CN117565493A - 一种基于短切吸波纤维无序分布的吸波材料及其制备方法 - Google Patents
一种基于短切吸波纤维无序分布的吸波材料及其制备方法 Download PDFInfo
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Abstract
本发明属于吸波复合材料领域。本发明提供一种基于短切吸波纤维无序分布的吸波材料及其制备方法。该吸波材料引入了多层共振结构,所述结构包括吸波层和介质层。吸波层由无序分布的吸波纤维构成,介质层为织物或平板。吸波材料的吸波性能由各层吸波层电磁参数、介质层介电常数和介质层厚度决定。吸波层电磁性能由吸波纤维长度和含量进行调控,n层吸波层所含最短纤维长度满足L1<L2<…<Ln(n≥3)。该吸波材料由于多层结构的电损耗、谐振损耗以及干涉作用,可实现GHz频带内的超宽频吸收。
Description
技术领域
本发明涉及吸波复合材料领域,尤其涉及一种基于短切吸波纤维无序分布的吸波材料及其制备方法。
背景技术
随着电磁波应用范围的不断拓宽,不同频率的电磁波充斥着人们的生活空间,在给人类生产生活带来了极大的便利的同时,随之而来日趋严重的电磁污染却也成为不可忽视的问题。另外,在军事领域,雷达技术快速发展,飞行器与军事防御系统更容易被敌人检测、跟踪和攻击,这将严重威胁着军事目标的生存能力。因此,适应多频段且有效的电磁防护手段对日常生产生活和国防安全极为重要。吸波材料的开发和应用是雷达隐身技术发展的关键技术之一,吸波材料能将入射的电磁波能量转换为热能耗散掉或使其产生干涉相消,减少回波。吸波材料的损耗原理主要包括干涉相消、介质损耗和谐振损耗,若想实现宽频段吸收还需要多重损耗同时作用,对吸波剂的选择和吸波结构的设计具有一定的挑战。
短切吸波纤维大长径比的特殊结构可以延长微波在材料内部的传输路径,增加其衰减性能,纤维和电磁波波长的良好谐振效应也可有效增加电磁波的吸收,通过对纤维长径比的合理调控,以及纤维吸波层的构建为制备宽频复合吸波材料提供有效策略。Jaumann吸收体结构类似于多层的Salisbury屏吸收体,其引入了多层共振结构,吸波性能由各吸波层电磁性能、介质层电磁参数和介质层厚度决定,具备宽频吸波功能。如,专利CN101740143A公开了一种含有玻璃包覆磁性非晶纤维的电磁吸波材料制备方法,采用筛分方式将纤维散布在基体材料上,利用调控纤维长度及退火处理制备单层吸波材料,但是根据该专利实施例内只能实现窄带的吸收。公开号为CN 11519651A的发明专利公开了一种多层结构的改性碳纤维-莫来石陶瓷吸波材料制备方法,该专利构建了改性碳纤维-莫来石陶瓷基体“夹心饼干”的多层结构,其具有优异的耐高温及吸波性能。公开号为CN114619718A的中国发明专利公开了一种由金属复合材料制备的反射层、改性碳化硅陶瓷制备的损耗层和具有周期性结构的匹配层叠层而成的宽频吸波复合材料。
发明内容
(一)解决的技术问题
目前,所公布的吸波材料吸波效能有限,吸波带宽相对较窄,且所采用的吸波剂均需要通过改性处理或者叠加复杂结构层,制备工艺复杂、无法做到对吸波体吸波性能快速简单调控。另外宽频复合吸波体一般质量重,厚度大,限制其在实际场景中的应用。因此,亟需提供一种制备工艺简单,对吸波体吸波性能快速简单调控,质量轻,厚度小,实际场景中应用广泛的宽频复合吸波体。
(二)技术方案
为了达到上述目的,本发明采用的主要技术方案包括:
其一,本发明提供一种基于短切吸波纤维无序分布的吸波材料,所述吸波材料包括:n层吸波层和n层介质层;所述吸波层由吸波纤维构成,所述介质层由织物或高聚物构成;所述n层吸波层所含最短纤维长度满足:l1<l2<…<ln(n≥3);所述吸波层和所述介质层相互间隔分布,通过粘合剂按照顺序复合为吸波体。
进一步地,所述吸波纤维包括金属纤维和非金属纤维;所述金属纤维为玻璃包覆非晶磁性纤维、不锈钢纤维、多晶铁纤维、铁镍纤维和铁钴镍纤维的一种或几种;所述非金属纤维为导电的非金属类纤维,典型如碳纤维、改性碳纤维和改性碳化硅纤维的一种或几种。
