CN105038217A - 一种碳纤维增强尼龙微发泡材料及其制备方法 - Google Patents
一种碳纤维增强尼龙微发泡材料及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种微发泡尼龙材料及其制备方法,尤其是一种碳纤维增强尼龙微发泡材料及其制备方法,属于高分子材料技术领域。本发明的原料由以下重量份的组分组成:尼龙40-70份,碳纤维10-40份,相容剂1-10份,发泡母粒0.5-6份,抗氧剂0.5-2份。本发明采用质轻、高强、高模、高耐热的碳纤维增强尼龙微发泡复合材料,显著提高了材料的抗拉强度、弯曲模量、耐热性能,同时减轻了材料重量,获得了一种具有轻量化特征的高性能尼龙微发泡材料。本发明可应用到汽车结构制件,如散热器风扇、进气歧管、空气滤清器壳体、发电机盖、电器外壳、冷却排管、座椅主体、座椅滑轨、油门踏板等,实现汽车结构制件用材料轻量化;也可用于其它领域,比如电动工具、建筑等。
Description
技术领域
本发明属于高分子材料技术领域,涉及一种尼龙微发泡复合材料及其制备方法,尤其是一种碳纤维增强尼龙微发泡复合材料及其制备方法。
背景技术
轻量化、环保节能、安全舒适已经成为汽车发展重要趋势,这也同样成为汽车材料努力改进方向。微发泡技术是一种能够制备具有独有的致密表层和发泡芯层结构材料的技术。在保证材料基本性能的前提下,显著减轻制件重量,有利于实现汽车轻量化。其中,尼龙微发泡材料已在汽车部件,如发动机罩盖、门把手等部件应用。
然而,由于尼龙微发泡材料综合性能较低,目前仍无法应用到比如,散热器风扇、进气歧管、空气滤清器壳体、发电机盖、电器外壳、冷却排管、座椅主体、座椅滑轨、油门踏板等结构部件上,严重阻碍了尼龙微发泡材料发展。
发明内容
本发明采用轻质、高强、高模、高耐热碳纤维作为增强体,保证尼龙微发泡材料轻量化优势前提下,大幅提高其抗拉、抗弯强度、模量和耐热性能,获得了具有轻量化特征的高性能尼龙微发泡材料,并提供该材料的制备方法。本发明工艺简单,生产效率高、易于实现工业化。
技术方案
本发明通过以下技术方案解决技术问题:
一种碳纤维增强尼龙微发泡材料,原料包括以下重量份的组分:
尼龙40-70份
碳纤维10-40份
相容剂1-10份
发泡剂母粒0.5-6份
抗氧剂0.5-2份。
进一步的技术方案,组分中还包括填充剂0-20份,所述的填充
剂为碳酸钙、玻璃微珠、滑石粉中的一种。
进一步的技术方案,所述的尼龙为PA6、PA66、PA1010中的一种;
所述的碳纤维表面经过硅烷偶联剂处理,碳纤维为连续碳纤维或者短切碳纤维;
所述的相容剂为马来酸酐接枝POE或者马来酸酐接枝PE;
所述的发泡剂母粒的主要成份为碳酸氢铵、碳酸氢钠、偶氮二甲
酰胺、甲苯磺酞氨基脲、偶氮二碳酸胺中的一种;
所述的抗氧剂包括主抗氧剂和辅抗氧剂。
进一步的技术方案,所述的碳纤维是碳含量≥95%,抗拉强度≥4000MPa,单丝直径是5~8μm的连续碳纤维。
进一步的技术方案,所述的相容剂是马来酸酐接枝POE型。
进一步的技术方案,所述的发泡剂母粒的主要成分是偶氮二甲酰胺。
进一步的技术方案,所述的主抗氧剂是抗氧剂1098,所述的辅抗氧剂是抗氧剂168。
一种碳纤维增强尼龙微发泡材料的制备方法,包括以下步骤:
(1)将尼龙、相容剂、填充剂、抗氧剂按一定重量比例放入高速混合机中混合4-6min,获得组分混合物;
(2)将上述组分混合物由料斗连续加入双螺杆挤出机,碳纤维由侧喂料口加入到双螺杆挤出机中混炼挤出,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料;
(3)将步骤(2)中所得到的碳纤维增强尼龙复合材料和发泡剂母粒按94-99.5份和0.5-6份混合后加入到注塑机中,注塑成型得到高性能碳纤维增强尼龙微发泡材料。
进一步的技术方案,所述步骤(1)中,双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:220-240℃、II区:240-260℃、III区:245-265℃、IV区:250-270℃、V区:250-270℃、VI区:250-270℃、VII区:250-270℃、VIII区:245-265℃、IX区240-260℃,螺杆转速500r/min。
进一步的技术方案,所述步骤(3)中注塑机料筒温度为220-290℃,注射压力为60-100MPa,注射速度为50-90mm/s,冷却时间为10-40s。
有益效果
