CN114013127A - 非织造布增强复合材料及其制备方法 - Google Patents

非织造布增强复合材料及其制备方法 Download PDF

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CN114013127A
CN114013127A CN202210007361.3A CN202210007361A CN114013127A CN 114013127 A CN114013127 A CN 114013127A CN 202210007361 A CN202210007361 A CN 202210007361A CN 114013127 A CN114013127 A CN 114013127A
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woven fabric
fabric
yarn
composite material
reinforced composite
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CN114013127B (zh
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王春红
左祺
陈莉
潘国立
吴帅
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Tianjin Polytechnic University
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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Abstract

本发明提供了一种非织造布增强复合材料及其制备方法。非织造布增强复合材料包括由植物纤维和热塑性纤维所制备的混合纤维网或预针刺非织造布和由热塑性纱线包覆植物纤维纱线所制备的二绞一平均对称绞的纱罗网格织物；将纱罗网格织物作为混合纤维网或预针刺非织造布的加强筋，在纱罗网格织物的网格所在位置上进行定点网格针刺，使混合纤维网或预针刺非织造布中的纤维随着刺针的运动垂直填充到网格结构中，以降低非织造布增强复合材料的分层现象，并充分发挥纱罗网格织物加强筋对非织造布增强复合材料的增强作用，实现同时改善非织造布增强复合材料的力学性能和层间性能。

Description

非织造布增强复合材料及其制备方法
技术领域
本发明属于复合材料的制备技术领域，涉及一种植物纤维增强热塑性纤维非织造布复合材料，尤其涉及了一种具有纱罗网格针刺结构的非织造布增强复合材料及其制备方法。
背景技术
非织造布增强复合材料指的是由植物纤维和热塑性纤维所制备的混合纤维网或预针刺非织造布增强的复合材料，这类非织造布增强复合材料具有密度小，各向同性，吸声隔热等优异的特性，在汽车内饰材料、轨道交通内饰材料、建筑装饰材料、体育用品等领域得到了广泛的应用。
非织造布增强复合材料通常采用针刺作为非织造布的常规加固方式，可以加固单层的非织造布，但是非织造布增强复合材料通常由多层铺叠的非织造布通过模压制备而成，层间仅通过热塑性纤维热粘合作用连接起来，极易发生分层现象，并且由于非织造布中纤维的无序取向，在应力传递中无法充分发挥植物纤维的承力效果，非织造布增强复合材料整体的拉伸、弯曲、剪切和冲击性能偏低，不利于进一步拓展非织造布增强复合材料在承力要求较高的领域中应用。
进一步的，加强筋技术已经被研究用于增强非织造布复合材料的力学性能。如使用平纹网格织物和经编网格织物作为加强筋，加强非织造布增强复合材料的力学性能。但是由于平纹网格织物和经编网格织物的尺寸稳定性差，使得嵌入有加强筋的非织造布复合材料具有严重的分层恶化现象。
有鉴于此，确有必要对现有技术中的非织造布复合材料的结构进行改进，以解决上述问题。
发明内容
本发明的目的在于提供一种非织造布增强复合材料及其制备方法，以克服非织造布增强复合材料力学性能和层间性能较差的问题。
为实现上述发明目的，本发明提供了一种非织造布增强复合材料的制备方法，包括以下步骤：
