CN114211787B - 一种多层空间结构的碳纤维层合板的制备方法 - Google Patents
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Abstract
一种多层空间结构的碳纤维层合板的制备方法,它涉及一种碳纤维层合板的制备方法。本发明的目的是要解决现有碳纤维复合材料点阵结构制备工艺复杂,批量生产困难,且面芯连接不牢固易发生断裂和脱落的问题。方法:一、模具预处理;二、纤维预浸料预处理;三、模压;四、固化脱模得到碳纤维波纹板;五、切割得到单层点阵芯子基板;六、叠合得到点阵芯子波纹板;七:组装,得到多层空间结构的碳纤维层合板。优点:制备工艺简单,利用推广,增加粘接接触面,提高点阵芯子波纹板的机械性能。本发明主要用于制备多层空间结构的碳纤维层合板。
Description
技术领域
本发明涉及一种碳纤维层合板的制备方法。
背景技术
点阵板材是一种中空结构板材,这种板材的质量密度很低,且具有较高的机械性能。目前,国内外对于金属点阵结构形式的研究已经较为成熟,已经提出金字塔、四面体、八面体等各种拓扑构型的点阵结构;但现有碳纤维复合材料点阵结构制备工艺复杂,批量生产困难,且面芯连接不牢固易发生断裂和脱落的问题。
发明内容
本发明的目的是要解决现有碳纤维复合材料点阵结构制备工艺复杂,批量生产困难,且面芯连接不牢固易发生断裂和脱落的问题,而提供一种多层空间结构的碳纤维层合板的制备方法。
一种多层空间结构的碳纤维层合板的制备方法,具体是按以下步骤完成的:
一、模具预处理:模具包括上挤压模板和下挤压模板,所述上挤压模板朝向所述下挤压模板方向一侧设有上波纹凸台,所述下挤压模板朝向所述上挤压模板方向一侧设有下波纹凸台,所述上波纹凸台与所述下波纹凸台啮合;采用丙酮对上波纹凸台和下波纹凸台进行清洗,然后在上波纹凸台和下波纹凸表面涂脱模剂,得到预处理后模具;
二、纤维预浸料预处理:根据实际需要碳纤维波纹板的厚度,依据单层单向碳纤维预浸料单层的厚度,计算单层单向碳纤维预浸料的具体层数n层,然后n层单层单向碳纤维预浸料按照0/45°/90°三个方向交替铺设,得到多层碳纤维预浸料,将多层碳纤维预浸料在温度为20~30℃下进行预热,得到预热后多层碳纤维预浸料;
三、压模:将预热后多层碳纤维预浸料铺设于下挤压模板的下波纹凸台表面,且使预热后多层碳纤维预浸料与下波纹凸台面接触贴合在一起,利用螺栓使上挤压模板和下挤压模板合模,并通过螺栓使成型压力控制为3MPa~8MPa,得到装载碳纤维预处理件的模具;
四、固化脱模:将装载碳纤维预处理件的模具置于固化炉进行固化,然后脱模,得到碳纤维波纹板;
五、切割:将碳纤维波纹板沿垂直碳纤维波纹板的波纹凸台方向对碳纤维波纹板的波纹凸台按照倒置波纹凸台的尺寸进行切割,得到单层点阵芯子基板;
六、叠合:将两个单层点阵芯子基板按照波纹凸台相互垂直以构成正四棱台形凸台形式对正叠加,且两个单层点阵芯子基板的面接触处采用刷胶粘接,得到点阵芯子波纹板;
七:组装:将上固定板与点阵芯子波纹板的正四棱台形凸台一侧对正叠加后刷胶粘接,将下固定板与点阵芯子波纹板的背离正四棱台形凸台方向一侧对正叠加后刷胶粘接,得到多层空间结构的碳纤维层合板。
本发明优点:
一、本发明只对碳纤维波纹板进行一次切割,制成单层点阵芯子基板,再利用两个单层点阵芯子基板叠加得到点阵芯子波纹板,制备工艺简单,便于进行大面积碳纤维层合板的制备,且有利于推广,进行批量化生产。
