CN109054296B - 一种表面带树脂肋的高强度碳纤维复合材料筋材及其制备方法 - Google Patents

一种表面带树脂肋的高强度碳纤维复合材料筋材及其制备方法 Download PDF

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CN109054296B
CN109054296B CN201810725391.1A CN201810725391A CN109054296B CN 109054296 B CN109054296 B CN 109054296B CN 201810725391 A CN201810725391 A CN 201810725391A CN 109054296 B CN109054296 B CN 109054296B
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CN109054296A (zh
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朱元林
刘礼华
张春雷
周佳琪
黄盛彬
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Fasten Group Co Ltd
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Abstract

本发明涉及一种表面带树脂肋的高强度碳纤维复合材料筋材及其制备方法，涉及建筑材料技术领域。本发明包括碳纤维及环氧树脂基体，所述筋材表面有连续螺旋式的环氧树脂肋，树脂肋的厚度在0.2mm‑0.4mm范围，树脂肋的宽度在5mm‑7mm范围，树脂肋的螺距在2mm‑4mm范围。本发明通过在成型过程中，尼龙带缠绕不对碳纤维束进行挤压，并且由于碳纤维束张力的存在，碳纤维束沿筋材长度方向保持平直，因此采用本发明方法制造的筋材具有高强度高模量的特点。