S1、非织造布的制备，采用一种或多种植物纤维和一种或多种热塑性纤维，制备由所述植物纤维和所述热塑性纤维混合制备的非织造布；
S2、包覆纱的制备，采用一种或多种所述植物纤维纺制芯纱，采用一种或多种热塑性纱线对所述芯纱进行包覆，制备纱线特数为200-1000tex的所述包覆纱；
S3、纱罗网格织物的制备，采用所述包覆纱作为地经和纬纱，利用绞经固结所述地经和所述纬纱，按照纱罗组织的交织规律织造得到网格尺寸为0.2-10cm的所述纱罗网格织物；
S4、非织造布预制件的制备，采用所述纱罗网格织物作为加强筋，铺叠在所述非织造布的上层、下层或者中间层，通过定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件；
S5、非织造布增强复合材料的制备，将具有纱罗网格针刺结构的所述非织造布预制件放入模压机，通过模压成型，制得具有纱罗网格针刺结构的非织造布增强复合材料。
作为本发明的进一步改进，所述植物纤维为黄麻纤维、汉麻纤维、苎麻纤维、亚麻纤维、剑麻纤维以及棕榈纤维中的任意一种或多种；所述热塑性纤维为聚丙烯纤维、聚酯纤维以及聚乳酸纤维中的任意一种或多种。
作为本发明的进一步改进，在所述步骤S1中，所述非织造布为混合纤维网或预针刺非织造布中的任一种，所述混合纤维网为采用所述植物纤维和所述热塑性纤维通过混合开松，梳理成网制备而成，所述预针刺非织造布为通过对所述混合纤维网进行预针刺制备获取。
作为本发明的进一步改进，在所述步骤S2中，所述芯纱为细纱、粗纱或者股线中的任一种；所述热塑性纱线由聚丙烯纤维或长丝、聚酯纤维或长丝以及聚乳酸纤维或长丝中的任意一种或多种制备而成。
作为本发明的进一步改进，所述步骤S3中，所述纱罗网格织物为使用两根所述绞经从左右两侧分别对一根所述地经进行绞纱，所述绞经平均分布于所述地经两侧，两根所述绞经和一根所述地经形成绞组，每个所述绞组需要两组骑综进行织造，以使得所述纱罗网格织物呈二绞一平均对称绞的所述纱罗组织的交织规律进行织造。
作为本发明的进一步改进，所述步骤S3中的所述绞经为聚丙烯纱线、聚酯纱线、聚乳酸纱线、黄麻纱线、汉麻纱线、苎麻纱线、亚麻纱线、芳纶纱线中的任意一种或多种，且所述绞经的特数为20-150tex。
作为本发明的进一步改进，在所述步骤S4中，所述定点网格针刺为将所述纱罗网格织物和所述非织造布混合铺叠后整体进行针刺，且针刺位置定点为所述纱罗网格织物的网格所在位置，通过对网格所在位置进行上针刺、下针刺或者上下针刺，使所述非织造布中的纤维随着刺针的运动垂直填充到所述纱罗网格织物的网格结构中。
作为本发明的进一步改进，所述定点网格针刺的植针密度为0.5-4针/cm、针刺速度为0.1-4刺/s、间歇式的输送动程为0.1-10cm/s。
作为本发明的进一步改进，在所述步骤S5中，所述非织造布预制件模压成型的模压温度为130~250℃，模压压力为1-20MPa，模压时间为10min-120min，且在降温卸压后，需在25℃的条件下放置24小时。
为实现上述发明目的，本发明还提供了一种非织造布增强复合材料，由采用植物纤维和热塑性纤维制备的非织造布和由热塑性纱线包覆植物纤维制备的包覆纱所制备的纱罗网格织物混合铺层后，经针刺、模压制备获取，且所述非织造布增强复合材料为采用前述的非织造布增强复合材料的制备方法制备获取。
本发明的有益效果：本发明的非织造布增强复合材料通过使用纱罗网格织物作为加强筋并使用针刺的方法将混层叠放的非织造布和纱罗网格织物进行固定，使得非织造布中的纤维在针刺过程中垂直进入纱罗网格织物的网格中，使得非织造布和纱罗网格织物中的纤维垂直纠缠，降低了非织造布与加强筋之间的分层现象，从而充分发挥纱罗网格织物加强筋对非织造布增强复合材料力学性能的加强效果，有效提升了非织造布增强复合材料的力学性能和层间性能，提高产品的综合性能和可靠性。
附图说明
图1 a为本发明的非织造布增强复合材料中纱罗网格织物的正面组织结构图；图1b为本发明的非织造布增强复合材料中纱罗网格织物的反面组织结构图。
图2 a为图1中纱罗网格织物另一角度的正面组织结构图；图2 b为图1中纱罗网格织物另一角度的反面组织结构图。
图3 为本发明非织造布与纱罗网格织物层叠针刺后纤维在纱罗网格织物的网格中的分布示意图。
