CN117601514A - 一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法 - Google Patents

一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法 Download PDF

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CN117601514A
CN117601514A CN202311560471.3A CN202311560471A CN117601514A CN 117601514 A CN117601514 A CN 117601514A CN 202311560471 A CN202311560471 A CN 202311560471A CN 117601514 A CN117601514 A CN 117601514A
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conductive
composite material
yarns
metal
carbon fiber
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益小苏
蒋民强
刘晓玲
王鑫
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University of Nottingham Ningbo China
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Abstract

本发明公开了一种导电、雷击防护、电磁屏蔽一体化复合材料，包括导电增强体、表面防护层和树脂基体，所述导电增强体采用导电织物层合成，导电织物由导电纬纱和碳纤维经纱编织而成；所述表面防护层与导电增强体通过树脂基体结合为整体。本发明还提供一种复合材料的制备方法，具体为：步骤S1，将导电纱线与碳纤维编织成导电织物；步骤S2，将导电织物在树脂体系中浸渍，再除去多余的树脂并烘干制备成导电织物预浸料；步骤S3，将导电织物预浸料裁剪后在模具上依次铺层，制备成预成形体；步骤S4，将表面防护层贴敷在预成形体上并压实；步骤S5，封装模具，并抽气形成负压；步骤S6，固化；步骤S7，冷却后将成型品与模具分离，获得复合材料结构件。