进一步地,所述吸波纤维长度为0.5~30mm,所述吸波层的每层吸波纤维含量为0.3~8.5g/m2。
进一步地,当所述吸波层包含一种所述吸波纤维长度时,所述吸波纤维长度为0.5~30mm中的一个固定长度;所述吸波纤维呈无规分布;当所述吸波层包含不少于3种所述吸波纤维长度时,所述吸波纤维长度为0.5~30mm中对应的长度,相邻两个所述吸波纤维长度相差不大于2mm,且所述吸波纤维长度呈梯度分布;所述吸波纤维呈无规则等量分布;当所述吸波层的所述吸波纤维长度呈中心正态分布时,所述中心吸波纤维长度为0.5~30mm中的一个固定长度,其它所述吸波纤维长度不少于三个长度,相邻两个所述吸波纤维长度相差不大于2mm。
进一步地,所述单层吸波层厚度为40~3000μm,所述单层吸波层的平方米克重不大于50g/m2。
进一步地,所述介质层介电常数为2.1~4.7;所述介质层厚度为0.5~12mm,每层所述介质层厚度通过电磁仿真模拟与对应所述吸波层厚度相匹配。
进一步地,所述单层介质层的重量不大于500g/m2;所述吸波体的重量不大于2000g/m2。
其二,本发明提供了一种基于短切吸波纤维无序分布的吸波材料制备方法,所述制备方法包括:S1,制备所述吸波层;S2,先分别形成所述吸波层和所述介质层,再通过粘合剂将所述介质层和所述吸波层复合形成所述基于短切吸波纤维无序分布的吸波材料,或,先形成第1层介质层,再通过粘合剂粘合形成第1层吸波层,逐层粘接,直到形成第n层吸波层和第n层介质层,粘接得到所述基于短切吸波纤维无序分布的吸波材料。
进一步地,所述制备所述吸波层,包括:湿法成网法、干法成网法或喷涂树脂粘合法;所述湿法成网法利用吸波纤维与普通纤维混合成纤维悬浮浆,输送到成网机构,加固成布,热粘合或针刺、水刺加固无纺布得到所述吸波层;所述干法成网法利用吸波纤维与普通纤维混合,机械打击处理得到均匀混合的纤维层;将所述纤维层铺设成网,热粘合或针刺、水刺加固纤维层,得到所述吸波层;所述喷涂树脂粘合法将吸波纤维裁切成相应长度,与粘合剂混合后进行喷涂得到所述吸波层;或将吸波纤维长丝通过喷涂机的纤维切割器裁切成相应长度,与粘合胶料在喷出的过程中均匀混合,得到所述吸波层。
进一步地,所述织物为粘胶纤维、聚酯纤维、尼龙纤维、纤维素纤维、聚丙烯纤维、聚乙烯纤维和棉纤维的一种或几种;所述高聚物为环氧树脂、聚四氟乙烯、尼龙和聚氯酯的一种或几种;所述粘合剂为聚氯酯、聚丙烯酸树脂、聚硫橡胶、硅橡胶、氯丁橡胶、丁基橡胶、环氧树脂、不饱和聚酯树脂、酚醛树脂和聚氯乙烯树脂中的一种或几种。
(三)有益效果
本发明有益效果是,与现有技术相比,提供了一种基于短切吸波纤维无序分布的吸波材料及其制备方法。
1.本发明提供的基于短切吸波纤维无序分布的吸波材料,具有多层共振结构,通过调控吸波层和介质层的参数有效调控电磁性能,可实现超宽频吸收。规定了各层吸波层纤维长度分布及含量、介质层厚度以及多层结构分布等。
2.本发明提供的基于短切吸波纤维无序分布的吸波材料,引入了纤维吸波剂,结合Jaumann吸波结构,使得吸波体兼具电损耗、谐振损耗以及干涉作用,可实现“轻、薄、宽、强”。
3.本发明提供的基于短切纤维无序分布的吸波材料的制备方法,包括单层和多层吸波材料的制备方法,兼具吸波和柔性,且厚度较薄,可应用于各种形态的装备上。
附图说明
为了更清楚地说明本发明实施例的技术方案,下面将对实施例中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的实施例。
图1示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的弓形法测试示意图;
图2示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的类Jaumann吸收体结构示意图;a)为平面示意图;b)为立体示意图;
图3示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的一种双层吸波织物叠合反射率曲线图;