图4为本发明的非织造布增强复合材料的制备方法的流程图。
附图标号：1-纬纱；2-地经；3-绞经；4-非织造布；5-纱罗网格织物；6-针刺刺针；7-纱罗网格织物的网格所在位置。
具体实施方式
为了使本发明的目的、技术方案和优点更加清楚，下面结合附图和具体实施例对本发明进行详细描述。
在此，需要说明的是，为了避免因不必要的细节而模糊了本发明，在附图中仅仅示出了与本发明的方案密切相关的结构和/或处理步骤，而省略了与本发明关系不大的其他细节。
另外，还需要说明的是，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。
本发明提供了的一种非织造布增强复合材料，非织造布增强复合材料由采用植物纤维和热塑性纤维制备的非织造布4和由热塑性纱线包覆植物纤维制备的包覆纱所制备的纱罗网格织物5混合铺层后，经针刺模压制备获取，具体的，非织造布增强复合材料为由非织造布4和纱罗网格织物5混合铺层、针刺后制备的非织造布预制件，如图1~3所示，经模压、降温后制备，且非织造布增强复合材料为采用本发明提供的非织造布增强复合材料的制备方法制备。
请参阅图4并结合图1~3所示，为本发明提供的非织造布增强复合材料的制备方法。非织造布增强复合材料的制备方法包括：
S1、非织造布4的制备，采用一种或多种植物纤维和一种或多种热塑性纤维，制备由所述植物纤维和所述热塑性纤维混合制备的非织造布4；
S2、包覆纱的制备，采用一种或多种所述植物纤维纺制芯纱，采用一种或多种热塑性纱线对所述芯纱进行包覆，制备纱线特数为200-1000tex的所述包覆纱；
S3、纱罗网格织物5的制备，采用所述包覆纱作为地经和纬纱，利用绞经固结所述地经和所述纬纱，按照纱罗组织的交织规律织造得到网格尺寸为0.2-10cm的所述纱罗网格织物5；
S4、非织造布预制件的制备，采用所述纱罗网格织物5作为加强筋，铺叠在所述非织造布4的上层、下层或者中间层，通过定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件；
S5、非织造布增强复合材料的制备，将具有纱罗网格针刺结构的所述非织造布预制件放入模压机，通过模压成型，制得具有纱罗网格针刺结构的非织造布增强复合材料。
以下说明书部分将针对步骤S1~S5进行详细的描述。
在步骤S1中，非织造布4为混合纤维网或预针刺非织造布中的任一种，具体的，混合纤维网为采用黄麻纤维、汉麻纤维、苎麻纤维、亚麻纤维、剑麻纤维以及棕榈纤维中的任意一种或多种植物纤维和聚丙烯纤维、聚酯纤维以及聚乳酸纤维中的任意一种或多种热塑性纤维，通过混合开松，梳理成网的工序混纺制成；进一步的，混合纤维网可直接作为非织造布4进行后续的处理，当然混合纤维网也可经过预针刺继而获取预针刺非织造布，并使用该预针刺非织造布进行后续的处理制备获得非织造布增强复合材料，即，在步骤S1非织造布4的类型可根据实际需要进行选择只需保证单层的非织造布4的面密度为50-350g/cm2即可。
步骤S2具体为包覆纱的制备，本发明中的包覆纱为制备纱罗网格织物5所用的纱线。包覆纱为芯纱和包覆在芯纱外层的饰纱经纺制而成，具体的，芯纱为细纱、粗纱或者股线中的任一种，且芯纱由黄麻纤维、汉麻纤维、苎麻纤维、亚麻纤维、剑麻纤维以及棕榈纤维中的任意一种或多种植物纤维纺制而成；饰纱由聚丙烯纤维或长丝、聚酯纤维或长丝以及聚乳酸纤维或长丝中的任意一种或多种经纺制获取的热塑性纱线，进一步的，采用花式捻线机将作为饰纱的热塑性纱线包覆在芯纱外部，继而制备获取纱线特数为200-1000tex的包覆纱，热塑性纱线在后续的模压工艺中熔融，将芯纱完全包裹起来，形成复合材料。优选的，作为饰纱的热塑性纱线的材料与用于制备非织造布4所用的热塑性纤维的材质相同，如此设置，使得包覆纱与非织造布4具有一样的熔融温度，以方便后续的模压加工。
步骤S3为采用包覆纱进行纱罗网格织物5的制备。如图1~2所示，纱罗网格织物5由纬纱1、地经2和绞经3按照纱罗组织的交织规律织造而成。具体的，纱罗网格织物5的纱罗组织结构为：将两根绞经3从左右两侧分别对一根地经2进行绞纱，绞经3平均分布于地经2两侧，两根绞经3和一根地经2形成绞组，每个绞组需要两组骑综进行织造，以使得纱罗网格织物5按照二绞一平均对称绞的交织规律进行织造，且纱罗网格织物5的网格尺寸为0.2-10cm。相较于常规的纱罗组织通常只用一组骑综，本发明中的纱罗网格织物5可达到良好的平均绞纱的效果。事实上，平均绞纱的组织结构更有利于地经2与纬纱1的固结，保证的纱罗网格织物5的尺寸稳定性。
