CN112848383A - 一种碳纤维层间剪切样条的制备方法和制备装置 - Google Patents
一种碳纤维层间剪切样条的制备方法和制备装置 Download PDFInfo
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Abstract
本发明涉及一种碳纤维层间剪切样条的制备方法和制备装置,其现有方法和装置不便于操作、测定误差大、可重复性差的技术问题,其包括如下步骤:在热压上下模具上均匀涂上脱模剂,预热;将所需碳纤维缠绕在缠丝板上,预热;称量并配制胶液,放入热压机中对树脂体系进行热熔;将所配透明状胶液涂抹在预热好的热碳纤维样品上;将涂有透明胶液的碳纤维从缠丝板上取下,放入热压下模具中,用纤维束夹持装置夹住纤维两端,加热;合模,加热;升温继续加热;再升温加热,降温冷却、脱模、切割,备测试用。本发明同时提供其设备。本发明可用于碳纤维的测试领域。
Description
技术领域
本发明涉及一种复合材料制备方法和制备装置,具体说是一种碳纤维层间剪切样条的制备方法和制备装置。
背景技术
碳纤维是指含碳量在90%以上的无机材料纤维,它具有密度小、质量轻、高强度、高比模量、耐磨损、耐腐蚀等一系列的优异性能,因此广泛用在航空航天、体育休闲、汽车轻量化、风电叶片等领域和行业。
随着我国碳纤维技术的逐步突破,碳纤维的生产打破了国外的技术垄断,T300、T700、T800等碳纤维已实现了稳定的国产化,稳定可靠的检测数据,为我国碳纤维行业突破国外技术壁垒提供了强有力的数据支持,为技术改进提供了指导依据。
碳纤维在生产过程中,层间剪切强度是表征界面处理优良的重要指标。现有制备技术碳纤维层间剪切强度样条均采用手工加压,所施加压力不可控,不能确保样条所受压力一致,且取出加压时温度没有保障,人工在此操作过程中随机性较大,因此造成层间剪切强度误差较大,离散系数较大,不能完全真实反应出高性能碳纤维的层间剪切强度,不能很好的指导生产过程界面处理工艺。
公开号为CN108426760A的中国发明专利申请公开了一种制备复合材料层间剪切强度样条方法,其包括如下步骤:a)在制样之前,根据碳纤维的规格和复合材料样条中纤维的含量计算所需碳纤维的根数;b)称量并配制适量的环氧树脂胶液,将其放入烘箱中热熔至透明状;c)将碳纤维置于退卷装置上,将其导入浸胶槽,将热熔后的环氧树脂胶液倒入浸胶槽中,没过纤维,并在缠丝板上缠绕相应根数浸渍胶液后的纤维;d)用刀片取下缠丝板上浸渍胶液的纤维,对称折叠3次后,平直放入提前在烘箱中预热且均匀涂有脱模剂的模具槽体的凹槽中;e)将纤维和槽体一并放入140℃的烘箱中加热60min,胶液***时取出模具槽体,放回140℃烘箱中继续加热60-90min,取出后再次加压150-280N·m,再放入160℃烘箱中固化2-4h后,冷却、脱模切割成所需尺寸测试样条。
但是,该方法主要存在如下问题:
1、先浸胶再缠丝,无法保证胶液在纤维上的均匀性;
2、胶液***时合模,则制备样条的含胶量难以控制;
3、首次加压时未明确控制压力,不便于操作和过程的可重复性;
4、合模、加压时需从烘箱中取出,造成操作过程中温度得不到控制;
5、人工操作过程中随机因素多,会造成层间剪切强度误差较大,离散系数较大。
发明内容
本发明就是为了解决现有方法和装置不便于操作、测定误差大、可重复性差的技术问题,提供一种测定方便、准确可靠、一致性好的碳纤维层间剪切样条的制备方法和制备装置。
