CN111716862A - 一种针刺+浅表缝合三维立体预制件及其制备方法 - Google Patents

一种针刺+浅表缝合三维立体预制件及其制备方法 Download PDF

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CN111716862A
CN111716862A CN202010443513.5A CN202010443513A CN111716862A CN 111716862 A CN111716862 A CN 111716862A CN 202010443513 A CN202010443513 A CN 202010443513A CN 111716862 A CN111716862 A CN 111716862A
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fiber
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尹锋
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Yixing Huaheng High Performance Fiber Textile Co ltd
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    • B32B2038/0052—Other operations not otherwise provided for
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    • B32—LAYERED PRODUCTS
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Abstract

本发明公开了一种针刺+浅表缝合三维立体预制件及其制备方法，该预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型。该预制件通过针刺和浅表缝合交替运用的技术特点，解决了以往预制体针刺成型后因厚度太厚而难以贯穿缝合的技术难题，也弥补了行业内单一针刺和单一引纤技术上的一些不足之处，发挥了该技术产品的综合优势，其优异的综合力学性能，尤其满足了军用领域一些重要的复合材料结构件的制备要求。

Description

一种针刺+浅表缝合三维立体预制件及其制备方法
技术领域
本发明属于三维立体预制件技术领域，具体涉及一种针刺+浅表缝合三维立体预制件及其制备方法，该三维立体预制件应用于航空航天等新材料军用高端领域。
技术背景
三维立体预制件，与各种功能基体材料复合，制成结构材料，其突出的多种优良性能，广泛应用于航空、航天、军工等高端领域，然而目前的技术大多采用针刺成型法或者整体贯穿引入成型法，虽然市场也普遍使用，但其工艺技术并不理想，都有各自的优缺点，针刺成型法高效，但连接性能低，强度低，使用寿命短，整体贯穿引入成型法整体连接性能优良，耐用性好，但生产周期长，成本太高。另外针刺预制体一旦达到一定厚度，想要贯穿缝合增强，往往因厚度太厚而难以实现贯穿缝合，其性能也达不到理想状态，本发明针对现有技术的不足，改进创新，提供了一种针刺+浅表缝合三维立体预制件及其制备方法。
发明内容
本发明的目的在于针对现有技术的不足，提供一种全新的综合性能优异的针刺+浅表缝合三维立体预制件及其制备方法。
为实现上述的发明目的，本发明提供以下技术方案：
一种针刺+浅表缝合三维立体预制件，该预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型。该预制件层面高度贴合，层面连接性优异，抗拉、抗剥离强度极高，层间的高度紧密贴合又使得该预制件的压缩比比普通预制件要高，密度高，强度也高。
作为一种优选技术方案，所述平面织物的纤维类型为碳纤维、石英纤维、玻璃纤维、预氧丝纤维中的至少一种；所述网毡的纤维类型为碳纤维、石英纤维、玻璃纤维、预氧丝纤维中的至少一种。
作为一种优选技术方案，所述的平面织物为单向布、平纹布、斜纹布、缎纹布中的至少一种。
作为一种优选技术方案，所述网毡的面密度为20-300g/m2；所述平面织物的面密度为20-300g/m2。
作为一种优选技术方案，所述Z向的针刺密度为5-40针/cm2。
作为一种优选技术方案，所述Z向的缝合间距为5×5mm-20×20mm，缝合深度为5-20mm。
作为一种优选技术方案，所述Z向的缝合纤维的规格为1K、3K、6K、12K、或75tex、85tex、190tex。
本发明所述针刺+浅表缝合三维立体预制件的密度为：0.30-1.0g/cm3。
上述针刺+浅表缝合三维立体预制件的制备方法，该方法包括如下步骤：
(1)制备纤维网毡：将纤维进行短切，再经过开松、梳理、气流成网，形成网毡；
(2)制备平面织物：将纱线经织布机织造成平面织物(单向或双向)；
(3)针刺+浅表缝合成型：将平面织物和网毡组合成单元结构层，以指定针刺密度叠加单元结构层重复针刺至一定厚度，然后在网毡毡体上利用缝合针按指定间距和深度缝入连续纤维，再叠加单元结构层针刺到一定厚度后继续缝合引入连续纤维，直至预制件达到要求厚度成型为止。
作为一种优选技术方案，步骤(1)和(2)中所述网毡和平面织物的纤维类型按照预制件的用途和性能组合铺层搭配。
作为一种优选技术方案，步骤(3)中所述的针刺和缝合过程是交替进行的，针刺完缝合，缝合完再针刺，依次循环连接成型。
本发明有益的技术效果在于：
本发明提供了一种针刺+浅表缝合三维立体预制件及其制备方法，通过针刺和浅表缝合交替运用的技术特点，解决了以往预制体针刺成型后因厚度太厚而难以贯穿缝合的技术难题，发挥了该技术产品的综合优势，其优异的综合力学性能，尤其满足了军用领域一些重要的复合材料结构件的制备要求。
附图说明
图1为针刺+浅表缝合三维立体预制件的结构图。
具体实施方式
下面结合实施例，对本发明进行具体描述。
实施例1一种针刺+浅表缝合三维立体预制件
预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型；具体制备过程为：
将12K碳纤维进行短切，再经过开松、梳理、气流成网，制成碳纤维网毡，面密度为50g/m2。
将12K碳纤维经织布机织造成平纹布，面密度为200g/m2，将平纹布和网毡按组合成单元结构层，用针刺纤维1(针把网毡刺进去的连接纤维，即12K碳纤维)叠层针刺至厚度10mm，针刺密度为20针/cm2，然后在网毡毡体上利用缝合针按间距10×10mm缝入缝合纤维2(3K碳纤维单纤)，缝合深度15mm，再叠加单元层针刺至总厚度20mm后继续缝合，间距10×10mm，缝合深度15mm，第一第二缝合间距错位5×5mm，依照此规律针刺和缝合交替进行，直至预制件达到要求厚度成型为止，制得的预制体3密度为0.6g/cm3(如图1所示)。
实施例2一种针刺+浅表缝合三维立体预制件
预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型；具体制备过程为：
将85tex石英纤维进行短切，再经过开松、梳理、气流成网，制成碳纤维网毡，面密度为100g/m2。
将12K碳纤维经织布机织造成缎纹布，面密度为260g/m2，将缎纹布和网毡按组合成单元结构层，用针刺纤维1(85tex石英纤维网毡的纤维束)叠层针刺至厚度8mm，针刺密度为10针/cm2，然后在网毡毡体上利用缝合针按间距8×8mm缝入缝合纤维2(195tex石英纤维单纤)，缝合深度12mm，再叠加单元层针刺至总厚度16mm后继续缝合，间距8×8mm，缝合深度12mm，第一第二缝合间距错位4×4mm，依照此规律针刺和缝合交替进行，直至预制件达到要求厚度成型为止，制得的三维立体预制体3密度为0.7g/cm3(如图1所示)。
实施例3一种针刺+浅表缝合三维立体预制件
预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型；具体制备过程为：
将玻璃纤维进行短切，再经过开松、梳理、气流成网，制成碳纤维网毡，面密度为200g/m2。
将玻璃纤维经织布机织造成斜纹布，面密度为200g/m2，将斜纹布和网毡按组合成单元结构层，用针刺纤维1(玻璃纤维)叠层针刺至厚度10mm，针刺密度为15针/cm2，然后在网毡毡体上利用缝合针按间距12×12mm缝入缝合纤维2(380tex石英纤维单纤)，缝合深度15mm，再叠加单元层针刺至总厚度20mm后继续缝合，间距12×12mm，缝合深度15mm，第一第二缝合间距错位6×6mm，依照此规律针刺和缝合交替进行，直至预制件达到要求厚度成型为止，制得的三维立体预制体3密度为0.75g/cm3(如图1所示)。
以上实施例描述了本发明的基本原理和主要特征，本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的具体工作原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内，本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (10)

