CN107226996A - 一种环氧树脂发泡材料基材及其制备工艺 - Google Patents
一种环氧树脂发泡材料基材及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种磨盘用环氧树脂发泡材料基材,所述基材按照质量份数计包括:环氧树脂:60‑70份、纳米材料溶液:10‑13份、填料:15‑18份、助剂:8‑11份、复合稀土:1‑2份、固化剂:30‑40份、增韧剂:15‑25份、发泡剂:40‑50份、促进剂:5‑10份、泡沫稳定剂:15‑18份、胶粘剂:4‑8份;本发明良好的耐磨性、强度、耐腐蚀性、及其较高的热稳定性。
Description
技术领域
本发明涉及一种环氧树脂发泡材料基材及其制备工艺。
背景技术
环氧发泡材料具有较好的热稳定性、力学性能、绝缘性能、隔热性能以及轻质等优点,已经广泛应用在汽车、电子灌封、飞机制件、船体外壳等领域,现有的环氧发泡材料的制备方法主要有物理发泡法和化学发泡法,采用化学发泡法制备的环氧发泡材料,一般泡孔尺寸较大,泡孔分布也不均匀,通过预反应增加体系的粘度可以使泡孔直径减小,但是材料的表观密度会增大,且通常难以制备出泡孔均匀的微孔发泡材料。
发明内容
本发明所要解决的技术问题是,针对以上现有技术存在的缺点,提供一种环氧树脂发泡材料基材及其制备工艺。
本发明解决以上技术问题的技术方案是:一种环氧树脂发泡材料基材,所述基材按照质量份数计包括:环氧树脂:80-90份、纳米材料溶液:8-10份、填料:10-13份、助剂:3-6份、复合稀土:1-2份、固化剂:20-25份、增韧剂:15-20份、发泡剂:5-10份、促进剂:5-10份、泡沫稳定剂:5-8份、胶粘剂:4-6份;
所述纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:10-13%,纳米二氧化钛:3.8-5.1%,纳米碳化硅:3.5-4.2%,纳米氧化锌:1.5-1.8%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.3-5.6%,有机氟防水剂:余量;
所述填料为滑石粉、石英粉或无机空心微球中的一种或多种;所述增韧剂为邻苯二甲酸二甲酯;
所述助剂为膨润土、硅藻土、云母粉或石棉中一种或多种;
所述复合稀土按重量百分比包含以下成分:La:12-16%,Y:15-17%,Sc:5-8%,Gd:8-10%,Sm:9-15%,Pr:13-16%,其余为镧系元素,以上各组分之和为100%;
所述发泡剂为偶氮二甲酰胺或2,2-偶氮二异丁腈;
所述泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯、聚二甲基硅氧烷-聚氧化烯烃共聚物或环氧乙烷-环氧丙烷嵌段共聚物中的一种。
本发明进一步限定的技术方案是:
前述的基材按照质量份数计包括:环氧树脂:85份、纳米材料溶液:8份、填料:10份、助剂:4份、复合稀土:1份、固化剂:20份、增韧剂:15份、发泡剂:8份、促进剂:5份、泡沫稳定剂:5份、胶粘剂:5份;
纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:11%,纳米二氧化钛:4.2%,纳米碳化硅:3.7%,纳米氧化锌:1.5%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.3%,有机氟防水剂:余量;
填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
助剂为膨润土和云母粉两种的混合物;
复合稀土按重量百分比包含以下成分:La:13%,Y:15%,Sc:6%,Gd:8%,Sm:12%,Pr:14%,其余为镧系元素,以上各组分之和为100%;
发泡剂为偶氮二甲酰胺;
泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯。
前述的基材按照质量份数计包括:环氧树脂:90份、纳米材料溶液:10份、填料:11份、助剂:5份、复合稀土:1.5份、固化剂:22份、增韧剂:18份、发泡剂:10份、促进剂:9份、泡沫稳定剂:7份、胶粘剂:6份;
纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:13%,纳米二氧化钛:4.8%,纳米碳化硅:4.2%,纳米氧化锌:1.7%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.6%,有机氟防水剂:余量;