图4示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的多层复合吸波层合板反射率曲线图;
图5示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的多层复合吸波织物反射率曲线图;
图6示出了本发明实施例的一种基于短切吸波纤维无序分布的吸波材料的另一种双层吸波织物叠合反射率曲线图。
具体实施方式
为了更好地解释本发明,以便于理解,下面结合附图,通过具体实施例,对本发明作详细描述。
下述实施例中所使用的实验方法如无特殊说明,均为常规方法。
下述实施例中所用的材料、试剂等,如无特殊说明,均可从商业途径得到。
根据GJB2038-2011《雷达吸波材料反射率测试方法》,采用弓形法测试多层吸波体的反射率,测试频段为2-18GHz。测试设备及环境如图1所示,发射天线、接收天线与样品台中心处于同一平面且指向圆心,样品尺寸为18cm×18cm。测试前矢量网络分析仪预热20min,先测试同样品尺寸大小的金属铝板的接收功率,再测试将样品放置在铝板上的接收功率,依据公式计算样品反射率。
基于吸波纤维无序分布,介质组合的层结构示意图如图2所示。
不同种类纤维基体材料和介质层可满足不同应用场合的需求,权利要求范围内介电常数的介质材料为常见材料的介电常数值范围,均能应用在复合吸波材料中。介质层厚度是由吸波纤维电磁谐振微波吸收特性和1/4波长匹配吸收特性共同决定的,故不同吸波纤维层所对应的介质层匹配厚度均不一致,介质层厚度可由仿真软件计算得出。
实施例1:
本实施例分析了不同长度的玻璃包覆非晶磁性纤维短切丝作为吸波纤维与纤维素纤维和涤纶纤维采用湿法成网工艺制备吸波层,纤维素纤维和涤纶纤维采用湿法成网工艺制备介质层,经过复合获得的双层吸波织物的反射率。
将细度为26dtex的玻璃包覆非晶磁性纤维(芯层的直径为18μm,壳层厚度为2μm),短切为4mm、5mm、6mm、7mm、8mm、9mm、10mm、11mm和12mm长度。将4mm、5mm、6mm和7mm的短切丝分别按照克重为1g/m2、0.5g/m2、0.5g/m2和1g/m2与纤维素纤维和涤纶纤维混合,制备无纺织物,总克重为100g/m2,作为第一层吸波层;纤维素纤维和涤纶纤维混合,制备无纺织物,总克重为50g/m2,作为第一层介质层;将8mm、9mm、10mm、11mm和12mm的短切丝均按照克重为0.8g/m2与纤维素纤维和涤纶纤维混合,制备无纺织物,总克重为160g/m2,作为第二层吸波层;纤维素纤维和涤纶纤维混合,制备无纺织物,总克重为70g/m2,作为第二层介质层;然后使用30%固含量的水性聚氯酯将织物进行粘接,获得双层吸波织物。
使用拱形法对获得的双层吸波织物进行反射率测试,测试结果如图3所示,在2-18GHz测试范围内,反射率出现双峰,分别为-7.4dB和-14.1dB;不大于-5dB的带宽为13.6GHz左右,不大于-10dB的带宽为5GHz左右。可见,双层复合吸波织物的在总厚度不大于3.5mm的情况下,具有较宽的吸波带宽,同时兼具柔性。
实施例2:
本实施例分析了不同长度的碳纤维短切丝作为吸波层粘接在不同厚度的环氧树脂平板介质层上制备获得的多层复合吸波层合板的反射率。吸波层用喷涂树脂粘合法制备,介质为高聚物。
将直径为8μm的碳纤维,短切为3.5mm、6mm、10mm和13.5mm长度。将3.5mm、6mm、10mm和13.5mm碳纤维短切丝按照克重分别为2g/m2、2g/m2、2.5g/m2和3g/m2,均匀、无序地分布在厚度为1mm、1mm、1.5mm和2mm的环氧树脂平板上,四层平板上均分别喷涂水性聚氯酯,将纤维和环氧树脂平板进行粘接,然后将这四层平板依次叠层,获得多层复合吸波合板。
对获得的多层复合吸波合板进行反射率测试,测试时第四层靠近金属背板,反射率测试结果如图4所示,在2-18GHz测试范围内,反射率出现双峰,分别为-13.1dB和-14dB;不大于-5dB的带宽为13GHz左右,不大于-10dB的带宽为8.16GHz左右。由此获得的多层复合吸波层合板具有强吸收、宽频带以及轻质的优异吸波性能。