Description

一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法
技术领域
本发明涉及功能性复合材料技术领域，具体是一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法。
背景技术
碳纤维增强聚合物基复合材料(Carbon Fiber Reinforced PolymerComposites,CFRP)是一种性能优异的结构材料，其具有比强度高、比模量大、抗疲劳、耐腐蚀性能好等优点，正越来越多地应用在航空器结构中。复合材料在航空器中的大量应用可以有效地减轻飞机重量，降低燃油消耗，减少二氧化碳排放，提高经济效益。目前复合材料在波音787梦想客机中和空客A350客机中的质量占比均已达到其总质量的50％。然而，复合材料由于其树脂基聚合物的本征电绝缘性，电导率远远低于铝合金等金属材料，特别是材料厚度方向的电导率极低，通常仅有10-4-10-2S/m左右。复合材料的低导电性能使得其不能满足航空器对电气整体性、雷击防护、电磁屏蔽等性能的要求，严重威胁飞行安全。因此，提高复合材料的导电性能，使其在结构轻量化的基础上能同时提供足够的导电、雷击防护和电磁屏蔽性能对于复合材料在航空器中的应用便显得由为重要。
针对复合材料的电导率低，无法满足航空器电气整体性设计要求的问题，现有的技术方案是在机身复合材料结构外部额外安装许多金属冗余部件以连接航空器各个部分，从而形成一个完整的满足要求的电气结构网络。这不可避免地增加了航空器的重量，提高了制造和维护成本，降低了经济效益。另一种改善复合材料导电性能的技术路线是设法提高复合材料固有的导电性能，特别是厚度方向的导电性能。目前有多种方法可以实现这一目标，包括导电填料改性树脂、本征导电聚合物、导电插层改性等。上述导电增强方案可以通过增强各个方向的电流分散能力来提高复合材料层合板的雷击损伤容限。然而，上述方案均聚集于对复合材料基体或复合材料层间结构的导电改性，没有从厚度方向上打破碳纤维织物增强体的阻隔，构建出兼具高厚度方向电导率和高面内方向电导率的导电网络体系。
针对复合材料雷击防护能力不足，航空复合材料结构的现有雷击防护方案是在复合材料结构之外采用附加的导电层，该导电层可以通过自身耗散电流以保护内部的复合材料结构。现有多种材料体系已被用作附加的导电层，包括金属网或金属箔、金属导电涂层、非金属结构以及金属/非金属混合材料结构。这些现有的结构可以基本满足复合材料对雷击防护的单一需求，但无法满足对电气整体性的要求，复合材料整体的导电性能仍然需要进一步地提高。
发明内容
本发明要解决的技术问题就在于：本发明提供一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法。
为解决上述技术问题，本发明提出的技术方案为：
一种导电、雷击防护、电磁屏蔽一体化复合材料，所述复合材料包括导电增强体、表面防护层和树脂基体，所述导电增强体采用导电织物层合成，导电织物由导电纬纱和碳纤维经纱编织而成；所述表面防护层与导电增强体通过树脂基体结合为整体。
作为上述技术方案地进一步改进为：
进一步地，所述导电纬纱选用纳米金属线、镀金属聚合物纱线、镀金属碳纤维纱线、碳纳米管纱线中一种或多种，金属是银、铜、镍、金、铝中一种或多种。
进一步地，所述表面防护层材质是金属延展网、金属编织网、镀金属导电聚合物无纺布、镀金属碳纤维无纺布、碳纳米管改性碳纤维毡、石墨烯改性碳纤维毡、MXene改性碳纤维毡中的一种或多种。
进一步地，所述树脂基体是不饱和聚酯树脂、环氧树脂、酚醛树脂、聚酰亚胺树脂、聚醚醚酮、聚醚酰亚胺、聚酰胺中的一种或多种。
本发明还提供了一种复合材料的制备方法，包括以下步骤：
步骤S1，将导电纱线与碳纤维编织成导电织物，导电纱线作为纬纱，碳纤维丝束作为经纱；
步骤S2，将编织的导电织物在树脂体系中浸渍，再除去多余的树脂并烘干，制备成导电织物预浸料备用；
步骤S3，将导电织物预浸料裁剪后按照设计的铺层顺序在模具上依次铺层，制备成预成形体；
步骤S4，将一层或多层表面防护层贴敷在制备好的预成形体的上层并压实；
步骤S5，封装装有导电增强体和表面防护层的模具，并抽气形成负压；
步骤S6，将装有预成形体的模具进行固化；
步骤S7，固化结束冷却后将成型品与模具分离，获得复合材料结构件。
本发明提供的导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法，与现有技术相比有以下优点：
(1)本发明导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法，实现了高导电性、防雷击和电磁屏蔽三项功能的有机结合，导电增强体内的导电纬纱可以在复合材料内部构建出完全连通的导电网络，实现了复合材料在厚度方向与面内方向上整体的高导电性，可以满足航空器电气结构完整性的设计要求。
(2)本发明导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法，表面防护层的高导电性可以在复合材料的外表面构建出充足的导电通路，满足航空器结构复合材料对雷击防护和电磁屏蔽的设计要求。导电增强体和表面防护层在复合材料中构成了一个完整的多功能的结构，材料各组分发挥协同作用，内外导电网络使导电、防雷击与电磁屏蔽性能互相增强。
(3)本发明导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法，采用协同增效原理，既实现了复合材料的多功能一体化设计，又保持了便捷的制造工艺，预期在性能和成本上均有优势，具有明显的创新性和进步性，可广泛用于航空航天等领域。
附图说明
图1是本发明复合材料的横截面结构示意图。
图2是本发明实施例1中复合材料的样品图。
图3是本发明实施例1中复合材料雷击测试后损伤图。
图4是本发明中实施例1中复合材料的导电性能图。
图5是本发明中实施例1中复合材料的电磁屏蔽性能图。
具体实施方式