Description

一种表面带树脂肋的高强度碳纤维复合材料筋材及其制备 方法
技术领域
本发明属于建筑材料技术领域，主要涉及一种表面带树脂肋的高强度碳纤维复合材料筋材，及一种表面带树脂肋的高强度碳纤维复合材料筋材的制备方法。
背景技术
碳纤维复合材料筋材具有轻质高强、耐腐蚀、耐疲劳、减震性能好等优异性能，将其用于桥梁缆索中的拉索部件，已成为提高桥梁跨径与耐久性的一个发展方向。但是一般光圆碳纤维复合材料筋锚固较为困难，这是制约其目前不能得到广泛应用的关键因素。目前，国内外开发出了三种表面带肋的碳纤维复合材料筋材，用于增加筋材表面与锚固料之间的机械咬合力，提高筋材的锚固效率。
第一种方法是先通过拉挤成型工艺生产光圆碳纤维复合材料筋材，纤维束浸渍环氧树脂在其表面缠绕，环氧树脂固化粘结成肋。这种方法制成带肋筋材的缠绕纤维束与光圆筋材的粘结强度低，容易脱粘，并不能充分发挥碳纤维复合材料筋材的拉伸性能。
第二种方法在将F4带缠绕在浸渍环氧树脂未固化的预成形筋材，一起牵引进入定型摸具中固化，固化后将F4带退绕，在筋材表面形成螺旋形凹槽。这种方法存在两个问题：一是由于F4带缠绕，使内部连续碳纤维束沿筋材长度方向取向发生波动，导致筋材的拉伸强度与弹性模量均大幅度下降；二是缠绕了F4带后，筋材表面凹凸不平，牵引进入定型摸具固化的过程中摩擦力非常大，容易发生堵模的问题。经过试验测试，该方法生产出来的筋材拉伸强度为2400MPa左右，拉伸模量为150GPa左右。
第三种方法是通过机械法在筋材表面加工形成螺纹结构。这种方法会切断筋材表面碳纤维束，影响筋材的拉伸强度及刚度，造成一定的材料浪费
发明内容
本发明的目的在于克服上述不足，设计出一种表面带树脂肋的高强度碳纤维复合材料筋材及其制备方法，该制备方法具有一次加工成型，工艺简便，不易堵模的的优点，制成的表面带环氧树脂肋的高强度碳纤维复合材料筋材，表面具有连续的螺旋形环氧树脂肋，具有便于锚固，高强度高模量的特点。
本发明的目的是这样实现的：一种表面带树脂肋的高强度碳纤维复合材料筋材，包括碳纤维及环氧树脂基体，所述筋材表面有连续螺旋式的环氧树脂肋，树脂肋的厚度在0.2mm-0.4mm范围，树脂肋的宽度在5mm-7mm范围，树脂肋的螺距在2mm-4mm范围。
一种表面带树脂肋的高强度碳纤维复合材料筋材制备方法如下：
步骤一、将若干束碳纤维束从纱架引出，碳纤维束的数量根据需要制成筋材的直径调整，通过纤维维束的数量控制纤维体积含量为70％-78％范围调整，牵引速度为300mm/min-600mm/min范围调整，使用张力控制器控制好线的张力，为了保证碳纤维束在浸渍时取向保持平直，张力取5.88N-9.80N范围调整；
步骤二、将碳纤维束牵引进入环氧树脂槽浸渍环氧树脂，出环氧树脂槽后进入预成型摸具，挤出多余环氧树脂，得到预定尺寸的筋材毛胚，预成型模具的内径为2mm-10mm范围调整，环氧树脂是采用树脂基体、固化剂和催化剂配制而成，其质量配比为1000:860:13.6；
步骤三、牵引筋材毛胚前进的同时，在筋材毛胚上缠绕尼龙带，尼龙带缠绕间距保持在5mm-7mm范围，控制缠绕张紧力，保证尼龙带只与筋材毛胚表面贴合，不勒紧筋材毛胚，筋材毛胚表面碳纤维束取向保持平直，不发生波动，尼龙带宽度2mm-4mm，厚度0.5mm-1mm；
步骤四、将表面缠绕有尼龙带的筋材毛胚牵引先后经过5个烘箱，5个烘箱温度设定分别为150℃、150℃、160℃、180℃、180℃，经过第一个烘箱预热后，筋材毛胚内部的环氧树脂受热后发生膨胀并且流动性变得非常好，开始从筋材毛胚内部往外溢出，逐渐填充满尼龙带间的缝隙，经过第二个烘箱后，环氧树脂发生凝胶，经过第三烘箱后，环氧树脂发生预固化，经过最后两个烘箱完成后固化过程，树脂肋的厚度受预热时间影响，通过控制第一个烘箱长度控制预热时间。
步骤五、固化完成后，将筋材表面的尼龙带进行退绕，尼龙带间隙中的环氧树脂形成螺旋式树脂肋，尼龙带退绕部位形成螺旋式凹槽。
步骤六、制成的带树脂肋筋材经过牵引机后收卷到收线机上。
与现有技术相比，本发明的优点在于：
1.筋材表面带连续螺旋式环氧树脂肋，环氧树脂肋与筋材中的环氧树脂基体一体成型，两者间的粘结强度高，不容易发生脱粘现象。采用环氧树脂粘结型锚固***锚固后，环氧树脂锚固料与筋材表面环氧树脂肋间形成机械咬合力，大大提高锚固效果。
2.在成型过程中，本申请的尼龙带缠绕不对碳纤维束进行挤压，并且由于碳纤维束张力的存在，碳纤维束沿筋材长度方向保持平直。不同于以往生产工艺中要通过尼龙带缠紧筋材而形成缠紧勒痕，改善了尼龙带对表层碳纤维的压迫以及破坏碳纤维的平直度的缺陷。因此采用本发明方法制造的筋材具有高强度高模量的特点。经过试验测试，本发明方法生产出来的筋材拉伸强度可达3300MPa左右，拉伸模量可达170GPa左右。
3.本发明方法具有一体成型，工艺简单的特点。
附图说明