二、本发明点阵芯子波纹板的凸台呈正四棱台形,点阵芯子波纹板与上固定板和下固定板通过刷胶粘接,与一般正四棱锥点阵结构夹芯板相比,正四棱台形凸台与上固定板的粘接一侧由点接触变成面接触,增加粘接接触面,避免芯板与固定板连接不牢固易发生断裂和脱落的问题,并且正四棱台形凸台对于集中载荷的分散效果更好。
三、点阵芯子波纹板由两个单层点阵芯子基板按照波纹凸台相互垂直互补的形式以构成完整的正四棱台形凸台,正四棱台形凸台的形成使两个单层点阵芯子基板之间存在相互作用的支撑力,提高点阵芯子波纹板的机械性能。
四、本发明根据实际需要碳纤维波纹板的厚度,依据单层单向碳纤维预浸料单层的厚度,计算单层单向碳纤维预浸料的具体层数,且可以根据实际需要碳纤维波纹板的厚度挑选适当厚度的第一限位板和第二限位板;能够精确的制备实际需要厚度的多层空间结构的碳纤维层合板。
附图说明
图1是本发明模具结构示意图。
图2是本发明一种多层空间结构的碳纤维层合板的结构示意图。
图3是本发明一种多层空间结构的碳纤维层合中点阵芯子波纹板的结构示意图。
图4是本发明单层点阵芯子基板的结构示意图。
附图中:1-上挤压模板、2-下挤压模板、3-点阵芯子波纹板、31-单层点阵芯子基板、32-正四棱台形凸台、4-上固定板、5-下固定板、6-第一限位板、7-第二限位板。
具体实施方式
具体实施方式一:本实施方式是一种多层空间结构的碳纤维层合板的制备方法,具体是按以下步骤完成的:
一、模具预处理:模具包括上挤压模板1和下挤压模板2,所述上挤压模板1朝向所述下挤压模板2方向一侧设有上波纹凸台,所述下挤压模板2朝向所述上挤压模板1方向一侧设有下波纹凸台,所述上波纹凸台与所述下波纹凸台啮合;采用丙酮对上波纹凸台和下波纹凸台进行清洗,然后在上波纹凸台和下波纹凸表面涂脱模剂,得到预处理后模具;
二、纤维预浸料预处理:根据实际需要碳纤维波纹板的厚度,依据单层单向碳纤维预浸料单层的厚度,计算单层单向碳纤维预浸料的具体层数n层,然后n层单层单向碳纤维预浸料按照0/45°/90°三个方向交替铺设,得到多层碳纤维预浸料,将多层碳纤维预浸料在温度为20~30℃下进行预热,得到预热后多层碳纤维预浸料;
三、压模:将预热后多层碳纤维预浸料铺设于下挤压模板2的下波纹凸台表面,且使预热后多层碳纤维预浸料与下波纹凸台面接触贴合在一起,利用螺栓使上挤压模板1和下挤压模板2合模,并通过螺栓使成型压力控制为3MPa~8MPa,得到装载碳纤维预处理件的模具;
四、固化脱模:将装载碳纤维预处理件的模具置于固化炉进行固化,然后脱模,得到碳纤维波纹板;
五、切割:将碳纤维波纹板沿垂直碳纤维波纹板的波纹凸台方向对碳纤维波纹板的波纹凸台按照倒置波纹凸台的尺寸进行切割,得到单层点阵芯子基板31;
六、叠合:将两个单层点阵芯子基板31按照波纹凸台相互垂直以构成正四棱台形凸台32形式对正叠加,且两个单层点阵芯子基板31的面接触处采用刷胶粘接,得到点阵芯子波纹板3;
七:组装:将上固定板4与点阵芯子波纹板3的正四棱台形凸台32一侧对正叠加后刷胶粘接,将下固定板5与点阵芯子波纹板3的背离正四棱台形凸台32方向一侧对正叠加后刷胶粘接,得到多层空间结构的碳纤维层合板。
具体实施方式二:本实施方式与具体实施方式一的不同点是:步骤一中所述模具包括第一限位板6和第二限位板7,第一限位板6和第二限位板7设于上挤压模板1和下挤压模板2之间相对的两侧。其他与具体实施方式一相同。
具体实施方式三:本实施方式与具体实施方式一或二之一不同点是:步骤二中所述多层碳纤维预浸料由上至下依次分为第一层、第二层、第三层、第四层和第五层,第一层由四层单向碳纤维预浸料由上至下按照45°/0/45°/0交替铺设,第二层由若干层单向碳纤维预浸料由上至下按照90°/0交替铺设,第三层由二层单向碳纤维预浸料由上至下按照45°/0交替铺设,第四层由若干层单向碳纤维预浸料由上至下按照90°/0交替铺设,第五层由二层单向碳纤维预浸料由上至下按照45°/90°交替铺设。其他与具体实施方式一或二相同。
