WO2014015805A1 - 复合纤维布、其应用和应用方法 - Google Patents

复合纤维布、其应用和应用方法 Download PDF

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Publication number
WO2014015805A1
WO2014015805A1 PCT/CN2013/080064 CN2013080064W WO2014015805A1 WO 2014015805 A1 WO2014015805 A1 WO 2014015805A1 CN 2013080064 W CN2013080064 W CN 2013080064W WO 2014015805 A1 WO2014015805 A1 WO 2014015805A1
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Prior art keywords
cloth
polypropylene
layer
composite fiber
fiberglass
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PCT/CN2013/080064
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English (en)
French (fr)
Inventor
姚雷
Original Assignee
深圳市科聚新材料有限公司
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Publication of WO2014015805A1 publication Critical patent/WO2014015805A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure

Definitions

  • the invention belongs to the field of engineering plastics, and in particular relates to a composite fiber cloth, its application and application method.
  • Polypropylene is a semi-crystalline material with the advantages of non-toxicity, odorlessness and low density. Its strength, rigidity and hardness are better than low-pressure polyethylene and can be used at around 100 degrees. It has good electrical properties and high-frequency insulation, and is not affected by humidity. It is suitable for general mechanical parts, corrosion-resistant parts and insulating parts. Common acid and alkali organic solvents have little effect on it and can also be used in food utensils.
  • the modified PP products have strong competitiveness in the automotive industry, but because of their low modulus and heat resistance, the impact strength is poor, so they cannot be directly used as auto parts.
  • the modified PP products are used in cars. It is modified by filling with reinforcing materials such as glass fiber or flame retardant. Its heat resistance can be increased from 80 °C to 145 °C ⁇ 150 °C, and it can withstand high temperature for 750 ⁇ 1000h without aging. Not cracked.
  • the glass fiber in such reinforcing materials usually exists in the shape of chopped fibers, and its mechanical properties are greatly different from those in its long continuous form, which limits the improvement of the performance of the parts, and the application field is limited.
  • a composite fiber cloth comprising a first polypropylene cloth layer, a fiberglass cloth layer and a second polypropylene cloth layer laminated in this order, the first polypropylene cloth layer according to the weight of the composite fiber cloth.
  • the sum of the weight percentage of the second polypropylene cloth layer is 30-50%, and the weight percentage of the fiberglass cloth layer is 50-70%; wherein the weight ratio of the first polypropylene cloth layer to the second polypropylene cloth layer is 1 : 1-2: 1 ,
  • the fiberglass cloth layer is the fiberglass cloth layer after the surface treatment of the coupling agent.
  • the composite fiber cloth is cut according to the shape of the mold, and placed in a predetermined product mold; the composite fiber cloth is subjected to hot melt molding treatment, and the process conditions of the hot melt molding treatment are: pre-pressing temperature: 190-200 ° C, pre- Pressing time 30-60s, pre-pressing pressure 3-7MPa; holding pressure 200-210 °C, holding time 30-119s, holding pressure 7-19MPa, deflation times 3-7 times; setting temperature 200-210 ° C, holding time 60-139s, holding pressure 7-19MPa.
  • the glass fiber has a long continuous structure by using a fiberglass cloth, so that the mechanical strength of the glass fiber is well preserved, and the composite fiber cloth is excellent by using polypropylene cloth and fiberglass cloth.
  • the weight percentage of polypropylene cloth and fiberglass cloth ensure that the polypropylene cloth can be completely infiltrated into the glass fiber after hot melting in the later application, while maintaining the uniform distribution of resin and fiber in the workpiece.
  • the application method of the composite fiber cloth of the present invention by applying the composite fiber cloth of the present invention, the application field of the composite fiber cloth can be expanded, and in particular, for some products requiring a complicated structure mold, it can also be applied.
  • Figure 1 is a schematic view showing the structure of a composite fiber cloth according to an embodiment of the present invention.
  • FIG. 1 shows the structure of a composite fiber cloth comprising a first polypropylene cloth layer 1, a fiberglass cloth layer 3 and a second polypropylene cloth which are sequentially laminated according to an embodiment of the present invention.
  • the weight ratio of the first polypropylene cloth layer 1 and the second polypropylene cloth layer 2 is 30-50%, and the weight percentage of the fiberglass cloth layer 3 is 50-70%;
  • the weight ratio of the first polypropylene cloth layer 1 and the second polypropylene cloth layer 2 is 1:1-2:1, and the fiberglass cloth layer is a fiberglass cloth layer which has been surface-treated by a coupling agent.
  • the material of the composite fiber cloth mainly comprises polypropylene fiber (PP) and glass fiber
  • the polypropylene fiber can be woven into two polypropylene cloths of the same specification, and the glass fiber is woven into the same width of the fiberglass cloth.
  • the composite fiber cloth has a sandwich structure as a whole, and polypropylene cloth (first polypropylene cloth layer and second polypropylene cloth layer) is laminated on both sides of the fiberglass cloth (glass fiber cloth layer).
  • the polypropylene cloth and the fiberglass cloth can be obtained by themselves or commercially.
