CN111572104A - 一种低成本复合材料芯管及其制造方法 - Google Patents

一种低成本复合材料芯管及其制造方法 Download PDF

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CN111572104A
CN111572104A CN202010475188.0A CN202010475188A CN111572104A CN 111572104 A CN111572104 A CN 111572104A CN 202010475188 A CN202010475188 A CN 202010475188A CN 111572104 A CN111572104 A CN 111572104A
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parts
resin system
low
composite core
curing
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孟玲宇
杨志忠
费春东
裴放
赵亮
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Shanghai Shenyong Electromechanical Equipment Co ltd
Harbin FRP Institute Co Ltd
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Shanghai Shenyong Electromechanical Equipment Co ltd
Harbin FRP Institute Co Ltd
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Abstract

一种低成本复合材料芯管及其制造方法，本发明涉及用于聚酯薄膜、聚氯乙烯薄膜和聚乙烯薄膜等卷绕的复合材料芯管及其制造方法，它为了解决现有薄膜卷绕纸芯管刚度不足，钢制芯管自重大且磕碰难修复的问题。本发明低成本复合材料芯管是由外表面层卷绕在内结构层复合形成管体，其中内结构层的材质按照质量份数由20～50份的常温固化树脂体系和50～80份的纤维复合而成；外表面层的材质按照质量份数由40～80份的常温固化树脂体系、20～60份表面毡和黑色染料糊复合而成。本发明所述的复合材料芯管具有承载能力强、质量轻、表面粗糙度高和磕碰可修复性等优点。