为此,本发明提供一种碳纤维层间剪切样条的制备方法,包括以下步骤:(1)在热压上下模具上均匀涂上脱模剂,设置温度为120℃,预热0.5h;(2)计算所需碳纤维的根数:n=1000*f*b*h/(d/D),式中:n—碳纤维根数;f—样品中纤维含量;b—模具厚度,mm;h—模具宽度,mm;d—纤维线密度,g/km;D—纤维体密度,g/cm3;(3)将碳纤维缠绕在缠丝板上,放入热压机中预热约10min;(4)称量并配制适量胶液,放入热压机中缓慢对树脂体系进行热熔,至透明状胶液;(5)将所配透明状胶液迅速均匀涂抹在预热好的热碳纤维样品上;(6)将涂有透明胶液的碳纤维从缠丝板上取下,折叠放入热压下模具中,用纤维束夹持装置夹住纤维两端,确保纤维平直,优选于120℃加热0.5h;(7)合模,设置预加压压力为(8~10)KN,留有缝隙不超过0.5mm,优选于140℃加热0.5h;(8)设置压力为(50~70)KN,优选于温度为160℃继续加热(2~3)h;(9)设置为优选180℃加热(1~2)h后降温冷却、脱模、切割,备测试用。
本发明同时提供一种碳纤维层间剪切样条的制备装置,其设有热压上模具、热压下模具、纤维束夹持装置、传动加压装置、保温层和控制***,所述热压上模具、热压下模具、纤维束夹持装置和传动加压装置设于所述保温层内;所述传动加压装置用于带动热压上模具的上下移动;所述保温层起到保护温场温度均匀性,无热量流失;所述控制***可以控制温度、压力、时间、位移,可以程序设置参数,具备存储功能,含显示面板。
优选的,所述热压上模具为凸型,用于加热、加压、上下移动。
优选的,所述热压上模具为凹型,用于加热和放置样条。
优选的,所述纤维束夹持装置设有定位螺钉,可以进一步微调夹紧,用于夹持纤维两端,确保纤维平直;
本发明具有以下有益效果:
1.实现了封闭环境下的自动控制,确保了温度、压力、时间可控;
2.样条各部位所承受压力一致,便于控制含胶量,大大提高了样条制备的成功率;
3.根据环氧树脂热分析结果,优化了温度设置,从而提高了样条固化质量和效率;
4.操作更加便捷、提高了检测效率、降低了人员成本;
5.避免了合模和转移模具时操作失误造成纤维卷曲或移动的可能性;
6.规避了高温模具转移时的安全隐患;
7.优化了操作环境,避免了样品转移时未固化树脂滴落造成的难清理现象;
8.通过本装置制备层间剪切样条,保证了检测结果准确可靠、一致性好。
附图说明
图1为本发明的结构示意图。
图中,1、热压上模具;2、热压下模具;3、纤维束夹持装置;4、传动加压装置;5、保温层和控制***;6、保温层。
具体实施方式
下面结合实施例对本发明做进一步描述。
如图1所示,本发明提供一种碳纤维层间剪切样条的制备装置,其设有热压上模具1、热压下模具2、纤维束夹持装置3、传动加压装置4、保温层6和控制***5,热压上模具1、热压下模具2、纤维束夹持装置3和传动加压装置4设于保温层6内,控制***5与电脑相连;传动加压装置4用于带动热压上模具1的上下移动;保温层6起到保护温场温度均匀性,无热量流失;控制***5可以控制温度、压力、时间、位移。热压上模具1为凸型,用于加热、加压、上下移动。热压下模具为凹型,用于加热和放置样条。纤维束夹持装置3设有定位螺钉。热压上模具下模具设有温度、压力、位移控制传感器。
实施例1:
1.在热压上下模具上均匀涂上脱模剂,设置温度为120℃,预热0.5h;
2.计算所需碳纤维的根数:
本实施例中所使用的纤维的线密度为808g/km,密度1.81g/cm3,假设碳纤维在试样中所占的体积分数为40%,模具宽为6mm,模具厚度为2mm,则碳纤维层间剪切强度样条所需的纤维根数为:n=40%×6×2×103/(808/1.81)=11根,即绕取纤维的圈数为11/2=5.5圈;
3.将碳纤维缠绕在缠丝板上,放入热压机中预热约10min;
4.称量并配制适量胶液,放入热压机中缓慢对树脂体系进行热熔,至透明状胶液;
5.将所配透明状胶液迅速均匀涂抹在预热好的热碳纤维样品上;