本发明采用碳纤维增强技术,大幅提高尼龙微发泡材料抗拉强度、弯曲模量和耐热性等性能的同时,进一步减轻材料重量,满足汽车工业对工程塑料轻量化和高性能化要求,产品可应用到汽车零部件中的结构件代替现有实心改性尼龙注塑制件,实现汽车材料轻量化,有利于促进汽车进一步节能减排。本发明制备方法中采用侧喂料口加入碳纤维,可以更好地保留玻纤长度,提高材料力学性能。本发明产品可在普通注塑机实现微发泡,操作简单,易于产业化。
具体实施方式
实施例一
将PA650份、马来酸酐接枝POE7.5份、抗氧剂10980.6份、抗氧剂1680.4份的混合物放入高速混合机,混合6分钟,然后,将上述组分混合物由料斗连续加入双螺杆挤出机,将经过硅烷偶联剂处理的碳含量≥95%,抗拉强度≥4000MPa,单丝直径是5~8m的连续碳纤维40份由挤出机中部喂料口以侧喂方式加入到双螺杆挤出机机筒中混炼,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料。双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:220℃、II区:240℃、III区:245℃、IV区:270℃、V区:270℃、VI区:270℃、VII区:250℃、VIII区:245℃、IX区240℃,螺杆转速500r/min;将所得到的碳纤维增强尼龙复合材料99.5份与主要成分是偶氮二甲酰胺的发泡母粒0.5份混合后放入到注塑机中,注塑成型得到高性能碳纤维增强尼龙微发泡材料;注塑机料筒温度220-290℃,注射压力为100MPa,注射速度为90mm/s,冷却时间为40s。所得微发泡材料与未加碳纤维材料性能对比如下:
表1碳纤维增强微发泡材料与未加纤材料性能对比
实施例二
将PA6640份、马来酸酐接枝POE10份、滑石粉20份、抗氧剂10981份、抗氧剂1681份的混合物放入高速混合机,混合6分钟,然后,将上述组分混合物由料斗连续加入双螺杆挤出机,将经过硅烷偶联剂处理的碳含量≥95%,抗拉强度≥4000MPa,单丝直径是5~8m的连续碳纤维22份,由挤出机中部喂料口以侧喂方式加入到双螺杆挤出机机筒中混炼,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料。双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:220℃、II区:250℃、III区:250℃、IV区:270℃、V区:270℃、VI区:270℃、VII区:270℃、VIII区:265℃、IX区260℃,螺杆转速500r/min;将所得到的碳纤维增强尼龙复合材料94份与主要成分是碳酸氢钠的发泡母粒6份加入到注塑机中,注塑成型得到碳纤维增强尼龙微发泡复合材料。注塑机料筒温度220-290℃,注射压力为60MPa,注射速度为50mm/s,冷却时间为10s。所得微发泡材料与未加碳纤材料性能对比如下:
表1碳纤维增强微发泡材料与未加纤材料性能对比
实施例三
将PA670份、马来酸酐接枝PE1份、碳酸钙10份、抗氧剂10980.3份、抗氧剂10100.2份的混合物放入高速混合机,混合5分钟,然后,将上述组分混合物由料斗连续加入双螺杆挤出机,将经过硅烷偶联剂处理的短切碳纤维16份,由挤出机中部喂料口以侧喂方式加入到双螺杆挤出机机筒中混炼,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料。双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:220℃、II区:240℃、III区:245℃、IV区:250℃、V区:250℃、VI区:250℃、VII区:250℃、VIII区:245℃、IX区240℃,螺杆转速500r/min;将所得到的碳纤维增强尼龙复合材料97.5份与主要成分是甲苯磺酞氨基脲的发泡母粒2.5份加入到注塑机中,注塑成型得到碳纤维增强尼龙微发泡复合材料。注塑机料筒温度220-290℃,注射压力为90MPa,注射速度为70mm/s,冷却时间为30s。所得微发泡材料与未加碳纤材料性能对比如下:
表1碳纤维增强微发泡材料与未加纤材料性能对比
实施例四
