CN112549727A - 表面复合碳纤维的低密度材料及其制备方法 - Google Patents
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Abstract
本发明涉及碳纤维复合材料技术领域，是一种表面复合碳纤维的低密度材料及其制备方法，其通过将碳纤维进行浸泡预处理，再将低密度材料与浸泡后的碳纤维在适宜相同温度下粘接并干燥后得到表面复合碳纤维的低密度材料。本本发明所述表面复合碳纤维的低密度材料，其通过采用适宜的粘接温度以及所述粘接处理，使低密度材料与碳纤维粘接融合过程中，产生的热应力减小，使碳纤维更加牢固地粘接在低密度材料表面，由此得到质轻、耐高温、耐摩擦、导电、导热及耐腐蚀的复合材料，其可应用于飞机、医疗器械制造等领域，并且采用本发明的制备方法能够提高碳纤维与低密度材料的粘接牢固度，使碳纤维与低密度材料不易分离。
Description
技术领域
本发明涉及碳纤维复合材料技术领域，是一种表面复合碳纤维的低密度材料及其制备方法。
背景技术
碳纤维主要是由碳元素组成的一种特种纤维，其含碳量随种类不同而异，一般在90%以上。碳纤维具有一般碳素材料的特性，如耐高温、耐摩擦、导电、导热及耐腐蚀等，但与一般碳素材料不同的是，其外形有显著的各向异性、柔软、可加工成各种织物，沿纤维轴方向表现出很高的强度。碳纤维比重小，因此有很高的比强度。
碳纤维是20世纪50年代初应火箭、宇航及航空等尖端科学技术的需要而产生的，还广泛应用于体育器械、纺织、化工机械及医学领域。随着尖端技术对新材料技术性能的要求日益苛刻，促使科技工作者不断努力提高。20世纪80年代初期，高性能及超高性能的碳纤维相继出现，这在技术上是又一次飞跃，同时也标志着碳纤维的研究和生产已进入一个高级阶段。
由碳纤维和环氧树脂结合而成的复合材料，由于其比重小、刚性好和强度高而成为一种先进的航空航天材料。因为航天飞行器的重量每减少1公斤，就可使运载火箭减轻500公斤。所以在航空航天工业中争相采用先进复合材料。有一种垂直起落战斗机，它所用的碳纤维复合材料已占全机重量的1/4，占机翼重量的1/3。据报道，美国航天飞机上3只火箭推进器的关键部件以及先进的MX导弹发射管等，都是用先进的碳纤维复合材料制成的。
（世界一级方程锦标赛）赛车，车身大部分结构都用碳纤维材料。顶级跑车的一大卖点也是周身使用碳纤维，用以提高气动性和结构强度。传统使用的碳纤维除用作绝热保温材料外，一般不单独使用，多作为增强材料加入到树脂、金属、陶瓷、混凝土等材料中，构成复合材料。碳纤维增强的复合材料可用作飞机结构材料、电磁屏蔽除电材料、人工韧带等身体代用材料以及用于制造火箭外壳、机动船、工业机器人、汽车板簧和驱动轴等。
对于低密度材料而言，通过材料表面复合可以增强局部功能，但是在其表面复合是碳纤维材料时，容易出现与碳纤维材料粘接不吻合，位置偏移等问题。这可能是因为粘接融合过程中，这两种材料粘接面温度不一致，导致产生热应力，后期在使用过程中容易脱层分离。
发明内容
本发明提供了一种表面复合碳纤维的低密度材料及其制备方法，克服了上述现有技术之不足，其能有效解决低密度材料与碳纤维的复合材料后期在使用过程中容易脱层分离的问题。
本发明的技术方案是通过以下措施来实现的：一种表面复合碳纤维的低密度材料的制备方法，包括下述步骤：
步骤1：将低密度材料处理后得到板材；
步骤2：将碳纤维浸入环氧树脂、酚醛树脂、脲醛树脂和聚胺酯中的一种或多种进行浸泡，将浸泡后的碳纤维放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维共同加热到表面温度为30℃至32℃时，在板材的粘接面均匀涂抹环氧树脂、酚醛树脂、脲醛树脂和聚胺酯中的一种或多种，接着将板材与干燥成型后的碳纤维粘接得到复合材料；
步骤4：将复合材料进行干燥后得到表面复合碳纤维的低密度材料。
优选的，低密度材料的密度为 0.05g/cm3至0.53g/cm3。
优选的，步骤1中，低密度材料按下述方法进行处理：将低密度材料依序经过切割、表面打磨、清洗、水浴超声和干燥后得到板材。
优选的，碳纤维采用碳纤维布。
