CN114193849A - 一种纤维增强复合材料油囊及其制备方法 - Google Patents
一种纤维增强复合材料油囊及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种纤维增强复合材料油囊及其制备方法,由纤维增强材料和热固性树脂制备成型。所述纤维增强材料分为4层,从内到外依次包括A层底膜层、B层增强层、C层防护层和D层面膜层。本发明的油囊经过纤维铺层设计,与热固性树脂和助剂固化而成。相比于传统的油囊,在耐油性优异的情况下,本发明的油囊具有更好的柔韧性、可弯折性、耐高温性、耐疲劳性、耐腐蚀性,使用寿命长,呈现出明显的性能优势。
Description
技术领域
本发明涉及油囊技术领域,特别涉及一种纤维增强复合材料油囊及其制备方法。
背景技术
油囊主要用于加注汽油、柴油等燃料,在补给、运输和储存等领域应用广泛。传统的油囊多采用TPU、PVC或橡胶材料。PVC或橡胶材料耐候性、耐磨性差,不环保;TPU相比于PVC和橡胶材料,其耐油性好、质量轻、柔韧性好、焊接性能优异,但聚酯型TPU的耐水解性差,储存介质含有水分时会对材料产生影响。另外,PVC、橡胶和TPU材料涂覆在织物表面,其复合材料的剥离强度、撕裂强度、耐油性和耐候性也不太令人满意。
CN103161624B的一种囊式油箱,包括套筒盖、油囊套筒、油囊、回油管和吸油管。所述油囊由可变形的橡胶纤维复合材料制成,底部为倒锥形。由于油囊由橡胶纤维复合材料制成,具有可变形的特征,因而具有一定的防撞能力,可以避免或减少油箱在碰撞事故中的破裂,而且由于橡胶纤维复合材料具有良好的耐久性、耐油性、轻便性及可变形性,不需要在油箱内表面进行防腐处理,使得所述囊式油箱同时兼有占地空间小,重量轻,易于制造和清理等优点。但是橡胶材质的油囊耐候性和耐磨性差。
CN104527190B的一种储油囊用TPU复合材料,其依次包括TPU面膜层、PU粘合层、改性纤维增强层、PU粘合层和TPU底膜层;是将聚醚型聚氨酯二液型胶水涂覆到改性纤维增强层的上下两面,烘干、收卷后经退卷装置,以热风预热激活后,再与流延TPU面膜和底膜在高温高压下贴合制得成品。与传统的TPU油囊材料相比,在耐油性优异的情况下,本发明赋予了TPU复合材料耐水性、耐寒性,也解决了复合材料剥离强度与撕裂强度的矛盾性,所得到的储油囊用TPU复合材料具有优异的抗油性、耐水性、耐寒性、抗撕裂和高剥离强度,呈现出明显的性能优势。但是需要借助水性聚氨酯,且TPU面膜层、改性纤维增强层、PU粘合层每一层都需要特殊的处理,操作复杂。例如水性聚氨酯涂层剂需要调整至粘度至480±20mPa.s,改性纤维增强层需要经过涂覆、烘干、收卷、退卷和热风预热等操作。
发明内容
有鉴于此,本发明旨在提出一种纤维增强复合材料油囊,以解决现有技术中油囊无法同时满足耐油性好、耐候性好、耐磨性好和耐水解性好的问题,并且能提高油囊的力学强度。
为达到上述目的,本发明的技术方案是这样实现的:
一种纤维增强复合材料油囊,所述油囊为规则或不规则的空心囊体,由纤维增强材料和树脂加入助剂后固化而成,所述纤维增强材料分为4层,从内到外依次包括A层底膜层、B层增强层、C层防护层和D层面膜层:
A层:包括1~5层表面毡;
B层:铺放在所述A层表面,包括1~3层纤维布;
C层:铺放在所述B层表面,包括1~3层芳纶布;
D层:铺放在所述C层表面,包括1~5层表面毡;
所述树脂为热固性树脂,所述助剂包括光稳定剂、阻燃剂和抗静电剂。
进一步的,所述A层底膜层织物与经线夹角为30~60°。
进一步的,所述A层底膜层织物与经线夹角为30~45°。
进一步的,所述B层增强层织物与经线夹角为10~75°。
进一步的,所述B层增强层织物与经线夹角为30~60°。
进一步的,所述C层防护层织物与经线夹角为0~90°。
进一步的,所述C层防护层织物与经线夹角为45~90°。
进一步的,所述D层面膜层织物与经线夹角为45~90°。
进一步的,所述D层面膜层织物与经线夹角为60~90°。