  • the total weight of the first polypropylene cloth layer 1 and the second polypropylene cloth layer 2 is 30% to 50% by weight of the composite fiber cloth, for example, 30%, 32%, 38%, 40%, 45 % or 47%, etc., preferably 30 to 40%, and the weight ratio of the first polypropylene cloth layer 1 to the second polypropylene cloth layer 2 is 1:1-2:1, preferably 1:1.
  • the weight of the glass fiber in the fiberglass cloth layer 3 is 50 to 70% by weight of the composite fiber cloth, for example, 55%, 59%, 64%, 68% or 70%, etc., preferably 60 to 70%.
  • the weight ratio of the total weight of the first polypropylene cloth layer 1 and the second polypropylene cloth layer 2 to the glass fiber is 3: 7-1:1, preferably 3:7 to 2:3.
  • the fiberglass cloth layer 3 is a fiberglass cloth layer which has been surface-treated by a coupling agent, and the surface treatment process can be applied: the glass fiber cloth is soaked into the aqueous solution of the coupling agent through a guide roller, and the concentration of the coupling agent aqueous solution is 1%; soaking time corresponds to different fiber surface densities, in 10 ⁇ 30 seconds In the case of high glass fiber content, the soaking time is long, and the degree of immersion of the guide roller and the speed of the guide roller are adjusted.
  • the fiberglass cloth layer 3 is combined with the resin fiber cloth to be dried to remove moisture. After the fiberglass cloth layer 3 is treated by the coupling agent, a coupling layer of a certain thickness is adhered to the fiber surface to improve the affinity between the resin and the fiber.
  • the mass of the coupling agent is within 0.2 to 0.7% of the total weight of the glass fiber.
  • the composite fiber cloth has a relative density of 1.43-1.58.
  • both the polypropylene fiber and the glass fiber are hook-shaped.
  • the polypropylene fibers selected for the first polypropylene cloth layer and the second polypropylene cloth layer have a relative density of 0.90-0.91 and a specification of 210D-800D, and can be selected from Dongguan Cainian Industrial Co., Ltd.
  • the fiberglass cloth is preferably a flame-retardant high-strength fiberglass cloth with a specification of 200 320 g/m 2 , and can be selected from the Russian gold basalt fiber company.
  • the coupling agent is preferably a silane coupling agent, preferably KH550, which can be selected from Shanghai Jinshan Chemical Co., Ltd.
  • the content of the coupling agent in the composite fiber cloth is controlled within 0.1 to 0.49%, and the coupling agent may also be selected from other silane coupling agents in the art.
  • the glass fiber is soaked in the coupling agent solution to make the surface of the glass fiber with a coupling agent.
  • the preparation method of the above composite fiber cloth is not limited.
  • the steps are as follows: a: The PP resin fiber is spun into a continuous cloth of an area specification such as a glass fiber cloth, and the mass ratio of the unit area is 3: 14-1 : 2 ;
  • Step S01 determining a target mold, and cutting the composite fiber cloth according to the shape of the mold, and placing it in a predetermined product mold;
  • Step S02 hot melt molding
  • the composite fiber cloth in the product mold is subjected to hot melt molding, and the process conditions of the hot melt molding process are as follows:
  • Molding The process can be carried out together with the mold, after which the pressure is cooled and cooled to room temperature to obtain the target part.
  • the target part mold is based on the applied product, for example, an automobile part mold, a tableware mold, and the like. Before the composite fiber cloth is placed in the mold, the composite fiber cloth is cut, so that the cut composite fiber cloth is consistent with the mold.
  • the composite fiber cloth used is as described in the foregoing embodiment, and will not be repeatedly described herein.
  • the weight percentage of the polypropylene fiber in the composite fiber cloth is 30-50%, the weight percentage of the glass fiber is 50-70%, especially the weight ratio of the polypropylene fiber to the glass fiber is 3: 7-1: 1.
  • the polypropylene fiber can be sufficiently wetted to the glass fiber to fully exert the reinforcing performance of the glass fiber, thereby imparting excellent mechanical properties to the target article.
  • the target article obtained by hot melt molding of the composite fiber cloth of the embodiment of the invention is low in cost and high in cost performance.
  • the composite fiber cloth according to the present invention has a simple implementation method and can be processed by a textile machine, and has lower heat demand and high production efficiency compared with the conventional twin-screw extruder.
  • the composite fiber cloth application method of the present invention by applying the composite fiber cloth of the embodiment of the present invention, the application field of the composite fiber cloth can be expanded, and in particular, for some products requiring a complicated structure mold, it can also be applied.
  • the glass fiber In the target part of the obtained glass fiber reinforced PP, the glass fiber has a long continuous structure, so that the mechanical strength of the glass fiber is well preserved.
  • thermosetting materials Compared with traditional thermosetting materials with the same processing method, the cost is lower, recycling and maintenance are more convenient, and there is more market prospect.