实施例3:
本实施例分析了不同长度的不锈钢纤维短切丝作为吸波层粘接在不同厚度的开孔聚氯酯海绵介质层上制备获得的多层复合吸波织物的反射率。吸波层用喷涂树脂粘合法制备,介质为织物。
将直径为35μm的不锈钢纤维,短切为0.8mm、1mm、1.5mm、2.6mm、4.5mm、5mm、5.5mm、10.5mm、11mm和15.5mm,将0.8mm、1mm、1.5mm和2.6mm的不锈钢纤维短切丝,按照克重分别为4g/m2、4.5g/m2、5g/m2和5.5g/m2,均匀、无序地撒在厚度为0.8mm的开孔聚氯酯海绵上,作为第一层吸波层;将4.5mm、5mm和5.5mm的不锈钢纤维短切丝按照克重分别为2.5g/m2、5g/m2和4g/m2,均匀、无序地撒在厚度为1.5mm的开孔聚氯酯海绵上,作为第二层吸波层;将10.5mm、11mm和15.5mm的不锈钢纤维短切丝按照克重分别为3g/m2、4g/m2和3g/m2,均匀、无序地撒在厚度为1.1mm的开孔聚氯酯海绵上,作为第三层吸波层。然后将三层吸波层依次叠层,使用油性聚氯酯进行粘接,获得多层复合吸波织物。
对获得的多层复合吸波织物进行反射率测试,测试结果如图5,在2-18GHz测试范围内,不大于-5dB的带宽为15.36GHz左右,不大于-10dB的带宽为7.84GHz左右,由此获得的多层不锈钢纤维吸波织物在厚度为3.4mm的情况下小于-5dB的带宽几乎可以覆盖整个2-18GHz频段,具有吸收频带宽、厚度薄和质量轻的优点。
实施例4:
本实施例分析了不同长度正态分布的玻璃包覆非晶磁性纤维短切丝作为吸波纤维与涤纶纤维采用干法成网工艺制备吸波层,涤纶纤维采用干法成网工艺制备介质层,经过复合获得的双层吸波织物的反射率。
将细度为26dtex的玻璃包覆非晶磁性纤维(芯层的直径为18μm,壳层厚度为2μm),短切为4mm、5mm、6mm、7mm、8mm、9mm、10mm、11mm和12mm长度。将4mm、5mm、6mm和7mm的短切丝分别按照克重为0.5g/m2、1g/m2、1g/m2和0.5g/m2与涤纶纤维混合,经过梳理成网、针刺加固工艺,获得无纺织物,总克重为100g/m2,作为第一层吸波层;涤纶纤维经过梳理成网、针刺加固工艺,获得无纺织物,总克重为50g/m2,作为第一层介质层;将8mm、9mm、10mm、11mm和12mm的短切丝分别按照克重为0.25g/m2、1g/m2、1.5g/m2、1g/m2和0.25g/m2与涤纶纤维混合,同样经过梳理成网、针刺加固工艺,获得无纺织物,总克重为160g/m2,作为第二层吸波层;涤纶纤维经过梳理成网、针刺加固工艺,获得无纺织物,总克重为70g/m2,作为第二层介质层;然后使用30%固含量的水性聚氯酯将织物进行粘接,获得双层吸波织物。
使用拱形法对获得的双层吸波织物进行反射率测试,测试结果如图6所示,在2-18GHz测试范围内,反射率出现双峰,分别为-9.5dB和-13.5dB;不大于-5dB的带宽为14GHz左右,不大于-10dB的带宽为4.5GHz左右。可见,相同纤维长度和介质层的情况下,由正态分布吸波纤维制备而成的双层复合吸波织物具有更宽的吸波带宽,对整体吸波性能的改善具有一定的促进作用。
综合以上实施例可以看出,本发明制备的吸波材料,以短切吸波纤维作为吸波剂,以树脂、聚氯酯等高聚物或者涤纶、丙纶等织物作为介质层,通过调控纤维长度、密度和分布、介质层厚度、以及各层结构设计,在2-18GHz频带内达到宽频吸收。且吸波材料的制备工艺简单,可做到对吸波体吸波性能快速简单调控。
Claims (10)
1.一种基于短切吸波纤维无序分布的吸波材料,其特征在于,所述吸波材料包括:n层吸波层和n层介质层,n为吸波层的层数;所述吸波层由吸波纤维构成,所述介质层由织物或高聚物构成;所述每层吸波层所含最短纤维长度满足:L1<L2<…<Ln(n≥3);