填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
助剂为膨润土和云母粉两种的混合物;
复合稀土按重量百分比包含以下成分:La:16%,Y:177%,Sc:7%,Gd:10%,Sm:13%,Pr:16%,其余为镧系元素,以上各组分之和为100%;
发泡剂为偶氮二甲酰胺;
泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯。
本发明还提供基材制备工艺,具体包括以下步骤:
步骤一:将环氧树脂、填料和助剂分别通过球磨机进行研磨,研磨后的填料过120-150目筛,助剂过90-100目筛;
步骤二:将环氧树脂、发泡剂和发泡稳定剂加入到反应箱内,以600-700r/min高速搅拌20-30min得到混合物A,然后将混合物A进行加热,时间为0.5-1h,加热分为分三段,温度分别为30-50℃,60-75℃、80-100℃,预热结束后将混合物A取出将温度降至20-30℃,备用;
步骤三:在步骤二中加入促进剂、填料和助剂,以800-900r/min搅拌10-15min,温度升至55-63℃,然后加入固化剂,以相同速度继续搅拌5-10min,温度升至75-88℃,使粘度在10-13Pa﹒s;
步骤四:在步骤三内加入复合稀土、增韧剂和胶粘剂以900-1000r/min搅拌1-2h,然后倒入模具中,放置烘箱中将温度升至200-210℃,取出后将温度以3-5℃降至室温,然后脱除模具,得到环氧树脂发泡材料;
步骤五:将步骤四得到的环氧树脂发泡材料送双螺杆挤出造粒机中混炼造粒,进行密炼加工,双螺杆挤出机共分三段,即入口段、中间段和出口段,其温度分别控制为 :50-55℃,60-73℃,83-95℃;
步骤六:将步骤五送入压延机内进行压延,温度控制在120-125℃,然后进行冷却得到基材;
步骤七:通过喷砂或用角磨机将基材表面打磨粗化,涂上一层底胶,在底胶上再涂有一层交联粘结胶,将复合膜贴在涂有交联粘结胶基材表面上,在复合膜表面喷涂纳米材料溶液,烘干后经机械热轧压处理,烘干温度为80-95℃。
本发明的有益效果是:本发明中加入填料能够降低成本,减小固化放热峰强度和收缩率,提高耐化学性,选用无机空心微球能够提高基材的强度和耐热性和尺寸稳定性;添加助剂能够使泡沫和填料位置稳定,防止上浮分层;添加增韧剂能够调节环氧树脂的粘弹性,抑制泡孔的合并和坍塌;在基材表面贴有复合膜,提高了其防腐蚀效果,增加了使用寿命;在复合膜表面喷涂纳米材料溶液,又能提高复合膜的耐磨损性;加入复合稀土,提高其耐腐蚀性,本发明原料制备工艺简单,设备简便,容易操作控制,且发泡倍率高,本发明制备的基材具有良好的耐磨性、强度、耐腐蚀性、及其较高的热稳定性。
具体实施方式
实施例1
本实施例提供一种环氧树脂发泡材料基材,基材按照质量份数计包括:环氧树脂:85份、纳米材料溶液:8份、填料:10份、助剂:4份、复合稀土:1份、固化剂:20份、增韧剂:15份、发泡剂:8份、促进剂:5份、泡沫稳定剂:5份、胶粘剂:5份;
纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:11%,纳米二氧化钛:4.2%,纳米碳化硅:3.7%,纳米氧化锌:1.5%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.3%,有机氟防水剂:余量;
填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
助剂为膨润土和云母粉两种的混合物;
复合稀土按重量百分比包含以下成分:La:13%,Y:15%,Sc:6%,Gd:8%,Sm:12%,Pr:14%,其余为镧系元素,以上各组分之和为100%;
发泡剂为偶氮二甲酰胺;
泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯。
本实施例还提供了基材制备工艺,具体包括以下步骤:
步骤一:将环氧树脂、填料和助剂分别通过球磨机进行研磨,研磨后的填料过130目筛,助剂过90目筛;
步骤二:将环氧树脂、发泡剂和发泡稳定剂加入到反应箱内,以600r/min高速搅拌30min得到混合物A,然后将混合物A进行加热,时间为0.7h,加热分为分三段,温度分别为35℃,67℃、94℃,预热结束后将混合物A取出将温度降至24℃,备用;
