脂中加入质量分数为0.5%的石墨烯吸收剂和适量固化剂,搅拌均匀,得到粘度为300mPa·s的吸波树脂;
S3、在平板模具上依次铺放开槽开孔的聚氨酯吸波泡沫平板芯材、脱模布、导流网,并铺设树脂管和真空管,然后用真空袋膜将其密封,采用树脂真空导入工艺将吸波树脂注入吸波泡沫芯材的槽和孔中,保持抽真空状态完成吸波树脂预固化,预固化完成后升温进行后固化,降至室温后脱模,得到树脂桁架结构增强的吸波泡沫芯材;
S4、在平板模具上依次铺放厚度为0.3mm的碳纤维底板、树脂桁架结构增强的吸波泡沫芯材和厚度为0.3mm芳纶纤维织物增强氰酸酯树脂玻璃钢面板,层间涂覆环氧树脂胶黏剂,涂覆施胶量为250g/m2,形成坯料,对坯料进行模压成型得到树脂桁架结构增强泡沫夹层吸波材料。
制得的树脂桁架结构增强泡沫吸波材料的测试数据列于表2中。
表2实施例2制得的树脂桁架结构增强泡沫吸波材料测试数据
由采用本发明技术的实施例1和采用现有技术的对比例1的测试数据可以看出,在面板、底板、吸波泡沫芯材、层间胶黏剂相同的前提下,本发明实施例制得的树脂桁架结构增强泡沫吸波材料的结构稳定性及低频宽带吸波性能均显著优于现有技术制备的层间力学增强的泡沫夹层吸波材料的结构稳定性及低频宽带吸波性能。
上述的实施例仅为本发明的优选技术方案,而不应视为对于本发明的限制,本发明的保护范围应以权利要求记载的技术方案,包括权利要求记载的技术方案中技术特征的等同替换方案为保护范围。即在此范围内的等同替换改进,也在本发明的保护范围之内。
Claims (9)
1.一种树脂桁架结构增强泡沫吸波材料,其特征是:包括玻璃钢面板(1)、吸波泡沫芯材(2)、吸波树脂柱(3)、碳纤维底板(4),上层为玻璃钢面板(1),下层为碳纤维底板(4),中间层设有吸波泡沫芯材(2),呈空间桁架结构形式的吸波树脂柱(3)分布于吸波泡沫芯材(2)中。
2.根据权利要求1所述一种树脂桁架结构增强泡沫吸波材料,其特征是:吸波泡沫芯材(2)由2-10个单泡沫层复合叠加而成,总厚度为10-100mm,所述单泡沫层为聚甲基丙烯酰亚胺泡沫、聚氨酯泡沫、环氧树脂泡沫中的任意一种。
3.根据权利要求1所述一种树脂桁架结构增强泡沫吸波材料,其特征是:吸波树脂柱(3)由树脂和吸收剂混合均匀后固化而成,所述树脂为乙烯基树脂、不饱和树脂、环氧树脂中的任意一种,所述吸收剂为短切碳纤维、炭黑、石墨烯中的任意一种或多种的复合,吸收剂添加量为树脂和吸收剂总质量的0.05-3%。
4.根据权利要求1所述一种树脂桁架结构增强泡沫吸波材料,其特征是:所述吸波树脂柱(3)空间桁架结构,吸波树脂柱(3)在三平面正交交汇处沿三个正交方向分别贯穿于吸波泡沫芯材(2),所述三平面包含吸波泡沫芯材(2)的上表面或下表面所在的平面;吸波树脂柱(3)斜交贯穿于吸波泡沫芯材(2)内部形成正四棱锥结构,所述斜交起点为吸波树脂柱(3)在吸波泡沫芯材(2)上表面正交交汇处,所述斜交终点分别位于吸波树脂柱(3)在吸波泡沫芯材(2)下表面的4个正交交汇处,形成吸波树脂柱(3)空间桁架结构。
5.根据权利要求1所述一种树脂桁架结构增强泡沫吸波材料,其特征是:玻璃钢面板(1)厚度为0.2-1mm,由纤维织物增强树脂复合材料构成,所述纤维织物为玻璃纤维织物、石英纤维织物、芳纶纤维织物中的任意一种,所述树脂为环氧树脂、氰酸酯树脂中的任意一种。
6.根据权利要求1所述一种树脂桁架结构增强泡沫吸波材料,其特征是:碳纤维底板(4)厚度为0.2-1mm,由碳纤维织物增强树脂复合材料构成,所述树脂为环氧树脂。
7.根据权利要求1-6任一项所述一种树脂桁架结构增强泡沫吸波材料的制备方法,其特征是:包括以下步骤:
S1、在吸波泡沫芯材(2)的上、下表面开正交分布的槽,并且分别在上、下表面正交槽的交汇处沿厚度方向开通孔,在吸波泡沫芯材(2)下表面正交槽的四个正交交汇处向上斜交,汇于上表面正交槽的一个正交交汇处并开四个通孔,使吸波泡沫芯材(2)内部斜交的孔道呈正四棱柱结构,得到开槽开孔的吸波泡沫芯材(2);
S2、向树脂中加入适量吸收剂和固化剂,搅拌均匀,得到吸波树脂;
S3、在平板模具上依次铺放开槽开孔的吸波泡沫芯材、脱模布、导流网,并铺设树脂管和真空管,然后用真空袋膜将其密封,采用树脂真空导入工艺将吸波树脂注入吸波泡沫芯材(2)的槽和孔中,保持抽真空状态完成吸波树脂柱(3)预固化,预固化完成后升温进行后固化,降至室温后脱模,得到树脂桁架结构增强的吸波泡沫芯材;
S4、在平板模具上依次铺放碳纤维底板(4)、树脂桁架结构增强的吸波泡沫芯材和玻璃钢面板(1),层间涂覆环氧树脂胶黏剂形成坯料,对坯料进行模压成型得到树脂桁架结构增强泡沫夹层吸波材料。
8.根据权利要求7所述一种树脂桁架结构增强泡沫吸波材料的制备方法,其特征是:开槽宽度为1-5mm,开槽深度1-5mm,开孔直径为1-5mm,槽孔间距为16-75mm。
9.根据权利要求7所述一种树脂桁架结构增强泡沫吸波材料的制备方法,其特征是:吸波树脂粘度控制在150~800mPa·s。
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