  • the 210D-size PP resin fiber is woven into a cloth, and the fiber cloth is a twill fabric having a warp and weft number of 69 g/m 2 ;
  • the fiberglass cloth is immersed in an aqueous solution of 1% KH550 coupling agent, and then guided by a roller guide to form a sandwich fabric with two layers of the above-mentioned specifications of PP fiber cloth in the middle of the PP fiber cloth on both sides, after which Through the process of pultrusion, leveling, drying, etc., the structure is flat, and finally the PP fiber is used to form a three-layer composite cloth structure to obtain a composite fiber cloth.
  • the glass fiber content is 70%.
  • the composite fiber cloth is cut according to the shape of the mold, and placed in a predetermined product mold, such as a car door, an engine cover, a trunk lid and the like, and the flat mold of 24*24*0.3cm is conveniently selected for testing performance;
  • the composite fiber cloth in the product mold is subjected to hot melt molding treatment.
  • the process conditions are: pre-pressing temperature 200 °C, pre-pressing time 30s, pre-pressing pressure 5MPa; holding temperature 200 °C, holding time 70s, holding pressure
  • the number of venting times of 17MPa is 5 times; the setting temperature is 210 °C, the holding time is 70s, and the holding pressure is 19MPa.
  • the pressure-resistant water was cooled to room temperature to obtain a target piece of reinforced continuous glass fiber fabric with a glass fiber content of 70%.
  • the 420D-size PP resin fiber is woven into a cloth, and the fiber cloth is a twill fabric having a warp and weft number of 106 g/m 2 ;
  • the fiberglass cloth is immersed in an aqueous solution of 1% KH550 coupling agent, and then guided by a roller guide to form a sandwich fabric with two layers of the above-mentioned specifications of PP fiber cloth in the middle of the PP fiber cloth on both sides, after which Through the process of pultrusion, leveling, drying, etc., the structure is flat, and finally the PP fiber is used to form a three-layer composite cloth structure to obtain a composite fiber cloth.
  • the composite fabric has a glass fiber content of 60%.
  • the composite fiber cloth is cut according to the shape of the mold and placed in a predetermined product mold; for example, a high-grade special safety box mold, the flat mold of 24*24*0.3cm is conveniently selected for testing performance;
  • the composite fiber cloth in the product mold is subjected to hot melt molding treatment.
  • the process conditions are: pre-pressing temperature 200 °C, pre-pressing time 30s, pre-pressing pressure 5MPa; holding temperature 200 °C, holding time 70s, holding pressure
  • the number of venting times of 17MPa is 5 times; the setting temperature is 210 °C, the holding time is 70s, and the holding pressure is 19MPa.
  • a method for preparing a composite fiber cloth according to the present invention is as follows:
  • the 800D PP resin fiber is woven into a cloth, and the fiber cloth is a twill fabric having a warp and weft number of 160 g/m 2 ;
  • the glass fiber cloth is immersed in an aqueous solution of 1% KH550 coupling agent, and then guided by a roller guide to form a sandwich fabric with two layers of PP fiber cloth of the above-mentioned specification to form a fiberglass cloth on the both sides of the PP fiber cloth, and then The process of pultrusion, leveling and drying is flat, and finally the PP fiber is used to form a three-layer composite cloth structure to obtain a composite fiber cloth.
  • the glass fiber content is 50%.
  • the composite fiber cloth is cut according to the shape of the mold and placed in a predetermined product mold, such as a decorative floor mold with complicated patterns.
  • a predetermined product mold such as a decorative floor mold with complicated patterns.
  • the flat mold of 24*24*0.3cm is conveniently selected for testing performance;
  • the composite fiber cloth in the product mold is subjected to hot melt molding treatment.
  • the process conditions are: pre-pressing temperature 200 °C, pre-pressing time 30s, pre-pressing pressure 5MPa; holding temperature 200 °C, holding time 70s, holding pressure
  • the number of venting times of 17MPa is 5 times; the setting temperature is 210 °C, the holding time is 70s, and the holding pressure is 19MPa.
  • the pressure-resistant water cooled to room temperature to obtain a target article with a glass fiber content of 50% continuous glass fiber reinforced fabric.
  • the preparation method of the composite fiber cloth of the present comparative example is as follows:
  • the 800D PP resin fiber is woven into a cloth, and the fiber cloth is a twill fabric having a warp and weft number of 160 g/m 2 ;
  • the fiberglass cloth is immersed in an aqueous solution of 1% KH550 coupling agent, and then formed under the guide roller machine with two layers of the above-mentioned two specifications of the same size PP fiber cloth to form a fiberglass cloth in the middle of the PP fiber cloth on both sides
  • the sandwich structure is then flattened by pultrusion, smoothing, drying, etc., and finally made of a three-layer composite fabric structure with PP fibers to obtain a composite fiber cloth.
  • the glass fiber content is 33%.
  • the application method of the composite fiber cloth of the present comparative example is as follows:
  • the composite fiber cloth is cut according to the shape of the mold and placed in a predetermined product mold, such as a large continuous sheet mold, and the flat mold of 24*24*0.3cm is conveniently selected for testing performance;
  • the composite fiber cloth in the product mold is subjected to hot melt molding treatment.