步骤三:在步骤二中加入促进剂、填料和助剂,以820r/min搅拌13min,温度升至58℃,然后加入固化剂,以相同速度继续搅拌8min,温度升至82℃,使粘度在10Pa﹒s;
步骤四:在步骤三内加入复合稀土、增韧剂和胶粘剂以960r/min搅拌1.5h,然后倒入模具中,放置烘箱中将温度升至204℃,取出后将温度以4℃降至室温,然后脱除模具,得到环氧树脂发泡材料;
步骤五:将步骤四得到的环氧树脂发泡材料送双螺杆挤出造粒机中混炼造粒,进行密炼加工,双螺杆挤出机共分三段,即入口段、中间段和出口段,其温度分别控制为 :53℃,66℃,90℃;
步骤六:将步骤五送入压延机内进行压延,温度控制在122℃,然后进行冷却得到基材;
步骤七:通过喷砂或用角磨机将基材表面打磨粗化,涂上一层底胶,在底胶上再涂有一层交联粘结胶,将复合膜贴在涂有交联粘结胶基材表面上,在复合膜表面喷涂纳米材料溶液,烘干后经机械热轧压处理,烘干温度为83℃。
实施例2
本实施例提供一种环氧树脂发泡材料基材,基材按照质量份数计包括:环氧树脂:90份、纳米材料溶液:10份、填料:11份、助剂:5份、复合稀土:1.5份、固化剂:22份、增韧剂:18份、发泡剂:10份、促进剂:9份、泡沫稳定剂:7份、胶粘剂:6份;
纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:13%,纳米二氧化钛:4.8%,纳米碳化硅:4.2%,纳米氧化锌:1.7%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.6%,有机氟防水剂:余量;
填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
助剂为膨润土和云母粉两种的混合物;
复合稀土按重量百分比包含以下成分:La:16%,Y:177%,Sc:7%,Gd:10%,Sm:13%,Pr:16%,其余为镧系元素,以上各组分之和为100%;
发泡剂为偶氮二甲酰胺;
泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯。
本实施例还提供了基材制备工艺,具体包括以下步骤:
步骤一:将环氧树脂、填料和助剂分别通过球磨机进行研磨,研磨后的填料过150目筛,助剂过100目筛;
步骤二:将环氧树脂、发泡剂和发泡稳定剂加入到反应箱内,以700r/min高速搅拌20min得到混合物A,然后将混合物A进行加热,时间为0.6h,加热分为分三段,温度分别为42℃,70℃、96℃,预热结束后将混合物A取出将温度降至22℃,备用;
步骤三:在步骤二中加入促进剂、填料和助剂,以900r/min搅拌10min,温度升至60℃,然后加入固化剂,以相同速度继续搅拌10min,温度升至85℃,使粘度在13Pa﹒s;
步骤四:在步骤三内加入复合稀土、增韧剂和胶粘剂以980r/min搅拌1.2h,然后倒入模具中,放置烘箱中将温度升至208℃,取出后将温度以5℃降至室温,然后脱除模具,得到环氧树脂发泡材料;
步骤五:将步骤四得到的环氧树脂发泡材料送双螺杆挤出造粒机中混炼造粒,进行密炼加工,双螺杆挤出机共分三段,即入口段、中间段和出口段,其温度分别控制为 :55℃,69℃,92℃;
步骤六:将步骤五送入压延机内进行压延,温度控制在125℃,然后进行冷却得到基材;
步骤七:通过喷砂或用角磨机将基材表面打磨粗化,涂上一层底胶,在底胶上再涂有一层交联粘结胶,将复合膜贴在涂有交联粘结胶基材表面上,在复合膜表面喷涂纳米材料溶液,烘干后经机械热轧压处理,烘干温度为88℃。
除上述实施例外,本发明还可以有其他实施方式。凡采用等同替换或等效变换形成的技术方案,均落在本发明要求的保护范围。
Claims (4)
1.一种环氧树脂发泡材料基材,其特征在于:所述基材按照质量份数计包括:环氧树脂:80-90份、纳米材料溶液:8-10份、填料:10-13份、助剂:3-6份、复合稀土:1-2份、固化剂:20-25份、增韧剂:15-20份、发泡剂:5-10份、促进剂:5-10份、泡沫稳定剂:5-8份、胶粘剂:4-6份;
所述纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:10-13%,纳米二氧化钛:3.8-5.1%,纳米碳化硅:3.5-4.2%,纳米氧化锌:1.5-1.8%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.3-5.6%,有机氟防水剂:余量;