6.将涂有透明胶液的碳纤维从缠丝板上取下,折叠放入热压下模具中,用纤维束夹持装置夹住纤维两端,确保纤维平直,于120℃加热0.5h;
7.合模,设置预加压压力为10KN,留有缝隙不超过0.5mm,140℃加热0.5h;
8.设置压力为70KN,温度为160℃继续加热2h;
9.设置为180℃加热1.5h后降温冷却、脱模、切割,备测试用。
本实施例中,层间剪切强度子样离散系数为(1.5-2.0)%,整个制样工序需要操作工1名,用时(5.5-6.5)小时。
实施例2:
1.在热压上下模具上均匀涂上脱模剂,设置温度为120℃,预热0.5h;
2.计算所需碳纤维的根数:
本实施例中所使用的纤维的线密度为514g/km,密度1.78g/cm3,假设碳纤维在试样中所占的体积分数为60%,模具宽为6mm,模具厚度为2mm,则碳纤维层间剪切强度样条所需的纤维根数为:n=60%×6×2×103/(514/1.78)=25根,即绕取纤维的圈数为25/2=12.5圈;
3.将碳纤维缠绕在缠丝板上,放入热压机中预热约10min;
4.称量并配制适量胶液,放入热压机中缓慢对树脂体系进行热熔,至透明状胶液;
5.将所配透明状胶液迅速均匀涂抹在预热好的热碳纤维样品上;
6.将涂有透明胶液的碳纤维从缠丝板上取下,折叠放入热压下模具中,用纤维束夹持装置夹住纤维两端,确保纤维平直,于120℃加热0.5h;
7.合模,设置预加压压力为8KN,留有缝隙不超过0.5mm,140℃加热0.5h;
8.设置压力为50KN,温度为160℃继续加热2.5h;
9.设置为180℃加热1h后降温冷却、脱模、切割,备测试用。
本实施例中,层间剪切强度离散系数为(1.8-2.5)%,整个制样工序需要操作工1名,用时(5-6)小时。
对比例1:
1.模具预热:在模具的槽体内和上盖的凸台上分别均匀涂抹脱模剂,放入140℃的烘箱中进行预热。
2.计算纤维根数:本对比例中所使用的纤维的线密度为808g/km,密度1.81g/cm3,假设碳纤维在试样中所占的体积分数为40%,模具宽为6mm,模具厚度为2mm,则碳纤维层间剪切强度样条所需的纤维根数为:n=40%×6×2×103/(808/1.81)=11根,即绕取纤维的圈数为11/2=5.5圈;
3.利用浸胶装置对碳纤维丝束浸渍胶液,通过调节退卷张力为10N,控制纤维的树脂含量。
4.将浸渍有环氧树脂的碳纤维丝束对折3次后对其施加一定的张力,保证其处于伸直状态,然后放入模具槽体内,碳纤维丝束的两端伸出槽体两侧,将模具连同折叠后的纤维一并放入140℃的烘箱中加热60min,取出后,将上盖的凸台和槽体契合,加压至模具留有0.8mm的缝隙后放回140℃烘箱中继续加热90min,取出后用力矩扳手对夹紧装置施加150N·m的力。
5.将二次加压的模具放入烘箱中,使试样在160℃固化4h。
6.取出烘箱中的模具冷却至室温后,将模具内的样条取出,切割,备测试用。
层间剪切强度离散系数为(5.1-5.9)%,整个制样工序需要操作工1名,用时8-9小时。
通过对比例1与实施例1的对比可以看出,同一轴碳纤维,同样模具尺寸和树脂含量,对比例1的层间剪切强度离散系数是实施例1的3倍,用时是实施例1的1.4倍。可见,实施例1制备的样条质量更高,耗时更短。
对比例2:
1.模具预热:在模具的槽体内和上盖的凸台上分别均匀涂抹脱模剂,放入140℃的烘箱中进行预热。
2.计算纤维根数:本对比例中所使用的纤维的线密度为514g/km,密度1.78g/cm3,假设碳纤维在试样中所占的体积分数为60%,模具宽为6mm,模具厚度为2mm,则碳纤维层间剪切强度样条所需的纤维根数为:n=60%×6×2×103/(514/1.78)=25根,即绕取纤维的圈数为23/2=12.5圈;