Description

一种低成本复合材料芯管及其制造方法
技术领域
本发明涉及用于聚酯薄膜、聚氯乙烯薄膜和聚乙烯薄膜等卷绕的复合材料芯管及其制造方法。
背景技术
在聚酯薄膜、聚氯乙烯薄膜和聚乙烯薄膜等行业的生产及转运过程中，薄膜通过设备卷绕至芯管上，芯管承担薄膜所有重量，每卷薄膜重量大概10kg～1000kg不等。因此要求芯管具有高刚度、质量轻、抗疲劳性、较高表面粗糙度、耐腐蚀和可修复等特性。通常广泛应用的芯管为纸芯，其有刚度不足，耐腐蚀性差等缺点。另一种芯管为钢制，也存在许多不足，如自重大，容易被腐蚀等不足。新型芯管是由纤维增强树脂复合材料制造，此种芯管通过纤维缠绕工艺成型，因其轻质高强、耐腐蚀等优点，逐渐替代纸质或钢制芯管，但其制造成本较高，而且芯管表面受外力磕碰后无法修补。
发明内容
本发明的目的是为了解决现有薄膜卷绕纸芯管刚度不足，钢制芯管自重大且磕碰难修复的问题，而提供一种低成本复合材料芯管及其制造方法。
本发明低成本复合材料芯管是由外表面层卷绕在内结构层复合形成管体，其中内结构层的材质按照质量份数由20～50份的常温固化树脂体系和50～80份的纤维复合而成；外表面层的材质按照质量份数由40～80份的常温固化树脂体系、20～60份表面毡和黑色染料糊复合而成；
所述的常温固化树脂体系为不饱和聚酯树脂体系或者环氧树脂体系，不饱和聚酯树脂体系由不饱和聚酯树脂、引发剂和促进剂混合组成，环氧树脂体系由环氧树脂和固化剂混合组成。
本发明低成本复合材料芯管的制造方法按照以下步骤实现：
一、在芯模表面涂脱模剂，然后将常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维缠绕在芯模上(形成一定厚度)，然后人工缠绕脱模布，芯模内腔油浴循环加热进行固化处理，固化结束后去除脱模布，得到带有内结构层的芯模；
三、将常温固化树脂体系和黑色染料糊混合，均匀涂抹在内结构层表面，然后将表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，脱模后，得到复合芯管；
四、芯管定长切割后，采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
本发明所述的纤维增强复合材料芯管，具有高刚度、质量轻、抗疲劳性、较高表面粗糙度、耐腐蚀和可修复等特性。该复合材料芯管的结构由两部分组成，内层为纤维增强树脂基复合材料的结构层，外层为纤维毡增强树脂基复合材料的表面层。此芯管具有承载能力强、质量轻、表面粗糙度高和磕碰可修复性等优点，当芯管表面磕碰后，用成型芯管的常温固化树脂体系进行磕碰处填充，树脂体系固化后粘接在磕碰处，经1000目砂纸打磨修复处的凸点即可修复。
本发明低成本复合材料芯管的具体技术指标为：芯管表面粗糙度在1.6以上，承载重量约1000kg以内，圆柱度0.3mm以内，圆周跳动0.3mm以内，轴向弯曲强度大于100MPa，圆周方向弯曲强度大于300MPa，轴向弯曲模量大于10GPa，圆周方向弯曲模量大于18GPa。
附图说明
图1为本发明低成本复合材料芯管的结构示意图，其中1—内结构层，2—外表面层。
具体实施方式
具体实施方式一：本实施方式低成本复合材料芯管是由外表面层2卷绕在内结构层1复合形成管体，其中内结构层1的材质按照质量份数由20～50份的常温固化树脂体系和50～80份的纤维复合而成；外表面层2的材质按照质量份数由40～80份的常温固化树脂体系、20～60份表面毡和黑色染料糊复合而成；
所述的常温固化树脂体系为不饱和聚酯树脂体系或者环氧树脂体系，不饱和聚酯树脂体系由不饱和聚酯树脂、引发剂和促进剂混合组成，环氧树脂体系由环氧树脂和固化剂混合组成。
具体实施方式二：本实施方式与具体实施方式一不同的是内结构层1的厚度为4～10mm，外表面层的厚度为1～5mm。
具体实施方式三：本实施方式与具体实施方式一或二不同的是所述的纤维为玻璃纤维或碳纤维。
具体实施方式四：本实施方式与具体实施方式一至三之一不同的是不饱和聚酯树脂的型号是FL-199或FL-883。
具体实施方式五：本实施方式与具体实施方式一至四之一不同的是环氧树脂的型号是环氧树脂型号E-51或E-54。
具体实施方式六：本实施方式与具体实施方式一至五之一不同的是所述的表面毡为玻璃纤维表面毡或碳纤维表面毡。
本实施方式表面毡的规格为面密度30～100g/m2。
具体实施方式七：本实施方式与具体实施方式一至六之一不同的是不饱和聚酯树脂体系按照质量份数由100份不饱和聚酯树脂、1～5份引发剂和0.1～0.5份促进剂混合组成，所述的引发剂为过氧化甲乙酮，所述的促进剂为环烷酸钴。
具体实施方式八：本实施方式与具体实施方式一至七之一不同的是环氧树脂体系按照质量份数由100份环氧树脂和80～100份固化剂混合组成，所述的固化剂是聚酰胺651。
具体实施方式九：本实施方式低成本复合材料芯管的制造方法按照以下步骤实施：
一、在芯模表面涂脱模剂，然后将常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维缠绕在芯模上(形成一定厚度)，然后人工缠绕脱模布，芯模内腔油浴循环加热进行固化处理，固化结束后去除脱模布，得到带有内结构层的芯模；
三、将常温固化树脂体系和黑色染料糊混合，均匀涂抹在内结构层表面，然后将表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，脱模后，得到复合芯管；
四、芯管定长切割后，采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
具体实施方式十：本实施方式与具体实施方式九不同的是步骤二和步骤三中的固化处理是在40～60℃温度下固化1～2h。
实施例1：本实施例低成本复合材料芯管的制造方法按照以下步骤实施：
一、在圆柱形芯模表面涂脱模剂，按照质量份数将乙烯基酯树脂100份、引发剂3份、促进剂0.5份搅拌均匀，得到常温固化树脂体系，常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透玻璃纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维按螺旋型和环向交替缠绕在芯模上，直至管壁厚达到芯管内结构层规定厚度，然后人工缠绕脱模布，芯模内腔油浴循环加热在60℃的温度下固化2h，固化结束后去除脱模布，得到带有内结构层的芯模；
三、按照质量份数将乙烯基酯树脂100份、引发剂3份、促进剂0.5份和黑色染料糊5份混合均匀，均匀涂抹在内结构层表面，然后将玻璃纤维表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，在60℃的温度下固化2h，脱模后，得到复合芯管；
四、采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
本实施例内结构层中玻璃纤维与常温固化树脂体系的质量比为71：29，外表面层中玻璃纤维表面毡与常温固化树脂体系的质量比为20：80。
本实施例制备的得到的低成本复合材料芯管复合材料的轴向弯曲强度120MPa，圆周方向弯曲强度330MPa，轴向弯曲模量12GPa，圆周方向弯曲模量23GPa，显示出优异的力学性能。
实施例2：本实施例低成本复合材料芯管的制造方法按照以下步骤实施：
一、在圆柱形芯模表面涂脱模剂，按照质量份数将环氧树脂100份和固化剂80份搅拌均匀，得到常温固化树脂体系，常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透玻璃纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维按螺旋型和环向交替缠绕在芯模上，然后人工缠绕脱模布，芯模内腔油浴循环加热在60℃的温度下固化2h，固化结束后去除脱模布，得到带有内结构层的芯模；
三、按照质量份数将环氧树脂100份、固化剂80份和黑色染料糊5份混合均匀，均匀涂抹在内结构层表面，然后将玻璃纤维表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，在60℃的温度下固化2h，脱模后，得到复合芯管；
四、采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
本实施例内结构层中玻璃纤维与常温固化树脂体系的质量比为68：32，外表面层中玻璃纤维表面毡与常温固化树脂体系的质量比为20：80。
实施例3：本实施例低成本复合材料芯管的制造方法按照以下步骤实施：
一、在圆柱形芯模表面涂脱模剂，按照质量份数将环氧树脂100份和固化剂80份搅拌均匀，得到常温固化树脂体系，常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透碳纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维按螺旋型和环向交替缠绕在芯模上，然后人工缠绕脱模布，芯模内腔油浴循环加热在60℃的温度下固化2h，固化结束后去除脱模布，得到带有内结构层的芯模；
三、按照质量份数将环氧树脂100份、固化剂80份和黑色染料糊5份混合均匀，均匀涂抹在内结构层表面，然后将玻璃纤维表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，在60℃的温度下固化2h，脱模后，得到复合芯管；
四、采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
实施例4：本实施例与实施例1不同的是步骤二常温固化树脂体系浸透碳纤维，得到树脂浸透的纤维。