以下对本发明的具体实施方式进行详细说明。应当理解的是，此处所描述的具体实施方式仅用于说明和解释本发明，并不用于限制本发明。
图1示出了本发明导电、雷击防护、电磁屏蔽一体化复合材料的一种实施方式，复合材料由导电增强体、表面防护层和树脂基体构成。
导电增强体采用导电织物层合成，导电织物由导电纬纱和碳纤维经纱编织而成，其中导电纬纱选用纳米金属线、镀金属聚合物纱线、镀金属碳纤维纱线、碳纳米管纱线的一种或多种，金属可以是银、铜、镍、金、铝等的一种或多种。导电纬纱在复合材料内部构建立体导电网络，实现材料在厚度方向和面内方向的高导电性。
表面防护层材质是金属延展网、金属编织网、镀金属导电聚合物无纺布、镀金属碳纤维无纺布、碳纳米管改性碳纤维毡、石墨烯改性碳纤维毡、MXene改性碳纤维毡等中的一种或多种。
树脂基体是不饱和聚酯树脂、环氧树脂、酚醛树脂、聚酰亚胺树脂、聚醚醚酮(PEEK)、聚醚酰亚胺(PEI)、聚酰胺(PA)中的一种或多种。表面防护层与导电增强体通过树脂基体结合为一个整体，协同实现了复合材料在厚度和面内方向的高导电性以及复合材料对雷击的防护和对电磁波的屏蔽。
本发明复合材料的制备方法，包括如下步骤：
步骤S1，将导电纱线与碳纤维编织成导电织物，导电纱线作为纬纱，碳纤维丝束作为经纱。
步骤S2，将编织好的导电织物在树脂体系中浸渍，充分浸渍后经挤压辊除去多余的树脂并烘干，制备成导电织物预浸料备用。
步骤S3，将导电织物预浸料裁剪成矩形，按照设计的铺层顺序在模具上依次铺层，制备成预成形体。
步骤S4，将一层或多层表面防护层贴敷在制备好的预成形体的最上层并用辊轮压实。
表面防护层铺设1层、2层或更多层都可以，2层的雷击防护效果优于1层。由于飞机机身各部位遭受雷击的概率差异明显，故对雷击防护的要求也不一致。因此，可以根据实际需求选择合适的表面防护层层数。
步骤S5，使用真空薄膜封装装有导电增强体和表面防护层的模具，用真空泵抽气形成负压。
步骤S6，将装有预成形体的模具置入热压罐中，控制温度、压力和时间进行固化。
步骤S7，固化结束后，冷却降压至常温常压，将成型品与模具分离，即可获得所需的导电、雷击防护、电磁屏蔽一体化复合材料结构件。
实施例1
步骤S1，将镀金属聚合物纱线与碳纤维编织成平纹导电织物，镀金属聚合物纱线作为纬纱，纬纱密度为26根/10cm，碳纤维丝束作为经纱，经纱密度为36根/10cm。
步骤S2，将编织好的导电织物在中温固化环氧树脂体系中浸渍，充分浸渍后经挤压辊除去多余的树脂并烘干，制备成导电织物预浸料备用。
步骤S3，将导电织物预浸料裁剪成尺寸为400×400mm2的矩形，采用[0/90]4的铺层顺序在模具上依次铺层，制备成预成形体。
步骤S4，将两层镀金属导电聚合物无纺布贴敷在制备好的预成形体的最上层并用辊轮压实。
步骤S5，在预成形体的四周包裹一圈金属延展铝网用作雷击测试过程中的接地电极。
步骤S6：使用真空薄膜封装装有增强体和镀金属导电聚合物无纺布的模具，用真空泵抽气形成负压。
步骤S7：将装有成型材料的模具置入热压罐中，控制温度、压力和时间进行固化。首先以0.5bar/min的速率加压至7.0bar，随后以2℃/min的速率升温至130℃，并保温120min。
步骤8：固化结束后,以0.5bar/min的速率降压和3℃/min的速率冷却至常压常温，将成型品与模具分离，即可获得所需的导电、雷击防护、电磁屏蔽一体化复合材料结构件。
如图2至图5所示，所制备的导电、雷击防护、电磁屏蔽一体化复合材料结构件经过雷击电流放电测试后，复合材料的表面防护层呈现年轮状损伤，同时复合材料表面靠近导电增强体中导电纬纱的区域呈现有规律的平行断续线状损伤，但是复合材料基体的损伤极小，这表明了在表面防护层和导电增强体的协同作用下，复合材料具备优秀的雷击防护能力。同时，由于导电增强体中导电网络的作用，复合材料表现在厚度方向、面内垂直碳纤维方向，面内平行于碳纤维方向上均呈现出优异的导电性能，这表明复合材料具备优秀的整体导电性能。此外，由于表面防护层和导电增强体的协同作用，复合材料在测试的各频段上均呈现出90dB以上的高屏蔽效能，表明了复合材料具备优秀的电磁屏蔽性能。
实施例2
步骤S1，将镀金属聚合物纱线与碳纤维编织成平纹导电织物，镀金属聚合物纱线为纬纱，纬纱密度为30根/10cm，碳纤维丝束作为经纱，经纱密度为38根/10cm。
步骤S2，将编织好的导电织物裁剪成尺寸为300×300mm2的矩形，采用[0/90]2S的铺层顺序在模具上依次铺层，制备成预成形体。
步骤S3，将两层镀金属导电聚合物无纺布贴敷在制备好的预成形体的最上层并用辊轮压实。
步骤S4，在预成形体的四周包裹一圈金属延展铝网用作雷击测试过程中的接地电极。
步骤S5，使用真空薄膜封装装有增强体和镀金属导电聚合物无纺布的模具，用真空泵抽气形成负压。
步骤S6，利用负压将中温环氧树脂注入到装有增强体和镀金属导电聚合物无纺布的模具中。
步骤S7，将装有成型材料的模具置入热压机中，控制温度、压力和时间进行固化。加压至8.0bar，随后以2℃/min的速率升温至130℃，并保温120min。
步骤S8，固化结束后，随压机自然冷却至常压常温,将成型品与模具分离，即可获得所需的导电、雷击防护、电磁屏蔽一体化复合材料结构件。
所制备的导电、雷击防护、电磁屏蔽一体化复合材料结构件经过雷击电流放电测试后，复合材料的表面防护层呈现浅年轮状损伤，同时复合材料表面靠近导电增强体中导电纬纱的区域呈现有规律的平行断续线状损伤，但是复合材料基体的损伤极小，这表明了在表面防护层和导电增强体的协同作用下，复合材料具备优秀的雷击防护能力。同时，由于导电增强体中导电网络的作用，复合材料表现在厚度方向、面内垂直碳纤维方向，面内平行于碳纤维方向上均呈现出优异的导电性能，厚度方向电导率达49S/m，面内垂直碳纤维方向电导率达46506S/m，面内平行于碳纤维方向电导率达41164S/m，这表明复合材料具备优秀的整体导电性能。此外，由于表面防护层和导电增强体的协同作用，复合材料在测试的各频段上均呈现出90dB以上的高屏蔽效能，表明了复合材料具备优秀的电磁屏蔽性能。