  • the process conditions are: pre-pressing temperature 200 °C, pre-pressing time 30s, pre-pressing pressure 5MPa; holding temperature 200 °C, holding time 70s, holding pressure
  • the number of venting times of 17MPa is 5 times; the setting temperature is 210 °C, the holding time is 70s, and the holding pressure is 19MPa.
  • the pressure-resistant water cooled to room temperature to obtain a glass fiber content of 33% continuous fiberglass fabric reinforced target parts.
  • the preparation process of the composite fiber cloth of the present comparative example is as follows:
  • the 210D-size PP resin fiber is woven into a cloth, and the fiber cloth is a twill fabric having a warp and weft number of 50 g/m 2 ;
  • the fiberglass cloth is immersed in an aqueous solution of 1% KH550 coupling agent, and then guided by a roller guide to form a fiberglass cloth with a two-layer PP fiber cloth of the same width and above in the middle, and the PP fiber cloth is sandwiched on both sides of the sandwich structure.
  • the structure is flat, and finally the PP fiber is used to make a three-layer composite cloth structure, and the composite fiber cloth has a glass fiber content of 76%.
  • the application method of the composite fiber cloth of the present comparative example is as follows: The conjugated fiber cloth is cut according to the shape of the mold, and placed in a predetermined product mold, such as a product mold such as a home appliance casing having fire protection requirements, the place is convenient for testing performance.
  • a predetermined product mold such as a product mold such as a home appliance casing having fire protection requirements
  • the composite fiber cloth in the product mold is subjected to hot melt molding treatment.
  • the process conditions are: pre-pressing temperature 200 °C, pre-pressing time 30s, pre-pressing pressure 5MPa; holding temperature 200 °C, holding time 70s, holding pressure
  • the number of venting times of 17MPa is 5 times; the setting temperature is 210 °C, the holding time is 70s, and the holding pressure is 19MPa. Keep the pressure of water cooling to room temperature, and obtain the glass fiber content at 76
  • the sample preparation is cut by a universal sampler to test the material properties.
  • the fiber-resin composite molding material has excellent strength, and the mechanical properties of the material are best when the glass fiber content is 70%, and the resin composite material having a glass fiber content of 50 to 70% can be very