进一步的,所述A层底膜层和D层面膜层的表面毡材质包括但不限于玻璃纤维表面毡、聚酯纤维表面毡,所述表面毡的单位面积质量小于200g/m2。
进一步的,所述表面毡的单位面积质量为60~100g/m2。
进一步的,所述B层增强层的纤维布可选择但不限于玻璃纤维布、碳纤维布、玄武岩纤维布、尼龙纤维布、聚酯纤维布、聚丙烯纤维布。所述纤维布的单位面积质量小于500g/m2。
进一步的,所述纤维布的单位面积质量为200~400g/m2。
进一步的,所述C层防护层的芳纶布单位面积质量小于400g/m2。
进一步的,所述C层防护层的芳纶布单位面积质量为200~400g/m2。
进一步的,所述纤维增强材料和所述树脂的质量比为1~9:9~1。
进一步的,所述纤维增强材料和所述树脂的质量比为4~7:6~3。
进一步的,所述纤维布、芳纶布为双向平纹纤维织物或双向斜纹纤维织物或±45°的精编织物。
进一步的,所述纤维布、芳纶布为双向平纹纤维织物。
进一步的,所述纤维布、芳纶布的单层厚度为0.2~0.5mm。
进一步的,所述纤维布、芳纶布的单层厚度为0.25~0.35mm。
进一步的,所述树脂为环氧树脂,粘度小于1Pa·S。所述环氧树脂可提供良好的高低温性及柔韧性。
进一步的,所述树脂的粘度小于0.3Pa·S。
进一步的,所述阻燃剂选自TCPP、TDCPP、DMMP和IPPP中的至少一种;阻燃剂可提供良好的阻燃性能。
进一步的,所述阻燃剂为TCPP。
进一步的,所述光稳定剂选自UV-0、UV-P、UV-326和UV-531中的至少一种;光稳定剂可有效保护布料,防止受光照变质。
进一步的,所述光稳定剂选自UV-0。
进一步的,所述抗静电剂为乙氧基化烷基胺、乙氧基化烷基酸胺的一种或两种;抗静电剂可提供良好的抗静电性。
进一步的,所述抗静电剂为乙氧基化烷基胺。
进一步的,所述阻燃剂、光稳定剂和抗静电剂的质量比为3~10:0.5~2:0.5~2。
进一步的,所述阻燃剂、光稳定剂和抗静电剂的质量比为8:1:1。
进一步的,所述助剂的质量为所述热固性树脂质量的5~30%。
进一步的,所述助剂的质量为所述热固性树脂质量的10~20%。
本发明还提供了一种纤维增强复合材料油囊的制备方法,包括如下步骤:
S1:将纤维材料按照从内到外依次为A层底膜层、B层增强层、C层防护层和D层面膜层的顺序,铺层设计缠绕或铺放在模具的表面;
S2:将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.01~0.1MPa;
S3:配置胶液,将树脂注入袋膜内,与所述纤维材料结合并固化成形;
S4:固化脱除外部袋膜及内部模具,获得纤维增强复合材料油囊。
进一步的,步骤S3中,树脂固化温度为20~80℃,固化时间为2h~24h,相对湿度小于70%。
本发明所述的一种纤维增幅复合材料油囊及其制备方法,A层和D层为织物表面保护层,保护内层织物的平整性和尺寸一致性,可吸附胶液并降低织物间缝隙。B层为增强层,可以提高囊体的力学性能,保证囊体受力均匀。C层为防护层,避免囊体受外力破坏。通过多层组合,并铺层设计,使制备的油囊具有平整性,且织物间缝隙小,力学性能提高。能够在保证柔韧性的同时,其耐油水性、耐候性和力学强度更高。
此外,本发明所述的纤维增强复合材料油囊制备方法还具有过程简单,制备条件简单、不苛刻,易于实施的优点。
附图说明
构成本发明的一部分的附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。
图1为本发明纤维增强材料的示意图。
具体实施方式
需要说明的是,在不冲突的情况下,本发明中的实施例及实施例中的特征可以相互组合。
下面将参考附图并结合实施例来详细说明本发明。应理解,这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解,在阅读了本发明讲授的内容之后,本领域技术人员可以对本发明作各种改动或修改,这些等价形式同样落于本申请所附权利要求书所限定的范围。
在本发明的实施例中,原材料如无特别说明均为市售产品,所使用的装置或操作方法如无特别说明均为本领域常见装置或操作方法。
