CN1769561B - 聚合物粘结的纤维结块及其生产方法 - Google Patents
聚合物粘结的纤维结块及其生产方法 Download PDFInfo
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- CN1769561B CN1769561B CN2005101283259A CN200510128325A CN1769561B CN 1769561 B CN1769561 B CN 1769561B CN 2005101283259 A CN2005101283259 A CN 2005101283259A CN 200510128325 A CN200510128325 A CN 200510128325A CN 1769561 B CN1769561 B CN 1769561B
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Abstract
一种聚合物粘结的纤维结块,包含选自碳、陶瓷材料、玻璃、金属和有机聚合物中的短纤维,和选自合成树脂和热塑性塑料的聚合物胶粘树脂,其中,纤维结块在纤维方向上测量的平均长度为3mm-50mm,和在垂直于纤维方向测量的平均厚度为0.1mm-10mm,和所有所含纤维中的至少75%具有的长度为纤维结块平均长度的至少90%,并且不超过110%,用于生产纤维结块的工艺以及在纤维增强复合材料中的应用。
Description
技术领域
本发明涉及聚合物粘结的纤维结块,其制造方法以及在生产纤维增强复合材料中的使用。
背景技术
在制造纤维复合材料时,增强纤维通常使用长纤维(长丝和长丝纱)、短纤维、短纤维束或者片层结构(例如,机织织物、针织织物、毛圈针织物和无纺织物)。
尽管长丝的确定的取向目的用于长丝和长丝纱以及片层结构的加工(“长丝卷绕”,在成形和固化的模具中,树脂或热塑性塑料浸渍的机织物或毡或其它的片状结构的铺层),通常用短纤维增强的材料都有一个受加工方法影响的取向(在注射模塑或挤压成型的模具中由流动引起的短纤维的排列)和由材料生产(例如,在由粗纱也就是长丝束牵伸,在混合捏合机或挤出机中的纤维增强热塑性塑料的制造中)决定的纤维长度分布。
纤维增强材料的机械性能也是纤维长度和纤维长度分布的函数。
在短纤维增强的材料的制造中,纤维长度和其分布的可控选择,至今还不易实现。例如,通过使用磨碎的纤维或纤维束的筛网级分,可以以可控方式建立纤维束长度分布和宽度分布的范围;但是,使用具有不适合预定目的的纤维长度的级分带来一些问题,并且在某些环境下,不适合的级分必需被抛弃,或者纤维只能不完全实现它们预定的增强效果。
发明内容
本发明的目的是,提供一种工艺,利用该工艺,能够以可控的方式生产具有可调节纤维长度和长度分布的短纤维结块,所述纤维结块的长度分布尽可能地集中并且可以被选择。为了生产短纤维结块,结块中所含的纤维平均数量也具有重要性,这个“结块厚度”也应该在可控的生产工艺中能够被重复调节。
因此,本发明涉及聚合物粘结的纤维结块,所述纤维结块包含选自碳、陶瓷材料、玻璃、金属和有机聚合物的短纤维,和选自合成树脂(热固性树脂)和热塑性塑料的聚合物胶粘树脂,其中,纤维结块在纤维方向上测量的平均长度为3-50mm,和垂直于纤维方向测量的平均厚度为0.1-10mm,并且所有所含纤维中的至少75%的纤维具有的长度为平均纤维结块长度的至少90%,并且不超过 110%。
本发明还涉及包含纤维块和选自合成树脂和热塑性塑料的聚合物的聚合物粘结纤维结块的生产工艺,包括步骤:
-用液体或粉状的合成树脂或者液体或粉状的热塑性塑料浸泡长丝纱形成浸渍的长丝束;
-将浸渍的长丝束压到在平行方向上取向的长丝铺置材料上;
-在使用合成树脂时,通过热处理使合成树脂固化;
-将被压平的长丝束冷却;
-将长丝束切割到规定宽度和长度。
优选地,至少工艺步骤之一,特别优选的是上述所有工艺步骤都被连续地执行。
本发明还涉及用短纤维根据本发明制造的聚合物粘结纤维结块在短纤维增强的材料组分,尤其是用短纤维增强的陶瓷材料生产中的使用。
本发明还涉及包含纤维结块的纤维增强复合材料,所述纤维结块在纤维方向上测量的平均长度为3-50mm,和在垂直于纤维方向测量的平均厚度为0.1-10mm,其中,所有所含纤维中的至少75%具有的长度为纤维结块平均长度的至少90%,并且不超过110%。
本发明还涉及一种工艺,根据该工艺,被压平成狭带的聚合物粘结长丝束,在被切断之前在优选800℃以上的温度通过热处理去除氧化物质被碳化,胶粘树脂被转化成碳,其中所使用的长丝可以是碳、高熔点的金属或陶瓷材料的长丝。此后,优选的可以有一个额外的步骤,其中在碳化的狭带上涂覆沥青,之后涂覆了沥青的狭带可以被再次碳化,沥青被转化成碳。作为可供选择的一个步骤或者该步骤之后,碳化狭带可进一步用沥青或可碳化的聚合物通过筛网印花工艺或者应用滚筒来涂覆,这些涂层组合物也可以包含填充物,例如,粉末陶瓷材料或碳粉或金属粉末;碳粉和石墨粉,碳化硅和氮化硅碳化硼粉末,还有硅的粉末和硅与其它金属的合金,例如,铁、铬、钼和其它的形成碳化物的元素。优选的是,这个任选过程中的单个步骤或所有的步骤可以被连续执行。
本发明还涉及制造纤维增强陶瓷复合材料的生产工艺,该工艺除包括上述步骤之外,还包括
-纤维结块与可碳化的聚合物的混合,
-在压力和升高的温度下形成混合物,得到成形制品,
-加热成形制品以去除氧化物质,形成具有碳基质的纤维增强的多孔体,
-用一种或多种形成碳化物的元素的熔体渗透多孔碳体,和将至少基质中的一些碳转化成碳化物。
在本文中,“可碳化的聚合物”是指聚合物加热到至少800℃以上以去除氧化物质后形成碳渣,其重量是所用聚合物重量的至少20%。
硅优选用作形成碳化物的元素,或者硅与选自铁、镍、钴、铜、铬、钼、钒、铝、锰和钨的金属的合金。
优选的是,聚合物粘结的纤维结块有一个与长度L和宽度W的给定值之间的长度标准偏差sL和宽度标准偏差sW,最多sL=0.1*L,sW=0.1*W。
更优选的聚合物粘结的纤维结块的长宽比从2∶1至100∶1,特别优选的是从4∶1至50∶1。
选择用作为胶粘树脂的热塑性和热固性树脂,使它们可被塑化加工的温度远低于长丝软化温度。因此,例如,对于粘结聚酯长丝(聚对苯二甲酸乙二醇酯)或聚酰胺长丝(PA6或PA66)来说,除了低熔点的酚醛树脂外,还使用低熔点的热塑性塑料,例如聚酰胺11或聚酰胺12或乙烯/醋酸乙烯酯共聚物。凝胶纺丝的高强度聚乙烯长丝能够只用在低温就已经固化的热固性树脂有利地粘合。对于碳、陶瓷材料、玻璃或金属的长丝,这些注意事项当然不太重要。
优选实施该工艺使得纤维结块中的纤维层数最多为三层,优选的是不超过两层,特别优选的是接近一层。这可以通过在浸渍或浸泡前使长丝束成扇形散开和选择压制压力来确保。在这个过程中,通过吹送气体,优选的为加热气体,在此未处于张力下的长丝束分裂成单个长丝,然后被并排引导绕过一个罗拉或一个导丝盘。
在用聚合物浸泡前,优选的是,长丝束通过洗涤和干燥或热处理来摆脱粘结。然后,长丝束经过转向导辊进入合成树脂或热塑性塑料的熔体或溶液浴中,或者也可以引导例如通过吹送压缩空气使成扇形散开的长丝束穿过合成树脂粉末或热塑性粉末的流化床。如果吹送步骤是用的加热气体,粉末可以特别好地粘附在长丝上。