  • the linear relationship between the good reaction performance and the glass fiber content indicates that the material properties are determined by the glass fiber content under the condition that the resin and the glass fiber are fully infiltrated.
  • Comparative Example 1 since the glass fiber content is too small, it is difficult to uniformly disperse the excess resin and the glass fiber, and the workpiece is easily broken at the resin enrichment first after the force is applied, thereby causing overall damage, and the The superior performance of the materials, and the high cost of the resin fiber, the higher the cost of textile processing and hot-melt processing, resulting in lower cost performance of the product parts; in contrast, 76% of the glass fiber composite material due to too little resin It is difficult to fully infiltrate the fiber, so that the product part is not subjected to resin dispersion stress in the insufficiently wetted part after the force is applied, so that the fiber first breaks, thereby destroying the integrity of the composite material, and the fracture is generated.
  • the composite material with a glass fiber content of 50 to 70% is the best ratio.

Landscapes

  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

一种复合纤维布，其应用和应用方法。该复合纤维布包括依次层叠的第一聚丙烯布层（1）、玻纤布层（3）和第二聚丙烯布层（2）。通过使用玻纤布使得玻纤为长连续结构，使玻纤机械强度得到很好的保存，通过采用聚丙烯布和玻纤布，使得复合纤维布具有优异的柔性。

Description

复合纤维布、 其应用和应用方法 技术领域
本发明属于工程塑料领域， 尤其涉及一种复合纤维布， 其应用和应 用方法。
背景技术
聚丙烯 （PP ) 是一种半结晶性材料， 其具有无毒、 无味， 密度小的 优点， 强度、刚度、硬度耐热性均优于低压聚乙烯,可在 100度左右使用。 具有良好的电性能和高频绝缘性， 且不受湿度影响， 适于制作一般机械 零件， 耐腐蚀零件和绝缘零件。 常见的酸、 碱有机溶剂对它几乎不起作 用， 也可用于食具。
PP 材料用于汽车工业具有较强的竟争力， 但因其模量和耐热性较 低， 冲击强度较差， 因此不能直接用作汽车配件， 轿车中使用的均为改 性 PP产品， 其通过填充玻璃纤维等增强材料或阻燃剂的方法对其性能 进行改性，其耐热性可由 80 °C提高到 145 °C ~ 150 °C ,并能承受高温 750 ~ 1000h后不老化、 不龟裂。 但这类加强材料中的玻纤通常以短切纤维形 态存在， 其力学性能与其长连续形态时相差很大， 使制件性能提高受到 了一定限制， 应用领域受到限制。
发明内容
依据本发明的一方面提供一种复合纤维布， 包括依次层叠的第一聚 丙烯布层、 玻纤布层和第二聚丙烯布层， 按该复合纤维布重量计， 第一 聚丙烯布层和第二聚丙烯布层的重量百分比总和为 30~50%, 玻纤布层 的重量百分比为 50~70%； 其中， 第一聚丙烯布层和第二聚丙烯布层的 重量比为 1 : 1-2: 1 , 玻纤布层为经过偶联剂表面处理后的玻纤布层。
依据本发明的另一方面提供上述复合纤维布在汽车轻量化配件、 餐 具、 家用电器、 建筑装潢材料或航海船舶中的应用。
依据本发明的另一方面提供上述复合纤维布的应用方法， 包括如下 步骤：
将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中； 将该复合纤维布进行热熔模压处理，该热熔模压处理的工艺条件为： 预压温度 190-200 °C , 预压时间 30-60s , 预压压力 3-7MPa; 保压温 度 200-210 °C , 保压时间 30-119s , 保压压力 7-19MPa, 放气次数 3-7次； 定型温度 200-210 °C , 保压时间 60-139s, 保压压力 7-19MPa。