实施例1制造直径为1m的椭圆形油囊
(1)纤维材料的铺设方法为:
A层:含有3层玻璃纤维表面毡,织物与经线夹角为45°,A层所述玻璃纤维表面毡的单位面积质量为200g/m2;
B层:铺放在A层表面,包含2层玻璃纤维布,织物与经线夹角为60°,所述玻璃纤维布的单位面积质量为500g/m2,单层厚度为0.5mm;
C层:铺放在B层表面,含1层芳纶布,织物与经线夹角为45°,所述芳纶布的单位面积质量为400g/m2,单层厚度为0.4mm;
D层:铺放C层表面,含5层玻璃纤维表面毡,织物与经线夹角为90°,D层所述玻璃纤维表面毡的单位面积质量为180g/m2。
上述织物均旋转缠绕在椭圆形模具表面。
(2)树脂胶液的配制:
将乙氧基化烷基胺、UV-0和TCPP按照1:1:8混合后加入到粘度为1Pa·S的环氧树脂中,助剂乙氧基化烷基胺、UV-0和TCPP的添加量为环氧树脂的15%。环氧树脂和纤维材料的质量比为3:7。
(3)成型过程:
将所述纤维材料按照铺层设计缠绕在模具的表面;将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.1MPa;随后将树脂胶液注入袋膜内,与(1)中的纤维材料结合并固化成形。
树脂固化温度为30℃,固化时间为12h,相对湿度60%,真空度为0.09~0.1MPa。固化后脱除袋膜及内部模具,获得直径为1m、厚度为1.4mm的椭圆形油囊。
实施例2制造直径为1m的圆形油囊
(1)纤维材料的铺设方法为:
A层:含有1层玻璃纤维表面毡,织物与经线夹角为60°,A层所述玻璃纤维表面毡的单位面积质量为150g/m2;
B层:铺放在A层表面,包含1层碳纤维布,织物与经线夹角为75°,所述碳纤维布的单位面积质量为400g/m2,单层厚度为0.4mm;
C层:铺放在B层表面,含1层芳纶布,织物与经线夹角为90°,所述芳纶布的单位面积质量为300g/m2,单层厚度为0.35mm;
D层:铺放C层表面,含5层聚酯纤维表面毡,织物与经线夹角为45°,D层所述聚酯纤维表面毡的单位面积质量为120g/m2。
上述织物均旋转缠绕在圆形模具表面。
(2)树脂胶液的配制:
将助剂乙氧基化烷基酸胺、UV-P和TDCPP按照2:2:6混合后加入到粘度为0.3Pa·S的环氧树脂中,助剂添加量为环氧树脂的30%。环氧树脂和纤维材料的质量比为1:9。
(3)成型过程:
将所述纤维材料按照铺层设计缠绕在模具的表面;将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.01MPa;随后将树脂胶液注入袋膜内,与(1)中的纤维材料结合并固化成形。
树脂固化温度为80℃,固化时间为10h,相对湿度50%,真空度为0.09~0.1MPa。固化后脱除袋膜及内部模具,获得直径为1m、厚度为1.4mm的圆形油囊。
实施例3制造直径为1m的椭圆形油囊
(1)纤维材料的铺设方法为:
A层:含有5层聚酯纤维表面毡,织物与经线夹角为30°,A层所述聚酯纤维表面毡的单位面积质量为60g/m2;
B层:铺放在A层表面,包含2层玄武岩纤维布,织物与经线夹角为10°,所述玄武岩纤维布的单位面积质量为200g/m2,单层厚度为0.3mm;
C层:铺放在B层表面,含3层芳纶布,织物与经线夹角为0°,所述芳纶布的单位面积质量为200g/m2,单层厚度为0.3mm;
D层:铺放C层表面,含5层聚酯纤维表面毡,织物与经线夹角为45°,D层所述聚酯纤维表面毡的单位面积质量为60g/m2。
上述织物均旋转缠绕在椭圆形模具表面。
(2)树脂胶液的配制:
将助剂乙氧基化烷基胺、UV-326和IPPP按照0.5:0.5:9混合后加入到粘度为0.2Pa·S的环氧树脂中,助剂添加量为环氧树脂的5%。环氧树脂和纤维材料的质量比为9:1。
(3)成型过程:
将所述纤维材料按照铺层设计缠绕在模具的表面;将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.05MPa;随后将树脂胶液注入袋膜内,与(1)中的纤维材料结合并固化成形。