在浸泡或浸渍之后,长丝束被引导经过滚压机、砑光机或者带式压机或其它的合适的连续压紧装置。在这个压紧装置中,过量的聚合物优选通过几个连 续安置的用于减少内部宽度的罗拉钳口从长丝束挤压出,并且,丝束被压制到优选只形成一个长丝基本平行运行的纤维层。压紧是在热状态下进行的,在该状态下,热塑性塑料仍然可以流动,因此,可以使长丝均匀弄湿。在所述热压过程中合成l树脂已经开始凝固,因此加热区将与特殊的材料相匹配。
在罗拉钳口处,还可以优选地冷却扁平的粘结长丝束。当离开滚压机或者带式压机时,长丝束呈扁平的单向狭带的形式(“UD带”)。
这些狭带优选通过尸个切断辊或几个并排的切断辊在纵向上被切成所需的宽度。也可以在还没有完全凝固的状态,通过在狭带路径上被张紧的金属丝切断狭带。
在离开纵向上的切断装置后,在该装置中,狭带被分割成规定的宽度,材料传送入—个长度切断装置,优选的是该装置也被连续操作。此外,也可以在具有不同的狭带速度的独立的过程中,实现长度的切割;为了这个目的,被切割成选定宽度的狭带被卷绕在筒管上然后被传送到长度切割装置。
用来切割狭带到所需长度的连续工艺优选地用刀片辊执行。
狭带的切断件,即纤维结块被装入适当的容器,传送到后续使用。
根据本发明的工艺可以用简单的和可重复的方式生产舰定宽度和长度的纤维结块。通过压除聚合物粘合剂和建立薄层,优选的为单层,也即,纤维结块的高度几乎和单个长丝的直径相当,保留在纤维结块中的聚合物粘舍剂的数量可以非常低。
用于生产用短纤维增强的材料时,这些规定长度和宽度的纤维结块可以作为单一的品种或可以各种长度或宽度混合使用。通过选择合适的聚合物粘合剂,可以确保当纤维结块与基质材料或者在陶瓷材料情况下为陶瓷材料前体混合时,纤维结块不会产生破坏,或者破坏不太显著。也可以用这种方式确保,增强纤维有—致的长度和强度;在不同的纤维结块的混合物情况下,它们纤维的长度分布或厚度分布的范围,可以同样地以受控方式进行调节。
高耐热的纤维,例如碳或陶瓷材料纤维当然也可以被用于增强陶瓷材料。
用下述实施例来说明增强纤维束的这些固定规格(长度、宽度和厚度)的材料的优点。
实施例
用于生产120cm宽的长丝狭带时,48支 C30T060 BPY(SGL Technic Ltd.制造)长丝束通过膜传输工艺平行地用酚醛树脂 N 1203,Cary Valley)浸泡,然后加热预稳定。单个长丝束之间的距离是10mm。树脂浸泡过的长丝束被卷绕在具有中间纸层的卷芯板上。
在接下来的步骤中,借助双皮带式压机将长丝网压缩到规定的130μm厚度。同时,树脂被加热到180℃发生凝固,保持长丝狭带的尺寸稳定性。为此,经加热预稳定的长丝狭带通过退绕站被引导入带式压机。在这个过程中,长丝带之间的空当由流动分离的长丝/树脂带填充。由此形成130μm均匀厚度的连续的长丝片层。用切割装置将这个长丝片层切割成长12mm、宽1.5mm规定的纤维结块。
被切割到规定尺寸的500g这种纤维结块与300g酚醛树脂 N 1203)和200g KS6石墨(天然石墨粉)在Eirich的混合机中以200转/分的旋转速度混合。在混合5分钟以后,混合容器被倒空。截面为160mm×160mm的压制模具由压制组合物填满。填充的模具中的材料被压缩到密度为1.2g/cm3,在180℃下在Joos压机中固化。