所述吸波层和所述介质层相互间隔分布,通过粘合剂按照顺序复合为吸波体。
2.根据权利要求1所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,所述吸波纤维包括金属纤维和非金属纤维;
所述金属纤维为玻璃包覆非晶磁性纤维、不锈钢纤维、多晶铁纤维、铁镍纤维和铁钴镍纤维的一种或几种;
所述非金属纤维为导电的非金属类纤维,包括碳纤维、改性碳纤维和改性碳化硅纤维的一种或几种。
3.根据权利要求1所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,所述吸波纤维长度为0.5~30mm,所述吸波层的每层吸波纤维含量为0.3~8.5g/m2。
4.根据权利要求3所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,当所述吸波层包含一种所述吸波纤维长度时,所述吸波纤维长度为0.5~30mm中的一个固定长度;所述吸波纤维呈无规分布;
当所述吸波层包含不少于3种所述吸波纤维长度时,所述吸波纤维长度为0.5~30mm中对应的长度,相邻两个所述吸波纤维长度相差不大于2mm,且所述吸波纤维长度呈梯度分布;所述吸波纤维呈无规则等量分布;
当所述吸波层的所述吸波纤维长度呈中心正态分布时,所述中心吸波纤维长度为0.5~30mm中的一个固定长度,其它所述吸波纤维长度不少于三个长度,相邻两个所述吸波纤维长度相差不大于2mm。
5.根据权利要求1所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,所述单层吸波层厚度为40~3000μm,所述单层吸波层的平方米克重不大于50g/m2。
6.根据权利要求5所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,所述介质层介电常数为2.1~4.7;所述介质层厚度为0.5~12mm,每层所述介质层厚度通过电磁仿真模拟与对应所述吸波层厚度相匹配。
7.根据权利要求1所述的基于短切吸波纤维无序分布的吸波材料,其特征在于,所述单层介质层的重量不大于500g/m2;所述吸波体的重量不大于2000g/m2。
8.一种基于短切吸波纤维无序分布的吸波材料制备方法,其特征在于,应用于权利要求1~7任一项所述的基于短切吸波纤维无序分布的吸波材料,所述制备方法包括:
S1,制备所述吸波层;
S2,先分别形成所述吸波层和所述介质层,再通过粘合剂将所述介质层和所述吸波层复合形成所述基于短切吸波纤维无序分布的吸波材料,或,先形成第1层介质层,再通过粘合剂粘合形成第1层吸波层,逐层粘接,直到形成第n层吸波层和第n层介质层,粘接得到所述基于短切吸波纤维无序分布的吸波材料。
9.根据权利要求8所述的基于短切吸波纤维无序分布的吸波材料制备方法,其特征在于,所述制备所述吸波层,包括:湿法成网法、干法成网法或喷涂树脂粘合法;
所述湿法成网法利用吸波纤维与普通纤维混合成纤维悬浮浆,输送到成网机构,加固成布,热粘合或针刺、水刺加固无纺布得到所述吸波层;
所述干法成网法利用吸波纤维与普通纤维混合,机械打击处理得到均匀混合的纤维层;将所述纤维层铺设成网,热粘合或针刺、水刺加固纤维层,得到所述吸波层;
所述喷涂树脂粘合法将吸波纤维裁切成相应长度,与粘合剂混合后进行喷涂得到所述吸波层;或将吸波纤维长丝通过喷涂机的纤维切割器裁切成相应长度,与粘合胶料在喷出的过程中均匀混合,得到所述吸波层。
10.根据权利要求8所述的基于短切吸波纤维无序分布的吸波材料制备方法,其特征在于,所述织物为粘胶纤维、聚酯纤维、尼龙纤维、纤维素纤维、聚丙烯纤维、聚乙烯纤维和棉纤维的一种或几种;所述高聚物为环氧树脂、聚四氟乙烯、尼龙和聚氯酯的一种或几种;所述粘合剂为聚氯酯、聚丙烯酸树脂、聚硫橡胶、硅橡胶、氯丁橡胶、丁基橡胶、环氧树脂、不饱和聚酯树脂、酚醛树脂和聚氯乙烯树脂中的一种或几种。
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