具体实施方式四:本实施方式与具体实施方式一至三之一不同点是:步骤四中所述固化的具体过程如下:先以1℃/min~4℃/min的升温速率将固化炉内温度从室温升温至110~130℃,然后在温度为110~130℃条件下保温60min~120min,再随炉冷却至50~60℃,完成固化。其他与具体实施方式一至三相同。
具体实施方式五:本实施方式与具体实施方式一至四之一不同点是:步骤五中所述单层点阵芯子基板31厚度为1.5mm~3mm。其他与具体实施方式一至四相同。
具体实施方式六:本实施方式与具体实施方式一至五之一不同点是:步骤五中所述单层点阵芯子基板31的波纹凸台顶部宽度为12mm,波纹凸台底部宽度为27mm,波纹凸台的高度为20mm。其他与具体实施方式一至五相同。
具体实施方式七:本实施方式与具体实施方式一至六之一不同点是:步骤六中所述点阵芯子波纹板3的正四棱台形凸台32的顶部呈正方形,边长为12mm,正四棱台形凸台32的底部呈正方形,边长为27mm。其他与具体实施方式一至六相同。
具体实施方式八:本实施方式与具体实施方式一至七之一不同点是:步骤七中所述上固定板4和下固定板5均为碳纤维板材。其他与具体实施方式一至七相同。
具体实施方式九:本实施方式与具体实施方式八额不同点是:所述碳纤维板材的厚度为2mm。其他与具体实施方式八相同。
具体实施方式十:本实施方式与具体实施方式一至九之一不同点是:步骤六中和步骤七中所述胶为DP460环氧树脂胶。其他与具体实施方式一至九相同。
本发明内容不仅限于上述各实施方式的内容,其中一个或几个具体实施方式的组合同样也可以实现发明的目的。
采用下述实验验证本发明效果:
实施例1:一种多层空间结构的碳纤维层合板的制备方法,具体是按以下步骤完成的:
一、模具预处理:模具包括上挤压模板1和下挤压模板2,所述上挤压模板1朝向所述下挤压模板2方向一侧设有上波纹凸台,所述下挤压模板2朝向所述上挤压模板1方向一侧设有下波纹凸台,所述上波纹凸台与所述下波纹凸台啮合;采用丙酮对上波纹凸台和下波纹凸台进行清洗,然后在上波纹凸台和下波纹凸表面涂脱模剂,得到预处理后模具;
二、纤维预浸料预处理:根据实际需要碳纤维波纹板的厚度2mm,依据单层单向碳纤维预浸料单层的厚度为0.125mm,计算单层单向碳纤维预浸料的具体层数16层,然后16层单层单向碳纤维预浸料按照0/45°/90°三个方向交替铺设,得到多层碳纤维预浸料,所述多层碳纤维预浸料由上至下依次分为第一层、第二层、第三层、第四层和第五层,第一层由四层单向碳纤维预浸料由上至下按照45°/0/45°/0交替铺设,第二层由四层单向碳纤维预浸料由上至下按照90°/0交替铺设,第三层由二层单向碳纤维预浸料由上至下按照45°/0交替铺设,第四层由四层单向碳纤维预浸料由上至下按照90°/0交替铺设,第五层由二层单向碳纤维预浸料由上至下按照45°/90°交替铺设;将多层碳纤维预浸料在温度为25℃下进行预热,得到预热后多层碳纤维预浸料;
三、压模:将预热后多层碳纤维预浸料铺设于下挤压模板2的下波纹凸台表面,且使预热后多层碳纤维预浸料与下波纹凸台面接触贴合在一起,利用螺栓使上挤压模板1和下挤压模板2合模,并通过螺栓使成型压力控制为5MPa,得到装载碳纤维预处理件的模具;
四、固化脱模:将装载碳纤维预处理件的模具置于固化炉进行固化,然后脱模,得到碳纤维波纹板;
五、切割:将碳纤维波纹板沿垂直碳纤维波纹板的波纹凸台方向对碳纤维波纹板的波纹凸台按照倒置波纹凸台的尺寸进行切割,得到单层点阵芯子基板31;