用这种方法获得的挤压制品在900℃氮气氛中被热解。冷却后,得到多孔C/C体(用碳纤维增强的多孔碳),在下面的步骤中,在1550℃,在大约10hPa(10mbar)的低压下,用液态硅经多孔C/C芯渗透。用这种方法得到的密度为2.3g/cm3的C/SiC材料(基质中含有碳化硅、硅和没有反应的剩余的碳,增强碳纤维基本保持不变)的性质具有高强度和高断裂伸长。在弯曲试验中测得强度为110MPa-120Mpa,伸长0.3%-0.4%。
复合材料中的纤维长度的均匀分布对强度和伸长具有有利影响,而通常的复合材料中,强度的提高只能以牺牲伸长为代价,伸长增加,强度下降。
在本文中已经证明比较有利的是,复合材料中增强纤维的平均长度在5mm-40mm之间,优选的在8mm-30mm之间,更优选的在10mm-25mm之间,增强纤维重量的至少为90%具有的长度在平均纤维长度的90%-110%之间。这种纤维长度分布也被称为“规定纤维长度”。纤维结块厚度同样被确定也已经被证明是有利的,也就是说,所有被包含的纤维的至少90%具有的厚度是纤维结块平均厚度的90%-110%。纤维结块的平均厚度在此优选的在0.2mm-5mm之间,特别优选的在0.5mm-4mm之间,特别的在0.8mm-3mm之间。
这种具有规定长度和厚度的窄分布的短纤维结块用现有技术是得不到的。
Claims (12)
1.一种聚合物粘结的纤维结块,包含选自碳、陶瓷材料、玻璃、金属和有机聚合物中的短纤维,和选自合成树脂和热塑性塑料的聚合物胶粘树脂,其中,纤维结块在纤维方向上测量的平均长度为3mm-50mm,和在垂直于纤维方向测量的平均厚度为0.1mm-10mm,所有所含纤维中的至少75%具有的长度为纤维结块平均长度的至少90%,并且不超过110%,其特征在于,最多有三层纤维层。
2.根据权利要求1所述的聚合物粘结的纤维结块,其特征在于,它们的长宽比从2∶1至100∶1。
3.根据权利要求1所述的聚合物粘结的纤维结块,其特征在于,含有碳纤维。
4.生产如权利要求1所述的聚合物粘结的纤维结块的工艺,包括下述步骤
-用液体或粉状的合成树脂或者液体或粉状的热塑性塑料浸泡长丝纱以形成浸渍的长丝束;
-将浸渍的长丝束压到在平行方向上取向的长丝铺置材料上;
-在使用合成树脂时,通过热处理使合成树脂固化;
-将被压平的长丝束冷却;
-将长丝束切割到规定的宽度和长度。
5.根据权利要求4所述的工艺,其特征在于,至少工艺步骤之一是被连续执行的。
6.根据权利要求4所述的工艺,其特征在于,在浸渍或浸泡前,通过吹送气体使长丝束成扇形散开。
7.根据权利要求4所述的工艺,其特征在于,在切断前,被压平成狭带的长丝束通过加热去除氧化物质而被碳化。
8.根据权利要求7所述的工艺,其特征在于,被碳化的狭带用沥青涂覆和之后再被碳化。
9.根据权利要求7或8所述的工艺,其特征在于,被碳化的狭带用可碳化的聚合物或沥青涂覆,也可以另外用选自碳粉、陶瓷粉末和形成碳化物的元素的粉末的填充料,与可碳化的聚合物或沥青一起施用或在用可碳化的聚合物或沥青涂覆之后施用。
10.根据权利要求7或8所述的工艺,其特征在于,至少步骤之一是连续 执行的。
11.根据权利要求9所述的工艺,其特征在于,至少步骤之一是连续执行的。
12.一种生产纤维增强陶瓷复合材料的工艺,包含权利要求4或9所述的步骤,还包括:
-纤维结块与可碳化的聚合物混合,
-在压力和升高温度下形成混合物,以得到成形制品,
-加热成形制品以去除氧化物质,形成具有碳基质的纤维增强多孔体,
-用一种或多种形成碳化物的元素的熔体渗透多孔碳体,至少基质中的一些碳转化成碳化物。
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