Claims (10)

1.一种低成本复合材料芯管，其特征在于该低成本复合材料芯管是由外表面层卷绕在内结构层复合形成管体，其中内结构层的材质按照质量份数由20～50份的常温固化树脂体系和50～80份的纤维复合而成；外表面层的材质按照质量份数由40～80份的常温固化树脂体系、20～60份表面毡和黑色染料糊复合而成；
所述的常温固化树脂体系为不饱和聚酯树脂体系或者环氧树脂体系，不饱和聚酯树脂体系由不饱和聚酯树脂、引发剂和引发剂促进剂混合组成，环氧树脂体系由环氧树脂和固化剂混合组成。
2.根据权利要求1所述的一种低成本复合材料芯管，其特征在于内结构层的厚度为4～10mm，外表面层的厚度为1～5mm。
3.根据权利要求1所述的一种低成本复合材料芯管，其特征在于所述的纤维为玻璃纤维或碳纤维。
4.根据权利要求1所述的一种低成本复合材料芯管，其特征在于不饱和聚酯树脂的型号是FL-199或FL-883。
5.根据权利要求1所述的一种低成本复合材料芯管，其特征在于环氧树脂的型号是环氧树脂型号E-51或E-54。
6.根据权利要求1所述的一种低成本复合材料芯管，其特征在于所述的表面毡为玻璃纤维表面毡或碳纤维表面毡。
7.根据权利要求1所述的一种低成本复合材料芯管，其特征在于不饱和聚酯树脂体系按照质量份数由100份不饱和聚酯树脂、1～5份引发剂和0.1～0.5份引发剂促进剂混合组成，所述的引发剂为过氧化甲乙酮，所述的引发剂促进剂为环烷酸钴。
8.根据权利要求1所述的一种低成本复合材料芯管，其特征在于环氧树脂体系按照质量份数由100份环氧树脂和80～100份固化剂混合组成，所述的固化剂是聚酰胺651。
9.低成本复合材料芯管的制造方法，其特征在于该制造方法按照以下步骤实现：
一、在芯模表面涂脱模剂，然后将常温固化树脂体系均匀地涂覆在芯模表面；
二、常温固化树脂体系浸透纤维，得到树脂浸透的纤维，通过缠绕机将树脂浸透的纤维缠绕在芯模上，然后人工缠绕脱模布，芯模内腔油浴循环加热进行固化处理，固化结束后去除脱模布，得到带有内结构层的芯模；
三、将常温固化树脂体系和黑色染料糊混合，均匀涂抹在内结构层表面，然后将表面毡卷绕在内结构层上并被树脂浸透，芯模内腔油浴循环加热进行固化处理，脱模后，得到复合芯管；
四、芯管定长切割后，采用外圆磨床对复合芯管的表面进行磨削处理，得到低成本复合材料芯管。
10.根据权利要求9所述的低成本复合材料芯管的制造方法，其特征在于步骤二和步骤三中的固化处理是在40～60℃温度下固化1～2h。
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