图1为本发明的表面带树脂肋的高强度碳纤维复合材料筋材结构示意图。
图2为本发明一种表面带树脂肋的高强度碳纤维复合材料筋材制备方法的工艺流程示意图。
其中：
1-碳纤维复合材料筋材，2-树脂肋。
具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
实施例一
一种表面带树脂肋的高强度碳纤维复合材料筋材，包括碳纤维及环氧树脂基体，筋材直径为7mm，筋材表面有连续螺旋式的环氧树脂肋，树脂肋的厚度为0.25mm，树脂肋的螺距为2.4mm。
一种表面带树脂肋的高强度碳纤维复合材料筋制备方法包括以下几个步骤：
步骤一、将62束碳纤维束从纱架引出，牵引速度为350mm/min，使用张力控制器控制好线的张力为6.88N；
步骤二、将碳纤维束牵引进入环氧树脂槽浸渍环氧树脂，出环氧树脂槽后进入预成型摸具，挤出多余环氧树脂，预成型模具的内径为7mm，得到直径7mm的筋材毛胚，筋材毛胚中的纤维体积含量为72％，环氧树脂是采用树脂基体、固化剂和催化剂配制而成，其质量配比为1000:860:13.6；
步骤三、牵引筋材毛胚前进的同时，在筋材毛胚上缠绕尼龙带，尼龙带缠绕间距保持在6.3mm，控制缠绕张紧力，保证尼龙带只与筋材毛胚表面贴合，而不勒紧筋材毛胚，筋材毛胚表面碳纤维束取向保持平直，不受尼龙带的压迫，不发生波动，尼龙带宽度2.5mm，厚度0.7mm；
步骤四、将表面缠绕有尼龙带的筋材毛胚以250-600mm/min的牵引速度先后经过5个烘箱，5个烘箱温度设定分别为150℃、150℃、160℃、180℃、180℃，经过第一个烘箱预热后，筋材毛胚内部的环氧树脂受热后发生膨胀并且流动性变得非常好，开始从筋材毛胚内部往外溢出，逐渐填充满尼龙带间的缝隙，经过第二个烘箱后，环氧树脂发生凝胶，经过第三烘箱后，环氧树脂发生预固化，经过最后两个烘箱完成后固化过程，树脂肋的厚度受预热时间影响，通过控制第一个烘箱的长度来控制预热时间，本申请第一烘箱的长度设置为3-7m，烘箱可分段加热，从而可调整实际烘箱的长度，本实施例中第一个烘箱的长度为。
步骤五、固化完成后，将筋材表面的尼龙带进行退绕，尼龙带间隙中的环氧树脂形成螺旋式树脂肋，尼龙带退绕部位形成螺旋式凹槽。
步骤六、制成的带树脂肋筋材经过牵引机后收卷到收线机上，制成的带树脂肋筋材的拉伸强度为3436MPa，拉伸模量为171GPa。
实施例二
一种表面带树脂肋的高强度碳纤维复合材料筋材，包括碳纤维及环氧树脂基体，筋材直径为5mm，筋材表面有连续螺旋式的环氧树脂肋，树脂肋的厚度为0.2mm，树脂肋的螺距为2mm。
一种表面带树脂肋的高强度碳纤维复合材料筋制备方法包括以下几个步骤：
步骤一、将32束碳纤维束从纱架引出，牵引速度为450mm/min，使用张力控制器控制好线的张力为6.2N；
步骤二、将碳纤维束牵引进入环氧树脂槽浸渍环氧树脂，出环氧树脂槽后进入预成型摸具，挤出多余环氧树脂，预成型模具的内径为5mm,得到直径5mm的筋材毛胚，筋材毛胚的纤维体积含量为75％，环氧树脂是采用树脂基体、固化剂和催化剂配制而成，其质量配比为1000:860:13.6；
步骤三、牵引筋材毛胚前进的同时，在筋材毛胚上缠绕尼龙带，尼龙带缠绕间距保持在5.2mm，控制缠绕张紧力，保证尼龙带只与筋材毛胚表面贴合，，不勒紧筋材毛胚，筋材毛胚表面碳纤维束取向保持平直，不发生波动，尼龙带宽度2mm，厚度0.5mm；
步骤四、将表面缠绕有尼龙带的筋材毛胚以400mm/min的牵引速度先后经过5个烘箱，5个烘箱温度设定分别为150℃、150℃、160℃、180℃、180℃，经过第一个烘箱预热后，筋材毛胚内部的环氧树脂受热后发生膨胀并且流动性变得非常好，开始从筋材毛胚内部往外溢出，逐渐填充满尼龙带间的缝隙，经过第二个烘箱后，环氧树脂发生凝胶，经过第三烘箱后，环氧树脂发生预固化，经过最后两个烘箱完成后固化过程，本实施例中第一个烘箱的长度为4m。
步骤五、固化完成后，将筋材表面的尼龙带进行退绕，尼龙带间隙中的环氧树脂形成螺旋式树脂肋，尼龙带退绕部位形成螺旋式凹槽。
步骤六、制成的带树脂肋筋材经过牵引机后收卷到收线机上，制成的带树脂肋筋材的拉伸强度为3560MPa，拉伸模量为174GPa。
本申请的固化剂选自薄荷烷二胺(MDA)、芳香胺，其中芳香胺可选m-XDA，其HDT温度为130-150℃，膨胀系数大。催化剂可以为胺类阴离子催化剂、无机盐、无机碱，包括氯化钙、氢氧化锂等。但不限于前述物料。
以上公开的本发明优选实施例只是用于帮助阐述本发明。优选实施例并没有详尽叙述所有的细节，也不限制该发明仅为所述的具体实施方式。显然，根据本说明书的内容，可作很多的修改和变化。本说明书选取并具体描述这些实施例，是为了更好地解释本发明的原理和实际应用，从而使所属技术领域技术人员能很好地理解和利用本发明。本发明仅受权利要求书及其全部范围和等效物的限制。