进一步的，用于织造纱罗网格织物5的纬纱1和地经2均为前述的包覆纱，绞经3为聚丙烯纱线、聚酯纱线、聚乳酸长纱线、黄麻纱线、汉麻纱线、苎麻纱线、亚麻纱线或者芳纶纱线中的任意一种或多种，且绞经的特数为20-150tex。事实上，采用热塑性纱线作为包覆纱的饰纱和绞经3使得热塑性纱线在交织点处交织，增加了交织点位置的树脂含量，提高了热塑性树脂的浸渍程度；进一步的，植物纤维纱线和高性能纤维纱线的选用则可以在复合材料的经纱方向额外地提高载荷。
步骤S4具体为将非织造布4和加强筋混合层叠后进行定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件。具体的，非织造布预制件的制备主要指的是将一层或者多层的由热塑性纱线包覆植物纤维的包覆纱所制备的纱罗网格织物5作为加强筋，铺叠在由植物纤维和热塑性纤维制备的混合纤维网或预针刺非织造布的上层、下层或者中间层，采用定点网格针刺的方式，配合纱罗网格织物加强筋的所在网格位置和网格尺寸，使紧挨着纱罗网格织物5上层、下层或者上下层的混合纤维网或预针刺非织造布中的纤维通过针刺的上下运动，垂直地填充到网格结构中，将纱罗网格织物5固定在多层的非织造布4之间或者上表面或者下表面，使多层非织造布4之间以及非织造布4与加强筋之间产生层间的连接。优选的，定点网格针刺的针刺参数与纱罗网格尺寸0.2-10cm相配合，其植针密度为0.5-4针/cm、针刺速度为0.1-4刺/s、间歇式的输送动程为0.1-10cm/s，如此可使得针刺刺针6，定点刺到纱罗网格织物5的网格所在位置7中，完成非织造布预制件的制备。
步骤S5具体为将非织造布预制件整体放入模压机中，加压并加热，通过模压成型，制得具有纱罗网格针刺结构的非织造布增强复合材料，且在本申请中，非织造布预制件模压成型的模压温度为130~250℃，模压压力为1-20MPa，模压时间为10min-120min，降温卸压后，在25℃条件下放置24小时，完成非织造布增强复合材料的制备。
具体的，非织造布预制件在模压过程中，纱罗网格织物5（即加强筋）中的热塑性纱线和非织造布4中的热塑性纤维熔融，或者同时将纱罗网格织物5的绞经3熔融，使其流动并与周围的植物纤维结合，事实上，非织造布预制件为经过针刺获得，针刺之后纱罗网格结构中具有一定的热塑性纤维与植物纤维，并且沿针刺方向分布；热塑性纱线和热塑性纤维的熔融拉近了热塑性树脂基体与植物纤维增强体的距离，有利于树脂浸润，且在基体熔融后，纱罗网格织物5中的网格所在位置形成了局部垂直方向的纤维增强复合材料，以此使非织造布4与纱罗网格织物5之间形成了层间联接。多层非织造布4层间也因为垂直方向的植物纤维和热塑性纤维形成层间纠缠，避免了非织造布4之间以及非织造布4与网格织物之间出现的严重分层问题，提高非织造布增强复合材料的力学性能。
以下说明书部分将通过设置3组具体实施例和3组对比例对使用本申请的非织造布增强复合材料的制备方法制备的非织造布增强复合材料与常规的制备方法制备的非织造布增强复合材料进行对比描述。
实施例1：
S1、将黄麻长纤维切断，长度为63mm。采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2、使用300tex的聚丙烯长丝包覆600tex的黄麻股线，得到聚丙烯热塑性长丝包覆黄麻纤维纱线的包覆纱，且包覆后的纱线特数为900tex。
S3、将步骤S2中的包覆纱作为纬纱1和地经2，利用300tex的聚丙烯热塑性长丝作为绞经3，固结地经2和纬纱1，按照二绞一平均对称绞纱罗组织的交织规律织造得到网格尺寸为0.5cm的纱罗网格织物5。
S4、以步骤S3中由聚丙烯热塑性长丝包覆黄麻纤维纱线所制备的纱罗网格织物5作为加强筋，铺叠在12层未预针刺的黄麻/聚丙烯非织造布4的中间层，采用2针/cm的植针密度，针刺速度1刺/s及0.5cm/s的输送动程，对非织造布4进行上下定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件。