将PA101066份、马来酸酐接枝POE5份、玻璃微珠15份、抗氧剂10980.6份、抗氧剂1680.4份的混合物放入高速混合机,混合4分钟,然后,将上述组分混合物由料斗连续加入双螺杆挤出机,将经过硅烷偶联剂处理的碳含量≥95%,抗拉强度≥4000MPa,单丝直径是5~8m的连续碳纤维10份,由挤出机中部喂料口以侧喂方式加入到双螺杆挤出机机筒中混炼,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料。双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:240℃、II区:260℃、III区:265℃、IV区:270℃、V区:270℃、VI区:270℃、VII区:270℃、VIII区:265℃、IX区260℃,螺杆转速500r/min;将所得到的碳纤维增强尼龙复合材料97份与主要成分是碳酸氢铵的发泡母粒3份加入到注塑机中,注塑成型得到碳纤维增强尼龙微发泡复合材料。注塑机料筒温度220-290℃,注射压力为80MPa,注射速度为80mm/s,冷却时间为20s。所得微发泡材料与未加碳纤材料性能对比如下:
表1碳纤维增强微发泡材料与未加纤材料性能对比
从以上实施例与未加纤尼龙微发泡材料性能对比可以看出,采用碳纤维增强技术,在保证了尼龙微发泡材料轻量化特征同时,碳纤维对尼龙微发泡材料力学强度等性能具有显著提升效果,强度、刚性明显优于未加碳纤样品。本发明的另一个特点是加工周期明显缩短,显著降低生产成本。产品具有优异的尺寸稳定性。另外,可根据不同需求,调整配方比例,达到所需目标性能,减少材料用量。
本发明采用碳纤维增强技术,在保证实现尼龙材料轻量化的前提下,有效改善产品尺寸稳定性,显著提高制品刚性、强度和耐热性能,实现尼龙微发泡材料高性能化。同时,缩短加工周期,提高生产效率。本产品可通过普通注塑工艺实现,操作简单,实用性强。产品除了适用于汽车结构制件外,还可用于建筑、电子、体育器材等行业领域。
以上所述仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,比如,填充剂亦可为玻璃纤维。任何熟悉本领域的技术人员在本发明的技术范围内,可不经过创造性劳动想到的变化或替换,都应涵盖在本发明的保护范围之内。
Claims (10)
1.一种碳纤维增强尼龙微发泡材料,其特征在于,原料包括以下重量份的组分:
尼龙40-70份
碳纤维10-40份
相容剂1-10份
发泡剂母粒0.5-6份
抗氧剂0.5-2份。
2.根据权利要求1所述的一种碳纤维增强尼龙微发泡材料,其特征在于,组分中还包括填充剂0-20份,所述的填充剂为碳酸钙、玻璃微珠、滑石粉中的一种。
3.根据权利要求1所述的一种碳纤维增强尼龙微发泡材料,其特征在于,所述的尼龙为PA6、PA66、PA1010中的一种;
所述的碳纤维表面经过硅烷偶联剂处理,碳纤维为连续碳纤维或者短切碳纤维;
所述的相容剂为马来酸酐接枝POE或者马来酸酐接枝PE;
所述的发泡剂母粒的主要成份为碳酸氢铵、碳酸氢钠、偶氮二甲酰胺、甲苯磺酞氨基脲、偶氮二碳酸胺中的一种;
所述的抗氧剂包括主抗氧剂和辅抗氧剂。
4.根据权利要求1或3所述的一种碳纤维增强尼龙微发泡材料,其特征在于,所述的碳纤维是碳含量≥95%,抗拉强度≥4000MPa,单丝直径是5~8μm的连续碳纤维。
5.根据权利要求1或3所述的一种碳纤维增强尼龙微发泡材料,其特征在于,所述的相容剂是马来酸酐接枝POE型。
6.根据权利要求1或3所述的一种碳纤维增强尼龙微发泡材料,其特征在于,所述的发泡剂母粒的主要成分是偶氮二甲酰胺。
7.根据权利要求3所述的一种碳纤维增强尼龙微发泡材料,其特征在于,所述的主抗氧剂是抗氧剂1098,所述的辅抗氧剂是抗氧剂168。
8.根据权利要求1-3任一项所述的一种碳纤维增强尼龙微发泡材料的制备方法,其特征在于,包括以下步骤:
(1)将尼龙、相容剂、填充剂、抗氧剂按一定重量比例放入高速混合机中混合4-6min,获得组分混合物;
(2)将上述组分混合物由料斗连续加入双螺杆挤出机,碳纤维由侧喂料口加入到双螺杆挤出机中混炼挤出,经过牵条、冷却、干燥、切粒,得到碳纤维增强尼龙复合材料;
(3)将步骤(2)中所得到的碳纤维增强尼龙复合材料和发泡剂母粒按94-99.5份和0.5-6份混合后加入到注塑机中,注塑成型得到高性能碳纤维增强尼龙微发泡材料。
9.根据权利要求8所述的一种碳纤维增强尼龙微发泡材料的制备方法,其特征在于,所述步骤(1)中,双螺杆挤出机料筒从加料口到机头各段温度范围为:I区:220-240℃、II区:240-260℃、III区:245-265℃、IV区:250-270℃、V区:250-270℃、VI区:250-270℃、VII区:250-270℃、VIII区:245-265℃、IX区240-260℃,螺杆转速500r/min。
10.根据权利要求8所述的一种碳纤维增强尼龙微发泡材料的制备方法,其特征在于,所述步骤(3)中注塑机料筒温度为220-290℃,注射压力为60-100MPa,注射速度为50-90mm/s,冷却时间为10-40s。
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