1.一种针刺+浅表缝合三维立体预制件，其特征在于，该预制件XY向由平面织物与网毡交替铺层，Z向通过针刺和浅表缝合技术同时引入网毡纤维束和缝合纤维束，由两种类型纤维束贯穿连接成型。
2.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述平面织物的纤维类型为碳纤维、石英纤维、玻璃纤维、预氧丝纤维中的至少一种；所述网毡的纤维类型为碳纤维、石英纤维、玻璃纤维、预氧丝纤维中的至少一种。
3.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述的平面织物为单向布、平纹布、斜纹布、缎纹布中的至少一种。
4.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述网毡的面密度为20-300g/m2；所述平面织物的面密度为20-300g/m2。
5.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述Z向的针刺密度为5-40针/cm2。
6.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述Z向的缝合间距为5×5mm-20×20mm，缝合深度为5-20mm。
7.根据权利要求1所述的针刺+浅表缝合三维立体预制件，其特征在于，所述Z向的缝合纤维的规格为1K、3K、6K、12K、或75tex、85tex、190tex。
8.权利要求1所述针刺+浅表缝合三维立体预制件的制备方法，其特征在于，该方法包括如下步骤：
(1)制备纤维网毡：将纤维进行短切，再经过开松、梳理、气流成网，形成网毡；
(2)制备平面织物：将纱线经织布机织造成平面织物；
(3)针刺+浅表缝合成型：将平面织物和网毡组合成单元结构层，以指定针刺密度叠加单元结构层重复针刺至一定厚度，然后在网毡毡体上利用缝合针按指定间距和深度缝入连续纤维，再叠加单元结构层针刺到一定厚度后继续缝合引入连续纤维，直至预制件达到要求厚度成型为止。
9.根据权利要求8所述的制备方法，其特征在于，步骤(1)和(2)中所述网毡和平面织物的纤维类型按照预制件的用途和性能组合铺层搭配。
10.根据权利要求8所述的制备方法，其特征在于，步骤(3)中所述的针刺和缝合过程是交替进行的，针刺完缝合，缝合完再针刺，依次循环连接成型。
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CN109371569A (zh) * 2018-10-30 2019-02-22 中材科技股份有限公司 一种密度可调可控的针刺预制体及其制备方法
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