S5、将具有纱罗网格针刺结构的非织造布预制件放入模压机，通过模压成型，模压温度185℃，模压压力10MPa，模压时间60min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得具有纱罗网格针刺结构的非织造布增强复合材料。
实施例2：
S1、将黄麻长纤维切断，长度为63mm。采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2、使用300tex的聚丙烯长丝包覆600tex的黄麻股线，得到聚丙烯热塑性长丝包覆黄麻纤维纱线的包覆纱，且包覆后的纱线特数为900tex。
S3、将步骤S2中的包覆纱作为纬纱1和地经2，利用300tex的聚丙烯热塑性长丝作为绞经3，固结地经2和纬纱1，按照二绞一平均对称绞纱罗组织的交织规律织造得到网格尺寸为0.5cm的纱罗网格织物5。
S4、以步骤S3中由聚丙烯热塑性长丝包覆黄麻纤维纱线所制备的纱罗网格织物5作为加强筋，铺叠在12层未预针刺的黄麻/聚丙烯非织造布4的中间层，采用4针/cm的植针密度，针刺速度2刺/s及0.5cm/s的输送动程，对非织造布4进行上下定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件。
S5、将具有纱罗网格针刺结构的非织造布预制件放入模压机，通过模压成型，模压温度185℃，模压压力15MPa，模压时间15min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得具有纱罗网格针刺结构的非织造布增强复合材料。
实施例3：
S1、将黄麻长纤维切断，长度为63mm，采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2、使用300tex的聚丙烯长丝包覆600tex的黄麻股线，得到聚丙烯热塑性长丝包覆黄麻纤维纱线的包覆纱，且包覆后的纱线特数为900tex。
S3、将步骤S2中的包覆纱作为纬纱1和地经2，利用300tex的聚丙烯热塑性长丝作为绞经3，固结地经2和纬纱1，按照二绞一平均对称绞纱罗组织的交织规律织造得到网格尺寸为1cm的纱罗网格织物5。
S4、以步骤S3中由聚丙烯热塑性长丝包覆黄麻纤维纱线所制备的纱罗网格织物5作为加强筋，铺叠在12层未预针刺的黄麻/聚丙烯非织造布4的中间层，采用2针/cm的植针密度，针刺速度1刺/s及1cm/s的输送动程，对非织造布4进行上下定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件。
S5、将具有纱罗网格针刺结构的非织造布预制件放入模压机，通过模压成型，模压温度185℃，模压压力15MPa，模压时间15min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得具有纱罗网格针刺结构的非织造布增强复合材料。
对比例1：
S1’、将黄麻长纤维切断，长度为63mm，采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2’、将12层未预针刺的黄麻/聚丙烯非织造布4预制件放入模压机，通过模压成型，模压温度185℃，模压压力15MPa，模压时间60min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得不含纱罗网格织物加强筋且未定点网格针刺的非织造布增强复合材料。
对比例2：
S1’、将黄麻长纤维切断，长度为63mm，采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2’、将12层未预针刺的黄麻/聚丙烯非织造布4，采用2针/cm的植针密度，针刺速度1刺/s及1cm/s的输送动程，对非织造布4进行上下定点网格针刺，得到具有不含有纱罗网格织物加强筋但含有定点针刺结构的非织造布预制件。
S3’、将不含有纱罗网格织物加强筋但含有定点针刺结构的非织造布预制件放入模压机，通过模压成型，模压温度185℃，模压压力15MPa，模压时间60min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得不含有纱罗网格织物加强筋但含有定点针刺结构的非织造布增强复合材料。