所述填料为滑石粉、石英粉或无机空心微球中的一种或多种;所述增韧剂为邻苯二甲酸二甲酯;
所述助剂为膨润土、硅藻土、云母粉或石棉中一种或多种;
所述复合稀土按重量百分比包含以下成分:La:12-16%,Y:15-17%,Sc:5-8%,Gd:8-10%,Sm:9-15%,Pr:13-16%,其余为镧系元素,以上各组分之和为100%;
所述发泡剂为偶氮二甲酰胺或2,2-偶氮二异丁腈;
所述泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯、聚二甲基硅氧烷-聚氧化烯烃共聚物或环氧乙烷-环氧丙烷嵌段共聚物中的一种。
2.根据权利要求1所述的环氧树脂发泡材料基材,其特征在于:所述基材按照质量份数计包括:环氧树脂:85份、纳米材料溶液:8份、填料:10份、助剂:4份、复合稀土:1份、固化剂:20份、增韧剂:15份、发泡剂:8份、促进剂:5份、泡沫稳定剂:5份、胶粘剂:5份;
所述纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:11%,纳米二氧化钛:4.2%,纳米碳化硅:3.7%,纳米氧化锌:1.5%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.3%,有机氟防水剂:余量;
所述填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
所述助剂为膨润土和云母粉两种的混合物;
所述复合稀土按重量百分比包含以下成分:La:13%,Y:15%,Sc:6%,Gd:8%,Sm:12%,Pr:14%,其余为镧系元素,以上各组分之和为100%;
所述发泡剂为2,2-偶氮二异丁腈;
所述泡沫稳定剂聚为氧乙烯山梨糖醇酐月桂酸酯。
3.根据权利要求1所述的环氧树脂发泡材料基材,其特征在于:所述基材按照质量份数计包括:环氧树脂:90份、纳米材料溶液:10份、填料:11份、助剂:5份、复合稀土:1.5份、固化剂:22份、增韧剂:18份、发泡剂:10份、促进剂:9份、泡沫稳定剂:7份、胶粘剂:6份;
所述纳米材料溶液的质量百分比组分为:锑掺杂氧化锡纳米晶:13%,纳米二氧化钛:4.8%,纳米碳化硅:4.2%,纳米氧化锌:1.7%,季戊四醇三-(3-氮丙啶基)-丙酸酯:5.6%,有机氟防水剂:余量;
所述填料为无机空心微球;所述增韧剂为邻苯二甲酸二甲酯;
所述助剂为膨润土和云母粉两种的混合物;
所述复合稀土按重量百分比包含以下成分:La:16%,Y:177%,Sc:7%,Gd:10%,Sm:13%,Pr:16%,其余为镧系元素,以上各组分之和为100%;
所述发泡剂为偶氮二甲酰胺;
所述泡沫稳定剂聚二甲基硅氧烷-聚氧化烯烃共聚物。
4.根据权利要求1-3任意所述的环氧树脂发泡材料基材,其特征在于:所述基材制备工艺,具体包括以下步骤:
步骤一:将环氧树脂、填料和助剂分别通过球磨机进行研磨,研磨后的填料过120-150目筛,助剂过90-100目筛;
步骤二:将环氧树脂、发泡剂和发泡稳定剂加入到反应箱内,以600-700r/min高速搅拌20-30min得到混合物A,然后将混合物A进行加热,时间为0.5-1h,加热分为分三段,温度分别为30-50℃,60-75℃、80-100℃,预热结束后将混合物A取出将温度降至20-30℃,备用;
步骤三:在步骤二中加入促进剂、填料和助剂,以800-900r/min搅拌10-15min,温度升至55-63℃,然后加入固化剂,以相同速度继续搅拌5-10min,温度升至75-88℃,使粘度在10-13Pa﹒s;
步骤四:在步骤三内加入复合稀土、增韧剂和胶粘剂以900-1000r/min搅拌1-2h,然后倒入模具中,放置烘箱中将温度升至200-210℃,取出后将温度以3-5℃降至室温,然后脱除模具,得到环氧树脂发泡材料;
步骤五:将步骤四得到的环氧树脂发泡材料送双螺杆挤出造粒机中混炼造粒,进行密炼加工,双螺杆挤出机共分三段,即入口段、中间段和出口段,其温度分别控制为 :50-55℃,60-73℃,83-95℃;
步骤六:将步骤五送入压延机内进行压延,温度控制在120-125℃,然后进行冷却得到基材;
步骤七:通过喷砂或用角磨机将基材表面打磨粗化,涂上一层底胶,在底胶上再涂有一层交联粘结胶,将复合膜贴在涂有交联粘结胶基材表面上,在复合膜表面喷涂纳米材料溶液,烘干后经机械热轧压处理,烘干温度为80-95℃。
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