Claims (5)

1.一种导电、雷击防护、电磁屏蔽一体化复合材料，其特征在于，所述复合材料包括导电增强体、表面防护层和树脂基体，所述导电增强体采用导电织物层合成，导电织物由导电纬纱和碳纤维经纱编织而成；所述表面防护层与导电增强体通过树脂基体结合为整体。
2.根据权利要求1所述的导电、雷击防护、电磁屏蔽一体化复合材料，其特征在于，所述导电纬纱选用纳米金属线、镀金属聚合物纱线、镀金属碳纤维纱线、碳纳米管纱线中一种或多种，金属是银、铜、镍、金、铝中一种或多种。
3.根据权利要求2所述的导电、雷击防护、电磁屏蔽一体化复合材料，其特征在于，所述表面防护层材质是金属延展网、金属编织网、镀金属导电聚合物无纺布、镀金属碳纤维无纺布、碳纳米管改性碳纤维毡、石墨烯改性碳纤维毡、MXene改性碳纤维毡中的一种或多种。
4.根据权利要求1所述的导电、雷击防护、电磁屏蔽一体化复合材料，其特征在于，所述树脂基体是不饱和聚酯树脂、环氧树脂、酚醛树脂、聚酰亚胺树脂、聚醚醚酮、聚醚酰亚胺、聚酰胺中的一种或多种。
5.一种复合材料的制备方法，其特征在于，用于制备权利要求1～4任一项所述的复合材料，包括以下步骤：
步骤S1，将导电纱线与碳纤维编织成导电织物，导电纱线作为纬纱，碳纤维丝束作为经纱；
步骤S2，将编织的导电织物在树脂体系中浸渍，再除去多余的树脂并烘干，制备成导电织物预浸料备用；
步骤S3，将导电织物预浸料裁剪后按照设计的铺层顺序在模具上依次铺层，制备成预成形体；
步骤S4，将一层或多层表面防护层贴敷在制备好的预成形体的上层并压实；
步骤S5，使用封装装有导电增强体和表面防护层的模具，并抽气形成负压制成预成形体；
步骤S6，将装有预成形体的模具进行固化；
步骤S7，固化结束冷却后将成型品与模具分离，获得复合材料结构件。
CN202311560471.3A 2023-11-22 2023-11-22 一种导电、雷击防护、电磁屏蔽一体化复合材料及其制备方法 Pending CN117601514A (zh)

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