本发明所述表面复合碳纤维的低密度材料，其通过采用适宜的粘接温度以及所述粘接处理，使低密度材料与碳纤维粘接融合过程中，产生的热应力减小，使碳纤维更加牢固地粘接在低密度材料表面，由此得到质轻、耐高温、耐摩擦、导电、导热及耐腐蚀的复合材料，其可应用于飞机、医疗器械制造等领域，并且采用本发明的制备方法能够提高碳纤维与低密度材料的粘接牢固度，使碳纤维与低密度材料不易分离。
具体实施方式
本发明不受下述实施例的限制，可根据本发明的技术方案与实际情况来确定具体的实施方式。本发明中所提到各种化学试剂和化学用品如无特殊说明，均为现有技术中公知公用的化学试剂和化学用品。
本发明中使用的低密度材料可以采用公开号为110229263公开的一种轻质高强高分子材料，也可以采用其它现有公知密度为 0.05g/cm3至0.53g/cm3的低密度材料。
下面结合实施例对本发明作进一步描述：
实施例1：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维布浸入环氧树脂中浸泡，将浸泡后的碳纤维布放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维布共同加热到表面温度为32℃时，在板材的粘接面均匀涂抹环氧树脂，接着将板材与干燥成型后的碳纤维布粘接得到复合材料；
步骤4：将复合材料在温度为80℃的烘箱中干燥5h后得到表面复合碳纤维的低密度材料。
实施例1中的碳纤维布采用T300碳纤维。
实施例2：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维布浸入聚胺酯和脲醛树脂的混合体系中的浸泡，将浸泡后的碳纤维布放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维布共同加热到表面温度为30℃时，在板材的粘接面均匀涂抹聚胺酯和脲醛树脂的混合体系，接着将板材与干燥成型后的碳纤维布粘接得到复合材料；
步骤4：将复合材料在温度为60℃的烘箱中干燥6h得到表面复合碳纤维的低密度材料。
实施例2中的碳纤维布采用T700碳纤维。
实施例3：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维布浸入环氧树脂、酚醛树脂和脲醛树脂的混合体系中浸泡，将浸泡后的碳纤维布放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维布共同加热到表面温度为31℃时，在板材的粘接面均匀涂抹环氧树脂、酚醛树脂和脲醛树脂的混合体系，接着将板材与干燥成型后的碳纤维布粘接得到复合材料；
步骤4：将复合材料在温度为90℃的烘箱中干燥5h后得到表面复合碳纤维的低密度材料。
实施例3中的碳纤维布采用石墨化碳纤维布。
实施例4：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维布浸入环氧树脂、酚醛树脂、脲醛树脂和聚胺酯的混合体系中浸泡，将浸泡后的碳纤维布放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维布共同加热到表面温度为32℃时，在板材的粘接面均匀涂抹环氧树脂、酚醛树脂、脲醛树脂和聚胺酯的混合体系，接着将板材与干燥成型后的碳纤维布粘接得到复合材料；
步骤4：将复合材料在温度为60℃的烘箱中干燥10h后得到表面复合碳纤维的低密度材料。
实施例4中的碳纤维布采用预氧化碳纤维布。
实施例5：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维片材依序经环氧树脂、酚醛树脂浸泡，将浸泡后的碳纤维片材放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维片材共同加热到表面温度为31℃时，在板材的粘接面依序经环氧树脂、酚醛树脂，接着将板材与干燥成型后的碳纤维片材粘接得到复合材料；
步骤4：将复合材料在温度为70℃的烘箱中干燥8h后得到表面复合碳纤维的低密度材料。
实施例5中的碳纤维布采用预氧化碳纤维布。