对比例3：
S1’、将黄麻长纤维切断，长度为63mm。采用切断后的黄麻纤维与长度为63mm的聚丙烯热塑性纤维进行混合开松及梳理，制备成面密度为265g/cm2的黄麻/聚丙烯混合纤维网，得到未预针刺的黄麻/聚丙烯非织造布4。
S2’、使300tex的聚丙烯长丝包覆600tex的黄麻股线，得到聚丙烯热塑性长丝包覆黄麻纤维纱线的包覆纱，包覆后的纱线特数为900tex。
S3’、将步骤S2’中聚丙烯热塑性长丝包覆黄麻纤维纱线的包覆纱作为地经和纬纱，利用300tex的聚丙烯热塑性长丝作为绞经，固结地经和纬纱，按照二绞一平均对称绞纱罗组织的交织规律织造得到纱罗网格织物5，使二根绞经在一根地经的两侧平均分布，得到由聚丙烯热塑性长丝包覆黄麻纤维纱线所制备的纱罗网格织物5，网格尺寸为0.5cm。
S4’、将步骤S3’中聚丙烯热塑性长丝包覆黄麻纤维纱线所制备的纱罗网格织物5作为加强筋，铺叠在12层未预针刺的黄麻/聚丙烯非织造布4的中间层，得到含有纱罗网格织物加强筋但不含有定点针刺结构的非织造布预制件。
S5’、将含有纱罗网格织物加强筋但不含有定点针刺结构的非织造布预制件放入模压机，通过模压成型，模压温度185℃，模压压力15MPa，模压时间60min，板厚3mm。降温卸压后，在25℃条件下放置24小时，制得含有纱罗网格织物加强筋但不含有定点针刺结构的非织造布增强复合材料。
对实施例1-3和对比例1-3制备的非织造布增强复合材料的拉伸、弯曲、冲击性能进行测试，测试结果如表1所示。
表1 非织造布增强复合材料的拉伸弯曲性能
拉伸强度/MPa 标准差 弯曲强度/MPa 标准差 简支梁冲击强度/KJ•m<sup>-2</sup> 标准差
实施例1 40.74 0.79 66.56 0.24 80.71 3.51
实施例2 43.09 1.25 71.3 2.3 85.31 2.90
实施例3 33.26 0.86 65.5 3.57 73.11 0.53
对比例1 20.32 2.12 51.98 3.45 22.94 4.87
对比例2 26.40 1.06 53.21 2.14 30.45 1.96
对比例3 32.21 0.85 53.37 6.42 65.18 2.11
由表1可知，相较于不含纱罗网格织物加强筋且未定点网格针刺的非织造布增强复合材料（对比例1）、不含有纱罗网格织物加强筋但含有定点针刺结构的非织造布增强复合材料（对比例2）以及含有纱罗网格织物加强筋但不含有定点针刺结构的非织造布增强复合材料（对比例3），采用本发明的非织造布增强复合材料的制备方法制备的非织造布增强复合材料具有良好的拉伸强度、弯曲强度以及简支梁冲击强度。
综上所述，本发明的非织造布增强复合材料通过使用纱罗网格织物5作为加强筋并使用针刺的方法将混层叠放的非织造布4和纱罗网格织物5进行固定，使得非织造布4中的纤维在针刺过程中垂直进入纱罗网格织物5的网格中，继而使得非织造布4和纱罗网格织物5中的纤维垂直纠缠，降低了非织造布4与加强筋之间的分层现象，从而充分发挥纱罗网格织物加强筋对非织造布增强复合材料力学性能的加强效果，有效提升了非织造布增强复合材料的力学性能和层间性能，提高产品的综合性能和可靠性。
以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的精神和范围。

Claims (10)

1.一种非织造布增强复合材料的制备方法，其特征在于，包括以下步骤：
S1、非织造布的制备，采用一种或多种植物纤维和一种或多种热塑性纤维，制备由所述植物纤维和所述热塑性纤维混合制备的非织造布；
S2、包覆纱的制备，采用一种或多种所述植物纤维纺制芯纱，采用一种或多种热塑性纱线对所述芯纱进行包覆，制备纱线特数为200-1000tex的所述包覆纱；
S3、纱罗网格织物的制备，采用所述包覆纱作为地经和纬纱，利用绞经固结所述地经和所述纬纱，按照纱罗组织的交织规律织造得到网格尺寸为0.2-10cm的所述纱罗网格织物；
S4、非织造布预制件的制备，采用所述纱罗网格织物作为加强筋，铺叠在所述非织造布的上层、下层或者中间层，通过定点网格针刺，得到具有纱罗网格针刺结构的非织造布预制件；