树脂固化温度为20℃,固化时间为24h,相对湿度65%,真空度为0.09~0.1MPa。固化后脱除袋膜及内部模具,获得直径为1m、厚度为1.4mm的椭圆形油囊。
实施例4制造直径为1m的椭圆形油囊
(1)纤维材料的铺设方法为:
A层:含有1层玻璃纤维表面毡和2层聚酯纤维表面毡,织物与经线夹角为30°,A层所述表面毡的单位面积质量为100g/m2;
B层:铺放在A层表面,包含2层尼龙纤维布,织物与经线夹角为30°,所述尼龙纤维布的单位面积质量为300g/m2,单层厚度为0.2mm;
C层:铺放在B层表面,含2层芳纶布,织物与经线夹角为90°,所述芳纶布的单位面积质量为100g/m2,单层厚度为0.2mm;
D层:铺放C层表面,含1层玻璃纤维表面毡,织物与经线夹角为60°,D层所述表面毡的单位面积质量为65g/m2。
上述织物均旋转缠绕在椭圆形模具表面。
(2)树脂胶液的配制:
将乙氧基化烷基胺、UV-0和TCPP按照1:1:8混合后加入到粘度为0.2Pa·S的环氧树脂中,助剂添加量为环氧树脂的10%。环氧树脂和纤维材料的质量比为6:4。
(3)成型过程:
将所述纤维材料按照铺层设计缠绕在模具的表面;将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.03MPa;随后将树脂胶液注入袋膜内,与(1)中的纤维材料结合并固化成形。
树脂固化温度为60℃,固化时间为15h,相对湿度40%,真空度为0.09~0.1MPa。固化后脱除袋膜及内部模具,获得直径为1m、厚度为1.4mm的椭圆形油囊。
实施例5制造直径为1m的圆形油囊
(1)纤维材料的铺设方法为:
A层:含有2层玻璃纤维表面毡,织物与经线夹角为40°,A层所述玻璃纤维表面毡的单位面积质量为90g/m2;
B层:铺放在A层表面,包含2层聚丙烯纤维布和1层聚酯纤维布,织物与经线夹角为45°,所述聚丙烯纤维布的单位面积质量为350g/m2,单层厚度为0.25mm,所述聚酯纤维布的单位面积质量为350g/m2,单层厚度为0.25mm;
C层:铺放在B层表面,含2层芳纶布,织物与经线夹角为70°,所述芳纶布的单位面积质量为150g/m2,单层厚度为0.2mm;
D层:铺放C层表面,含2层玻璃纤维表面毡和1层聚酯纤维表面毡,织物与经线夹角为75°,D层所述玻璃纤维表面毡的单位面积质量为100g/m2。
上述织物均旋转缠绕在圆形模具表面。
(2)树脂胶液的配制:
将乙氧基化烷基胺、UV-0和TCPP按照1:1:8混合后加入到环氧树脂中,助剂添加量为环氧树脂的20%。环氧树脂和纤维材料的质量比为5:5。
(3)成型过程:
将所述纤维材料按照铺层设计缠绕在模具的表面;将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.07MPa;随后将树脂胶液注入袋膜内,与(1)中的纤维材料结合并固化成形。
树脂固化温度为50℃,固化时间为8h,相对湿度50%,真空度为0.09~0.1MPa。固化后脱除袋膜及内部模具,获得直径为1m、厚度为1.38mm的圆形油囊。
对比例1
按照CN103161624B中实施例1的方法,采用橡胶复合材料制备油囊。
对比例2
按照CN104527190B中实施例1的方法,制备TPU复合材料,然后采用此TPU复合材料制备储油囊。
对比例3
按照CN109205123A的方法制备蒙皮机构,所述蒙皮机构从内到外依次包括第一热塑性树脂、芳纶纤维编织层、黏贴层、防渗层和第二热塑性树脂,所述黏贴层将芳纶纤维编织层和防渗层粘贴固定。将若干块蒙皮结构拼接成储油囊。
对比例4
对比例4的油囊购自于市面上传统的油囊产品。
将本发明制备的油囊和对比例制备的油囊产品进行性能对比,具体结果如表1所示。耐油性是通过测试各油囊产品于常温环境下柴油浸泡42天后的强力保持率,耐水解性是通过测试各油囊产品在70℃水中浸泡42天后的强力保持率。
表1