六、叠合:将两个单层点阵芯子基板31按照波纹凸台相互垂直以构成正四棱台形凸台32形式对正叠加,且两个单层点阵芯子基板31的面接触处采用刷胶粘接,得到点阵芯子波纹板3;
七:组装:将上固定板4与点阵芯子波纹板3的正四棱台形凸台32一侧对正叠加后刷胶粘接,将下固定板5与点阵芯子波纹板3的背离正四棱台形凸台32方向一侧对正叠加后刷胶粘接,得到多层空间结构的碳纤维层合板。
实施例1步骤一中所述模具包括第一限位板6和第二限位板7,第一限位板6和第二限位板7设于上挤压模板1和下挤压模板2之间相对的两侧。
实施例1步骤二中将12个单层单向碳纤维预浸料按照0/90°的方向交替铺设,得到多层碳纤维预浸料。
实施例1步骤四中所述固化的具体过程如下:先以2℃/min的升温速率将固化炉内温度从室温升温至120℃,然后在温度为120℃条件下保温90min,再随炉冷却至60℃,完成固化。
实施例1步骤五中所述单层点阵芯子基板31厚度为2mm;所述单层点阵芯子基板31的波纹凸台顶部宽度为12mm,波纹凸台底部宽度为27mm,波纹凸台的高度为20mm。
实施例1步骤六中所述点阵芯子波纹板3的正四棱台形凸台32的顶部呈正方形,边长为12mm,正四棱台形凸台32的底部呈正方形,边长为27mm。
实施例1步骤七中所述上固定板4和下固定板5均为碳纤维板材;所述碳纤维板材的厚度为2mm。
实施例1步骤六中和步骤七中所述胶为DP460环氧树脂胶。
对比例1:金字塔点阵结构夹芯板:
首先将厚度为2mm的碳纤维层合板分割成若干个正三角形碳纤维层合板,每四个正三角形碳纤维层合板通过刷胶粘接组合一个金字塔点阵,所述金字塔点阵的高度为20mm,将若干个金字塔点阵依次均布粘接于下固定板上,且相邻两个金字塔点阵有且只有一条边相互粘接,在金字塔点阵背离下固定板方向一侧粘接上固定板,得到金字塔点阵结构夹芯板;所述上固定板与实施例1中所述上固定板4相同,所述下固定板与实施例1中所述下固定板5相同。
对实施例1得到的多层空间结构的碳纤维层合板和对比例1得到的金字塔点阵结构夹芯板进行载荷测试,可知实施例1得到的多层空间结构的碳纤维层合板的载荷最大值为14464.3N,而对比例1得到的金字塔点阵结构夹芯板的载荷最大值为13158.6N,在厚度相同情况下,本发明制备的多层空间结构的碳纤维层合板在解决芯板与固定板连接不牢固易发生断裂和脱落的问题情况下,多层空间结构的碳纤维层合板的载荷有所提高。
Claims (10)
1.一种多层空间结构的碳纤维层合板的制备方法,其特征在于它是按以下步骤完成的:
一、模具预处理:模具包括上挤压模板(1)和下挤压模板(2),所述上挤压模板(1)朝向所述下挤压模板(2)方向一侧设有上波纹凸台,所述下挤压模板(2)朝向所述上挤压模板(1)方向一侧设有下波纹凸台,所述上波纹凸台与所述下波纹凸台啮合;采用丙酮对上波纹凸台和下波纹凸台进行清洗,然后在上波纹凸台和下波纹凸台表面涂脱模剂,得到预处理后模具;
二、纤维预浸料预处理:根据实际需要碳纤维波纹板的厚度,依据单层单向碳纤维预浸料单层的厚度,计算单层单向碳纤维预浸料的具体层数n层,然后n层单层单向碳纤维预浸料按照0/45°/90°三个方向交替铺设,得到多层碳纤维预浸料,将多层碳纤维预浸料在温度为20~30℃下进行预热,得到预热后多层碳纤维预浸料;
三、压模:将预热后多层碳纤维预浸料铺设于下挤压模板(2)的下波纹凸台表面,且使预热后多层碳纤维预浸料与下波纹凸台面接触贴合在一起,利用螺栓使上挤压模板(1)和下挤压模板(2)合模,并通过螺栓使成型压力控制为3MPa~8MPa,得到装载碳纤维预处理件的模具;