依据本发明的复合纤维布，通过使用玻纤布使得玻纤为长连续结构， 使玻纤机械强度得到很好的保存， 通过釆用聚丙烯布和玻纤布， 使得复 合纤维布具有优异的柔性， 适于制作各种结构的制件模具； 通过选用上 述重量百分比的聚丙烯布和玻纤布， 保证聚丙烯布在后期的应用中经热 熔后能够完全浸润至玻纤之中，同时保持制件中树脂与纤维的分布均匀。 依据本发明的复合纤维布应用方法， 通过应用本发明复合纤维布， 能够 扩大复合纤维布的应用领域，特别是对于一些需要复杂结构模具的产品， 也能够应用。
附图说明
图 1是依据本发明的一种实施例的复合纤维布结构示意图。
具体实施方式
为了使本发明的目的、 技术方案及优点更加清楚明白， 以下结合附 图及实施例， 对本发明进行进一步详细说明。 应当理解， 此处所描述的 具体实施例仅仅用以解释本发明， 并不用于限定本发明。
请参阅图 1 , 图 1显示依据本发明的一种实施例的复合纤维布的结 构， 该复合纤维布包括依次层叠的第一聚丙烯布层 1、 玻纤布层 3和第 二聚丙烯布层 2 , 按该复合纤维布重量计， 第一聚丙烯布层 1和第二聚 丙烯布层 2的重量百分比总和为 30~50%, 玻纤布层 3的重量百分比为 50-70%; 其中， 第一聚丙烯布层 1和第二聚丙烯布层 2的重量比为 1 : 1-2: 1 , 玻纤布层为经过偶联剂表面处理后的玻纤布层。
本实施例中复合纤维布的材质主要包括聚丙烯纤维（PP )和玻璃纤 维， 聚丙烯纤维可纺织成等规格的两块聚丙烯布， 玻璃纤维纺织成同幅 宽的玻纤布。 该复合纤维布整体呈三明治叠合结构， 聚丙烯布 （第一聚 丙烯布层和第二聚丙烯布层）层叠在玻纤布 （玻纤布层） 两侧。 该聚丙 烯布和玻纤布可以自行纺织得到， 也可以从市面上购买得到。
其中， 第一聚丙烯布层 1和第二聚丙烯布层 2的总重量占该复合纤 维布的重量的百分比为 30~50%, 例如， 30%、 32%、 38%、 40%、 45% 或 47%等， 优选为 30~40%, 第一聚丙烯布层 1 和该第二聚丙烯布层 2 的重量比为 1 : 1-2: 1 , 优选为 1 : 1。 玻纤布层 3 中玻璃纤维的重量占复 合纤维布重量的百分比为 50~70%, 例如， 55%、 59%、 64%、 68%或 70% 等， 优选为 60~70%。 特别地， 第一聚丙烯布层 1 和第二聚丙烯布层 2 的总重量与该玻璃纤维的重量比为 3 : 7-1 : 1 , 优选为 3 :7~2:3。 通过选 用上述重量百分比的聚丙烯布层及玻璃纤维， 能够保证在后续的应用方 法中， 该聚丙烯布层能够充分的浸润至玻璃纤维中， 实现所得到的制件 的内应力大大减小， 有效防止了制件断裂、 变形、 翘曲的问题。 通过釆 用聚丙烯布和玻纤布的形式， 经过后续的热熔模压后， 使聚丙烯树脂和 玻璃纤维能够均匀分散， 实现制件的内应力进一步降低。
玻纤布层 3为经过偶联剂表面处理后的玻纤布层， 该表面处理的过 程可釆用： 将玻纤布通过导辊浸泡进偶联剂的水溶液中， 偶联剂水溶液 的浓度为 1%; 浸泡时间对应不同纤维面密度有所不同， 在 10~30秒之 间， 玻纤含量高则浸泡时间长， 由导辊浸入程度与导辊转速调节。 玻纤 布层 3与树脂纤维布复合后烘干除去水分。 玻纤布层 3经过偶联剂处理 后， 其纤维表面附着有一定厚度的偶联剂层， 改善了树脂与纤维间的亲 和性。 通过控制表面处理的时间， 使该偶联剂的质量占玻纤纤维总重量 的 0.2~0.7%之内。
该复合纤维布的相对密度为 1.43-1.58 , 该复合纤维布中， 聚丙烯纤 维和玻璃纤维均勾分布。
第一聚丙烯布层和第二聚丙烯布层所选用的聚丙烯纤维的相对密度 为 0.90-0.91 , 规格为 210D - 800D , 可以选用东莞彩年实业有限公司的 产品。
该玻纤布优选阻燃高强度玻纤布， 规格为 200 320 g/m2 , 可以选用 俄金玄武岩纤维公司的产品。
偶联剂优选为硅烷偶联剂， 优选为 KH550 , 可以选用上海锦山化工 有限公司的产品。 偶联剂占复合纤维布的含量控制在 0.1~0.49%之内， 偶联剂还可以选用本领域中其他的硅烷偶联剂。 玻纤布中， 玻璃纤维经 过偶联剂溶液浸泡处理过， 使玻璃纤维表面带有偶联剂。 通过在玻璃纤 维中引入偶联剂， 使得玻璃纤维和聚丙烯纤维经过后续的热熔模压处理 后， 两者之间的相容性大大增加， 冷却后两者之间的结合力显著增强。
上述复合纤维布的制备方法， 没有限制， 例如， 步骤如下： a: 将 PP树脂纤维纺成与玻纤布等面积规格的连续布， 二者单位面 积的质量比为 3 : 14-1 :2;
b : 将玻纤布用偶联剂的水溶液浸泡， 然后通过导辊机继续导入两层 等面积等规格的 PP纤维布间， 呈三层的三明治叠合结构， PP纤维布在 两侧， 玻纤布在中间， 通过挤压、 平整、 烘干工序后以 PP 纤维线轧成 复合布结构， 得到复合纤维布。
依据本发明的另一方面，还提供上述复合纤维布在汽车配件、餐具、 家用电器、 建筑装潢材料或航海船舶中的应用。
依据本发明的另一方面的实施例， 还提供上述复合纤维布的应用方 法， 包括如下步骤：
步骤 S01 , 确定目标制件模具， 将上述复合纤维布根据模具形状进 行裁剪， 置于预定的产品模具中；
步骤 S02 , 热熔模压：
将该产品模具中的复合纤维布进行热熔模压处理， 该热熔模压处理 的工艺条件为：
预压温度 190-200 °C , 预压时间 30-60s , 预压压力 3-7MPa; 保压温 度 200-210 °C , 保压时间 30-119s , 保压压力 7-19MPa, 放气次数 3-7次； 定型温度 200-210 °C , 保压时间 60-139s, 保压压力 7-19MPa。 上述模压 过程可以连同模具一起进行，之后保压水冷降温至室温，得到目标制件。 步骤 S01中， 该目标制件模具以所应用的产品为准， 例如， 汽车配 件模具， 餐具模具等。 将复合纤维布放入模具前， 对复合纤维布进行裁 剪， 使裁剪后复合纤维布与模具一致。 所使用的复合纤维布见前述实施 例中的描述， 在此不重复阐述。