由表1可知,采用本发明方法制备的实施例1-5的油囊柔软性好,对比例1-4的油囊产品虽然也可以达到优良的柔软性,但是拉伸强度、撕裂强力、剥离强力、耐油性和耐水解性等性能不如实施例1-5制备的油囊。
实施例1-5制备的油囊在提高拉伸强度和撕裂强力的同时,剥离强力也得到了改善。拉伸强度可以达到9250~10200N/5cm,撕裂强力达到800~865N/5cm,剥离强力达到310~345N/5cm,解决了传统油囊材料剥离强度和撕裂强度相矛盾的难题。此外,实施例1-5制备的油囊在常温下柴油浸泡42天后强力保持率为98~99%,在70℃水中浸泡42天后强力保持率为97~99%。而对比例1-4的样品常温下柴油浸泡42天后强力保持率仅有50~65%,70℃水中浸泡42天后强力保持率53~68%,远远低于本申请制备的油囊产品。
采用本申请的配方及制备方法制备的油囊,具有更优异的强力,更好的耐油性、耐水解性、抗撕裂及剥离性能,且柔韧性良好。通过铺层设计,制备的复合材料囊体强度均匀性更好。更适宜于长期储存和盛装油。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种纤维增强复合材料油囊,其特征在于,所述油囊为规则或不规则的空心囊体,由纤维增强材料和树脂加入助剂后固化而成,所述纤维增强材料分为4层,从内到外依次包括A层底膜层、B层增强层、C层防护层和D层面膜层:
A层:包括1~5层表面毡;
B层:铺放在所述A层表面,包括1~3层纤维布;
C层:铺放在所述B层表面,包括1~3层芳纶布;
D层:铺放在所述C层表面,包括1~5层表面毡;
所述树脂为热固性树脂,所述助剂包括光稳定剂、阻燃剂和抗静电剂。
2.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述纤维增强材料和所述树脂的质量比为1~9:9~1。
3.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述表面毡选自玻璃纤维表面毡、聚酯纤维表面毡中的至少一种。
4.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述纤维布选自玻璃纤维布、碳纤维布、玄武岩纤维布、尼龙纤维布、聚酯纤维布、聚丙烯纤维布中的至少一种。
5.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述纤维布、芳纶布为双向平纹纤维织物或双向斜纹纤维织物或±45°的精编织物。
6.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述纤维布、芳纶布的单层厚度为0.2~0.5mm。
7.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述树脂为环氧树脂,粘度小于1Pa·S。
8.根据权利要求1所述的一种纤维增强复合材料油囊,其特征在于,所述光稳定剂选自UV-0、UV-P、UV-326和UV-531中的至少一种;所述阻燃剂选自TCPP、TDCPP、DMMP和IPPP中的至少一种;所述抗静电剂为乙氧基化烷基胺、乙氧基化烷基酸胺的一种或两种。
9.一种纤维增强复合材料油囊的制备方法,其特征在于,用于制备如权利要求1~8任一项所述的纤维增强复合材料油囊,制备方法包括如下步骤:
S1:将纤维材料按照从内到外依次为A层底膜层、B层增强层、C层防护层和D层面膜层的顺序,铺层设计缠绕或铺放在模具的表面;
S2:将真空袋膜包裹在纤维材料表面并抽真空,袋膜内的真空度为0.01~0.1MPa;
S3:配置胶液,将树脂注入袋膜内,与所述纤维材料结合并固化成形;
S4:固化脱除外部袋膜及内部模具,获得纤维增强复合材料油囊。
10.根据权利要求9所述的一种纤维增强复合材料油囊的制备方法,其特征在于,步骤S3中,树脂固化温度为20~80℃,固化时间为2h~24h,相对湿度小于70%。
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