四、固化脱模:将装载碳纤维预处理件的模具置于固化炉进行固化,然后脱模,得到碳纤维波纹板;
五、切割:将碳纤维波纹板沿垂直碳纤维波纹板的波纹凸台方向对碳纤维波纹板的波纹凸台按照倒置波纹凸台的尺寸进行切割,得到单层点阵芯子基板(31);
六、叠合:将两个单层点阵芯子基板(31)按照波纹凸台相互垂直以构成正四棱台形凸台(32)形式对正叠加,且两个单层点阵芯子基板(31)的面接触处采用刷胶粘接,得到点阵芯子波纹板(3);
七:组装:将上固定板(4)与点阵芯子波纹板(3)的正四棱台形凸台(32)一侧对正叠加后刷胶粘接,将下固定板(5)与点阵芯子波纹板(3)的背离正四棱台形凸台(32)方向一侧对正叠加后刷胶粘接,得到多层空间结构的碳纤维层合板。
2.根据权利要求1所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤一中所述模具包括第一限位板(6)和第二限位板(7),第一限位板(6)和第二限位板(7)设于上挤压模板(1)和下挤压模板(2)之间相对的两侧。
3.根据权利要求2所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤二中所述多层碳纤维预浸料由上至下依次分为第一层、第二层、第三层、第四层和第五层,第一层由四层单向碳纤维预浸料由上至下按照45°/0/45°/0交替铺设,第二层由若干层单向碳纤维预浸料由上至下按照90°/0交替铺设,第三层由二层单向碳纤维预浸料由上至下按照45°/0交替铺设,第四层由若干层单向碳纤维预浸料由上至下按照90°/0交替铺设,第五层由二层单向碳纤维预浸料由上至下按照45°/90°交替铺设。
4.根据权利要求3所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤四中所述固化的具体过程如下:先以1℃/min~4℃/min的升温速率将固化炉内温度从室温升温至110~130℃,然后在温度为110~130℃条件下保温60min~120min,再随炉冷却至50~60℃,完成固化。
5.根据权利要求4所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤五中所述单层点阵芯子基板(31)厚度为1.5mm~3mm。
6.根据权利要求5所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤五中所述单层点阵芯子基板(31)的波纹凸台顶部宽度为12mm,波纹凸台底部宽度为27mm,波纹凸台的高度为20mm。
7.根据权利要求6所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤六中所述点阵芯子波纹板(3)的正四棱台形凸台(32)的顶部呈正方形,边长为12mm,正四棱台形凸台(32)的底部呈正方形,边长为27mm。
8.根据权利要求7所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤七中所述上固定板(4)和下固定板(5)均为碳纤维板材。
9.根据权利要求8所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于所述碳纤维板材的厚度为2mm。
10.根据权利要求9所述的一种多层空间结构的碳纤维层合板的制备方法,其特征在于步骤六中和步骤七中所述胶为DP460环氧树脂胶。
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