实施例6：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维片材依序经酚醛树脂和脲醛树脂浸泡，将浸泡后的碳纤维片材放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维片材共同加热到表面温度为30℃时，在板材的粘接面均匀涂抹环氧树脂和酚醛树脂的混合体系，接着将板材与干燥成型后的碳纤维片材粘接得到复合材料；
步骤4：将复合材料在温度为85℃的烘箱中干燥6h得到表面复合碳纤维的低密度材料。
实施例6中的碳纤维布采用石墨化碳纤维布。
实施例7：该表面复合碳纤维的低密度材料按下述制备方法得到，包括下述步骤：
步骤1：将低密度材料经过切割、表面打磨、清洗、水浴超声和干燥后得到板材；
步骤2：将碳纤维片材浸入聚胺酯中浸泡，将浸泡后的碳纤维片材放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维片材共同加热到表面温度为32℃时，在板材的粘接面依序均匀涂抹环氧树脂、酚醛树脂和脲醛树脂，接着将板材与干燥成型后的碳纤维片材粘接得到复合材料；
步骤4：将复合材料在温度为65℃的烘箱中干燥5h后得到表面复合碳纤维的低密度材料。
实施例7中的碳纤维布采用T300碳纤维。
对比例1：与实施例1的不同之处在于，步骤3中的板材和干燥成型后的碳纤维布共同加热到表面温度为25℃。
对比例2：与实施例2的不同之处在于，步骤3中的板材和干燥成型后的碳纤维布共同加热到表面温度为40℃。
对比例3：将碳纤维先进行热压成型并冷却后，再将碳纤维与低密度材料放入模具中一次成型得到复合材料。
实施例1至7得到表面复合碳纤维的低密度材料以及对比例1至3得到的复合材料进行剥离测试，按照“GB8808-1988软质复合材料T型剥离强度测试方法”执行，实施例1至7得到表面复合碳纤维的低密度材料的剥离力明显高于对比例的剥离力，比如，实施例1得到表面复合碳纤维的低密度材料的平均剥离力为914N，对比例1得到的复合材料的平均剥离力623N。
本发明所述表面复合碳纤维的低密度材料，其通过采用适宜的粘接温度以及所述粘接处理，使低密度材料与碳纤维粘接融合过程中，产生的热应力减小，使碳纤维更加牢固地粘接在低密度材料表面，由此得到质轻、耐高温、耐摩擦、导电、导热及耐腐蚀的复合材料，其可应用于飞机、医疗器械制造等领域，并且采用本发明的制备方法能够提高碳纤维与低密度材料的粘接牢固度，使碳纤维与低密度材料不易分离。
以上技术特征构成了本发明的实施例，其具有较强的适应性和实施效果，可根据实际需要增减非必要的技术特征，来满足不同情况的需求。
Claims (6)
1.一种表面复合碳纤维的低密度材料的制备方法，其特征在于包括下述步骤：
步骤1：将低密度材料处理后得到板材；
步骤2：将碳纤维浸入环氧树脂、酚醛树脂、脲醛树脂和聚胺酯中的一种或多种进行浸泡，将浸泡后的碳纤维放入模具中并干燥成型；
步骤3：将板材和干燥成型后的碳纤维共同加热到表面温度为30℃至32℃时，在板材的粘接面均匀涂抹环氧树脂、酚醛树脂、脲醛树脂和聚胺酯中的一种或多种，接着将板材与干燥成型后的碳纤维粘接得到复合材料；
步骤4：将复合材料进行干燥后得到表面复合碳纤维的低密度材料。
2.根据权利要求1所述的表面复合碳纤维的低密度材料的制备方法，其特征在于低密度材料的密度为 0.05g/cm3至0.53g/cm3。
3.根据权利要求1或2所述的表面复合碳纤维的低密度材料的制备方法，其特征在于步骤1中，低密度材料按下述方法进行处理：将低密度材料依序经过切割、表面打磨、清洗、水浴超声和干燥后得到板材。
4.根据权利要求1或2所述的表面复合碳纤维的低密度材料的制备方法，其特征在于碳纤维采用碳纤维布。
5.根据权利要求3所述的表面复合碳纤维的低密度材料的制备方法，其特征在于碳纤维采用碳纤维布。
6.一种根据权利要求1至5任意一项所述的表面复合碳纤维的低密度材料的制备方法制备得到的表面复合碳纤维的低密度材料。
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