S5、非织造布增强复合材料的制备，将具有纱罗网格针刺结构的所述非织造布预制件放入模压机，通过模压成型，制得具有纱罗网格针刺结构的非织造布增强复合材料。
2.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：在所述步骤S1中，所述植物纤维为黄麻纤维、汉麻纤维、苎麻纤维、亚麻纤维、剑麻纤维以及棕榈纤维中的任意一种或多种；所述热塑性纤维为聚丙烯纤维、聚酯纤维以及聚乳酸纤维中的任意一种或多种。
3.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：在所述步骤S1中，所述非织造布为混合纤维网或预针刺非织造布中的任一种，所述混合纤维网为采用所述植物纤维和所述热塑性纤维通过混合开松，梳理成网制备而成，所述预针刺非织造布为通过对所述混合纤维网进行预针刺制备获取。
4.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：在所述步骤S2中，所述芯纱为细纱、粗纱或者股线中的任一种；所述热塑性纱线由聚丙烯纤维或长丝、聚酯纤维或长丝以及聚乳酸纤维或长丝中的任意一种或多种制备而成。
5.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：所述步骤S3中，所述纱罗网格织物为使用两根所述绞经从左右两侧分别对一根所述地经进行绞纱，所述绞经平均分布于所述地经两侧，两根所述绞经和一根所述地经形成绞组，每个所述绞组需要两组骑综进行织造，以使得所述纱罗网格织物呈二绞一平均对称绞的所述纱罗组织的交织规律进行织造。
6.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：所述步骤S3中的所述绞经为聚丙烯纱线、聚酯纱线、聚乳酸纱线、黄麻纱线、汉麻纱线、苎麻纱线、亚麻纱线、芳纶纱线中的任意一种或多种，且所述绞经的特数为20-150tex。
7.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：所述步骤S4中，所述定点网格针刺为将所述纱罗网格织物和所述非织造布混合铺叠后整体进行针刺，且针刺位置定点为所述纱罗网格织物的网格所在位置，通过对网格所在位置进行上针刺、下针刺或者上下针刺，使所述非织造布中的纤维随着刺针的运动垂直填充到所述纱罗网格织物的网格结构中。
8.根据权利要求7所述的非织造布增强复合材料的制备方法，其特征在于：所述定点网格针刺的植针密度为0.5-4针/cm、针刺速度为0.1-4刺/s、间歇式的输送动程为0.1-10cm/s。
9.根据权利要求1所述的非织造布增强复合材料的制备方法，其特征在于：在所述步骤S5中，所述非织造布预制件模压成型的模压温度为130~250℃，模压压力为1-20MPa，模压时间为10min-120min，且在降温卸压后，需在25℃的条件下放置24小时。
10.一种非织造布增强复合材料，其特征在于：由采用植物纤维和热塑性纤维制备的非织造布和由热塑性纱线包覆植物纤维制备的包覆纱所制备的纱罗网格织物混合铺层后，经针刺、模压制备获取，且所述非织造布增强复合材料为采用权利要求1~9中任一项所述的非织造布增强复合材料的制备方法制备获取。
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CN113638134A (zh) * 2021-06-29 2021-11-12 天津工业大学 一种高体积分数高性能针刺预制体及其制备方法

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CN115503301A (zh) * 2022-09-02 2022-12-23 上海品诚控股集团有限公司 一种天然纤维增强热塑性复合材料及其制备方法
CN115503301B (zh) * 2022-09-02 2024-05-14 上海品诚控股集团有限公司 一种天然纤维增强热塑性复合材料及其制备方法

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