3.利用浸胶装置对碳纤维丝束浸渍胶液,通过调节退卷张力为5N,控制纤维的树脂含量。
4.将浸渍有环氧树脂的碳纤维丝束对折3次后对其施加一定的张力,保证其处于伸直状态,然后放入模具槽体内,碳纤维丝束的两端伸出槽体两侧,将模具连同折叠后的纤维一并放入140℃的烘箱中加热60min,取出后,将上盖的凸台和槽体契合,加压至模具留有0.5mm的缝隙后放回140℃烘箱中继续加热60min,取出后用力矩扳手对夹紧装置施加280N·m的力。
5.将二次加压的模具放入烘箱中,使试样在160℃固化4h。
6.取出烘箱中的模具冷却至室温后,将模具内的样条取出,切割,备测试用。
层间剪切强度离散系数为(4.8-5.7)%,整个制样工序需要操作工1名,用时7-8小时。
通过对比例2与实施例2的对比可以看出,同一轴碳纤维,同样模具尺寸和树脂含量,对比例2的层间剪切强度离散系数是实施例1的2.3倍,用时是实施例2的1.3倍。可见,实施例制备的样条质量更高,耗时更短。
惟以上所述者,仅为本发明的具体实施例而已,当不能以此限定本发明实施的范围,故其等同组件的置换,或依本发明专利保护范围所作的等同变化与修改,皆应仍属本发明权利要求书涵盖之范畴。
Claims (10)
1.一种碳纤维层间剪切样条的制备方法,其特征是,包括如下步骤:
(1)在热压上下模具上均匀涂上脱模剂,预热;
(2)计算所需碳纤维的根数:
n=1000*f*b*h/(d/D)
式中:
n——碳纤维根数;
f——样品中纤维含量;
b——模具厚度,mm;
h——模具宽度,mm;
d——纤维线密度,g/km;
D——纤维体密度,g/cm3;
(3)将碳纤维缠绕在缠丝板上,放入热压机中预热;
(4)称量并配制胶液,放入热压机中缓慢对树脂体系进行热熔,至透明状胶液;
(5)将所配透明状胶液迅速均匀涂抹在预热好的热碳纤维样品上;
(6)将涂有透明胶液的碳纤维从缠丝板上取下,折叠放入热压下模具中,用纤维束夹持装置夹住纤维两端,确保纤维平直,加热;
(7)合模,设置预加压压力为8~10KN,加热;
(8)设置压力为50~70KN,升温继续加热;
(9)再升温加热,降温冷却、脱模、切割,备测试用。
2.根据权利要求1所述的碳纤维层间剪切样条的制备方法,其特征在于,所述步骤(6)中的加热温度为120℃。
3.根据权利要求1所述的碳纤维层间剪切样条的制备方法,其特征在于,所述步骤(7)中的加热温度为140℃。
4.根据权利要求1所述的碳纤维层间剪切样条的制备方法,其特征在于,所述步骤(8)中的加热温度为160℃。
5.根据权利要求1所述的碳纤维层间剪切样条的制备方法,其特征在于,所述步骤(9)中的加热温度为180℃。
6.一种碳纤维层间剪切样条的制备装置,其特征是,设有热压上模具、热压下模具、纤维束夹持装置、传动加压装置、保温层和控制***,所述热压上模具、热压下模具、纤维束夹持装置和传动加压装置设于所述保温层内;
所述传动加压装置用于带动热压上模具的上下移动;
所述保温层起到保护温场温度均匀性,无热量流失;
所述控制***可以控制温度、压力、时间、位移。
7.根据权利要求6所述的碳纤维层间剪切样条的制备装置,其特征在于,所述热压上模具为凸型,用于加热、加压、上下移动。
8.根据权利要求6所述的碳纤维层间剪切样条的制备装置,其特征在于,所述热压上模具为凹型,用于加热和放置样条。
9.根据权利要求6所述的碳纤维层间剪切样条的制备装置,其特征在于,所述纤维束夹持装置设有定位螺钉。
10.根据权利要求6所述的碳纤维层间剪切样条的制备装置,其特征在于,所述热压上模具和热压下模具设有温度、压力、位移控制传感器。
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