由于复合纤维布中聚丙烯纤维的重量百分含量为 30~50%, 玻璃纤 维的重量百分含量为 50~70%, 尤其是聚丙烯纤维和玻璃纤维的重量比 为 3 : 7-1 : 1 , 结合步骤 S02中热熔模压的工艺条件， 能够使聚丙烯纤 维对玻璃纤维进行充分浸润， 使玻璃纤维的加强性能得到充分的发挥， 赋予目标制件优异的机械性能。 利用本发明实施例复合纤维布热熔模压 得到的目标制件， 成本低廉、 性价比高。
上述步骤中使用的模压模具没有限制， 例如汽车保险杠， 发动机舱 盖等模具。
依据本发明的复合纤维布的实现方法简单， 可利用纺织设备加工， 与传统双螺杆挤出机相比对热能需求低， 生产效率高。 依据本发明的复 合纤维布应用方法， 通过应用本发明实施例复合纤维布， 能够扩大复合 纤维布的应用领域， 特别是对于一些需要复杂结构模具的产品， 也能够 应用。
依据本发明的复合纤维布应用方法的实施例制备得到的目标制件， 具有如下效果：
1 : 制得的玻纤增强 PP的目标制件中， 玻纤为长连续结构， 使玻纤 机械强度得到很好的保存。
2: 玻纤与 PP树脂都以纤维形式存在， 二者以人工方式做到分布相 对均匀， 避免因为树脂分布不均引起的制件成型后内应力导致的制件因 此在使用中性能受影响。
3 : 与釆用相同加工方式的传统热固性材料相比成本更低， 回收、 维 护更方便， 更有市场前景。
以下结合具体实施例对依据本发明的复合纤维布及应用方法进行详 细阐述。
实施例 1
依据本发明的一种复合纤维布的制备过程如下：
将 210D 规格的 PP 树脂纤维织造成布， 纤维布规格为等经纬数 69g/m2的斜紋布；
将玻纤布浸入 1 %的 KH550偶联剂的水溶液当中， 然后在导辊机引 导下与等宽的两层上述规格 PP纤维布形成玻纤布在中间 PP纤维布在两 边的三明治结构， 之后经由拉挤、 平整、 烘干等工序呈平整结构， 最后 以 PP 纤维扎制成三层复合布结构， 得到复合纤维布。 其中玻纤含量为 70%。
本实施例复合纤维布的一种应用方法如下：
将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中， 如汽车车门， 发动机盖、 后备箱盖等产品模具， 本处为测试性能方便选 取 24*24*0.3cm的平板模具；
将产品模具中的复合纤维布进行热熔模压处理， 工艺条件为： 预压温度 200 °C , 预压时间 30s , 预压压力 5MPa; 保压温度 200 °C , 保压时间 70s , 保压压力 17MPa放气次数 5次； 定型温度 210 °C , 保压 时间 70s, 保压压力 19MPa。 保压水冷降温至室温， 制得玻纤含量在 70 %的连续玻纤织物加强的目标制件。
实施例 2
依据本发明的一种复合纤维布的制备过程如下：
将 420D 规格的 PP 树脂纤维织造成布， 纤维布规格为等经纬数 106g/m2的斜紋布；
将玻纤布浸入 1 %的 KH550偶联剂的水溶液当中， 然后在导辊机引 导下与等宽的两层上述规格 PP纤维布形成玻纤布在中间 PP纤维布在两 边的三明治结构， 之后经由拉挤、 平整、 烘干等工序呈平整结构， 最后 以 PP 纤维扎制成三层复合布结构， 得到复合纤维布。 该复合布中玻纤 含量为 60 % 。
本实施例复合纤维布的一种应用方法如下：
将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中； 如高级特种安全箱模具， 本处为测试性能方便选取 24*24*0.3cm的平板 模具；
将产品模具中的复合纤维布进行热熔模压处理， 工艺条件为： 预压温度 200 °C , 预压时间 30s , 预压压力 5MPa; 保压温度 200 °C , 保压时间 70s , 保压压力 17MPa放气次数 5次； 定型温度 210 °C , 保压 时间 70s , 保压压力 19MPa。 保压水冷降温至室温， 最终制得玻纤含量 在 60 %的连续玻纤织物加强的目标制件。
实施例 3
依据本发明的一种复合纤维布的制备方法如下：
将 800D 规格的 PP 树脂纤维织造成布， 纤维布规格为等经纬数 160g/m2的斜紋布；
将玻纤布浸入 1 %的 KH550偶联剂的水溶液当中， 然后在导辊机引 导下与等宽两层上述规格 PP纤维布形成玻纤布在中间 PP纤维布在两边 的三明治结构， 之后经由拉挤、 平整、 烘干等工序呈平整结构， 最后以 PP 纤维扎制成三层复合布结构， 得到复合纤维布。 其中玻纤含量为 50 % 。 本实施例复合纤维布的一种应用方法如下：
将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中， 如复杂图案的装饰地板模具， 本处为测试性能方便选取 24*24*0.3cm的 平板模具；
将产品模具中的复合纤维布进行热熔模压处理， 工艺条件为： 预压温度 200 °C , 预压时间 30s , 预压压力 5MPa; 保压温度 200 °C , 保压时间 70s , 保压压力 17MPa放气次数 5次； 定型温度 210 °C , 保压 时间 70s, 保压压力 19MPa。 保压水冷降温至室温得玻纤含量在 50 %的 连续玻纤织物加强的目标制件。
对比例 1
本对比例复合纤维布的制备方法如下：
将 800D 规格的 PP 树脂纤维织造成布， 纤维布规格为等经纬数 160g/m2的斜紋布；
将玻纤布浸入 1 %的 KH550偶联剂的水溶液当中， 然后在导辊机引 导下与两侧各两层的等宽的上述规格 PP纤维布形成玻纤布在中间 PP纤 维布在两边的三明治结构， 之后经由拉挤、 平整、 烘干等工序呈平整结 构， 最后以 PP 纤维扎制成三层复合布结构， 得到复合纤维布。 其中玻 纤含量为 33 % 。