Claims (3)

1.一种表面带环氧树脂肋的高强度碳纤维复合材料筋材的制备方法，表面带树脂肋的高强度碳纤维复合材料筋材包括碳纤维及环氧树脂基体，所述筋材基体表面有连续螺旋式的环氧树脂肋，其特征在于：所述方法包括以下几个步骤：
步骤一、将若干束碳纤维束从纱架引出，碳纤维束的数量根据需要制成筋材的直径调整，通过纤维束的数量控制纤维占筋材毛坯的体积含量为70%-78%，牵引速度在300mm/min-600mm/min范围调整，使用张力控制器控制好线的张力，张力在5.88N-9.80N范围调整；
步骤二、将碳纤维束牵引进入环氧树脂槽浸渍环氧树脂，出环氧树脂槽后进入预成型模具，挤出多余环氧树脂，得到预定尺寸的筋材毛胚，预成型模具的内径为2mm-10mm范围；
步骤三、牵引筋材毛胚前进的同时，在筋材毛胚上缠绕尼龙带，控制缠绕张紧力，尼龙带只与筋材毛胚表面贴合而不勒紧筋材毛坯，筋材毛胚表面碳纤维束取向保持平直，尼龙带宽度2mm-4mm，厚度0.5mm-1mm；
步骤四、将表面缠绕有尼龙带的筋材毛胚牵引先后经过5个烘箱，5个烘箱温度设定分别为150℃、150℃、160℃、180℃、180℃，经过第一个烘箱预热后，筋材毛胚内部的环氧树脂受热后发生膨胀并且流动性变得非常好，开始从筋材毛胚内部往外溢出，逐渐填充满尼龙带间的缝隙，经过第二个烘箱后，环氧树脂发生凝胶，经过第三烘箱后，环氧树脂发生预固化，经过最后两个烘箱完成后固化过程；
步骤五、固化完成后，将筋材表面的尼龙带进行退绕，尼龙带间隙溢出的环氧树脂形成螺旋式树脂肋，尼龙带退绕部位形成螺旋式凹槽；
步骤六、制成的带树脂肋筋材经过牵引机后收卷到收线机上。
2.根据权利要求1所述的一种表面带环氧 树脂肋的高强度碳纤维复合材料筋材的制备方法，其特征在于，所述树脂肋的厚度在0.2mm-0.4mm范围，所述树脂肋的宽度在5mm-7mm范围，所述树脂肋的螺距在2mm-4mm范围。
3.根据权利要求1所述的一种表面带环氧 树脂肋的高强度碳纤维复合材料筋材的制备方法，其特征在于，所述步骤二中环氧树脂是采用树脂基体、固化剂和催化剂配制而成，其质量配比为1000:860:13.6。
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