本对比例复合纤维布应用方法如下：
将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中， 如大型连续板材模具， 本处为测试性能方便选取 24*24*0.3cm的平板模 具；
将产品模具中的复合纤维布进行热熔模压处理， 工艺条件为： 预压温度 200 °C , 预压时间 30s , 预压压力 5MPa; 保压温度 200 °C , 保压时间 70s , 保压压力 17MPa放气次数 5次； 定型温度 210 °C , 保压 时间 70s, 保压压力 19MPa。 保压水冷降温至室温得玻纤含量在 33 %的 连续玻纤织物加强的目标制件。
对比例 2
本对比例复合纤维布的制备过程如下：
将 210D 规格的 PP 树脂纤维织造成布， 纤维布规格为等经纬数 50g/m2的斜紋布；
将玻纤布浸入 1 %的 KH550偶联剂的水溶液当中， 然后在导辊机引 导下与等宽上述规格的两层 PP纤维布形成玻纤布在中间 PP纤维布在两 边的三明治结构， 之后经由拉挤、 平整、 烘干等工序呈平整结构， 最后 以 PP 纤维扎制成三层复合布结构， 得到复合纤维布其中玻纤含量为 76%。
本对比例复合纤维布应用方法如下： 将该复合纤维布根据模具形状进行裁剪， 置于预定的产品模具中， 如有防火要求的家电外壳等产品模具， 本处为测试性能方便选取
24*24*0.3cm的平板模具；
将产品模具中的复合纤维布进行热熔模压处理， 工艺条件为： 预压温度 200 °C , 预压时间 30s , 预压压力 5MPa; 保压温度 200 °C , 保压时间 70s , 保压压力 17MPa放气次数 5次； 定型温度 210 °C , 保压 时间 70s, 保压压力 19MPa。 保压水冷降温至室温， 制得玻纤含量在 76
%的连续玻纤织物加强的目标制件。
性能测试：
按 ASTM测试标准， 以万能制样机切割加工制样， 对材料性能进行 测试。
实施例 1~3及对比例 1~2配方及材料性能见表 1 :
表 1
Figure imgf000008_0001
由上表可以看出， 纤维树脂复合的模压材料具有极好的强度， 玻纤 含量在 70 %时材料的机械性能最好， 同时玻纤含量在 50~70%之间的树 脂复合材料能很好地反应性能与玻纤含量间的线性关系， 说明在树脂和 玻纤完全充分浸润的条件下，材料性能由玻纤含量决定。 而对比例 1中， 由于玻纤含量过少， 难以使过量的树脂与玻纤做到均匀分散， 其制件受 力后易在树脂富集处首先发生断裂， 进而造成整体破坏， 未发挥该类材 料的优势性能， 而且由于树脂纤维的含量高， 使其纺织加工与热熔加工 成本都较高， 导致产品制件性价比较低； 与其相对， 76%的玻纤含量复 合材料由于树脂过少， 难以做到对纤维的充分浸润， 使得产品制件在受 力后在浸润不充分的部分没有树脂分散受力，使该处纤维首先发生断裂， 进而破坏复合材料整体性， 由该断裂处产生受力集中，使制件整体破坏， 因此其性能不再随玻纤含量增加而提升， 同时其浸润不完全一定程度上 还对制件外观造成不利影响， 降低产品的成品率， 增加生产加工成本。 综上， 50~70%间的玻纤含量的复合材料是最佳的配比。 以上所述仅为本发明的较佳实施例而已， 并不用以限制本发明， 对 于本领域的一般技术人员， 依据本发明的思想， 可以对上述具体实施方 式进行变化。

Claims

权 利 要 求
1. 一种复合纤维布，其特征在于，包括依次层叠的第一聚丙烯布层、 玻纤布层和第二聚丙烯布层， 按所述复合纤维布重量计， 所述第一聚丙 烯布层和第二聚丙烯布层的重量百分比总和为 30~50%, 所述玻纤布层 的重量百分比为 50~70%； 其中， 所述第一聚丙烯布层和第二聚丙烯布 层的重量比为 1 : 1-2: 1 , 所述玻纤布层为经过偶联剂表面处理后的玻纤 布层。
2. 如权利要求 1所述的复合纤维布， 其特征在于， 所述第一聚丙烯 布层和第二聚丙烯布层的重量百分比总和为 30~40%。
3. 如权利要求 1所述的复合纤维布， 其特征在于， 所述玻璃纤维的 重量百分比为 60~70%。
4. 如权利要求 1所述的复合纤维布， 其特征在于， 所述第一聚丙烯 布层和第二聚丙烯布层的总重量与所述玻璃纤维的重量之比 3 : 7-1 : 1。
5. 如权利要求 1所述的复合纤维布， 其特征在于， 所述偶联剂为硅 烷偶联剂。
6. 如权利要求 1所述的复合纤维布， 其特征在于， 所述复合纤维布 的相对密度为 1.43 1.58。
7. 如权利要求 1所述的复合纤维布， 其特征在于， 所述第一聚丙烯 布层和第二聚丙烯布层中聚丙烯纤维的相对密度为 0.90~0.91。
8. 如权利 1~7任一项所述复合纤维布在汽车轻量化配件、 餐具、 家 用电器、 建筑装潢材料或航海船舶中的应用。
9. 如权利要求 1~7任一项所述复合纤维布的应用方法， 包括如下步 骤：
将所述复合纤维布根据模具形状进行裁剪，置于预定的产品模具中； 将所述产品模具中的复合纤维布进行热熔模压处理， 所述热熔模压 处理的工艺条件为：
预压温度 190-200 °C , 预压时间 30-60s , 预压压力 3-7MPa; 保压温 度 200-210 °C , 保压时间 30-119s , 保压压力 7-19MPa, 放气次数 3-7次； 定型温度 200-210 °C , 保压时间 60-139s, 保压压力 7-19MPa。
PCT/CN2013/080064 2012-07-27 2013-07-25 复合纤维布、其应用和应用方法 WO2014015805A1 (zh)

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