CN114434890A - 一种用于自动铺放液体成型的复合碳纤维带的制备方法 - Google Patents
一种用于自动铺放液体成型的复合碳纤维带的制备方法 Download PDFInfo
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Abstract
本发明涉及一种用于自动铺放液体成型的复合碳纤维带的制备方法。该方法包括：将聚醚酰亚胺树脂与聚芳砜树脂混合进行熔融纺丝，切割，得到短纤维，粘结成纤维毡；将成卷的碳纤维展纱成单向的碳纤维，粘结成单向碳纤维带；将纤维毡作为上下层，单向碳纤维带作为中间层，热压。该方法无离型纸及PE膜，生产工艺简单，成本低；制备得到的复合碳纤维带无需冷藏，室温存储稳定性好以及后续进行自动铺放工艺得到的制品品质高、可重复性好，孔隙率低。
Description
技术领域
本发明属于碳纤维材料的制备领域，特别涉及一种用于自动铺放液体成型的复合碳纤维带的制备方法。
背景技术
由于具有比强度和比模量高、广泛的材料可设计性和易于整体成型以及更好的抗疲劳和抗腐蚀特性等独特的性能，碳纤维复合材料在航空航天结构中获得越来越广泛的应用。采用自动化和液体成型技术相结合，可以大大的提高生产效率，降低生产成本，其中自动铺放技术可控，可实时的控制预浸纱的数目来满足实际铺放的要求，适合不规则外形和边界复杂大尺寸构件的自动化成型，该技术已成为大型复杂复合材料部件的典型制造工艺技术。然而国内目前研究最多的是预浸料的自动铺放技术，对于带有干感和自动铺放的单向纤维带的研究机构较少。并且由于预浸料带固化后厚度比较大，且后期进行热压罐固化的耗能很大，为了降低成本，以及应对碳纤维复合材料制造效率提升的挑战，限制了我国碳纤维复合材料自动化制造的发展。
中国专利CN112590252A公开了一种增强热塑性自动铺放构件层间性能的方法，该方法用不同分散度的碳纳米纸，采用自动铺放方法将热塑性纤维预浸料和碳纳米纸进行交替叠层铺放制备成型。该方法的优点是可以提高热塑性制品的层间力学特性，还能对碳纳米材料的层间分散性及多尺度力学特性间的工艺协调性进行有效调控。缺点是其制备工艺复杂，并且预浸料固化后厚度比较大，成本较高。
中国专利CN111941822A公开了面向自动铺放的单向高粘预浸窄带制备方法，获得适用于自动铺放成形工艺所需的高粘性长度连续、宽度恒定及退卷良好的单向预浸窄带。不足的是预浸料储存成本高，粘度高，影响自动铺放效率。
发明内容
本发明所要解决的技术问题是提供一种用于自动铺放液体成型的复合碳纤维带的制备方法，以克服现有技术中碳纤维复合材料自动铺放效率低、性能不稳定、成本高的缺陷。
本发明提供一种复合碳纤维带的制备方法，包括如下步骤：
(1)将聚醚酰亚胺树脂与聚芳砜树脂混合进行熔融纺丝，得到长纤维；
(2)将步骤(1)中长纤维，切割，得到短纤维，采用粘结剂粘结成纤维毡；
(3)将成卷的碳纤维展纱成单向的碳纤维，利用粘结剂粘结成单向碳纤维带；
(4)将步骤(2)中纤维毡作为上下层，步骤(3)中单向碳纤维带作为中间层，热压，得到用于自动铺放液体成型的复合碳纤维带。
优选地，所述步骤(1)中聚醚酰亚胺树脂与聚芳砜树脂的质量比为1：1～3。
优选地，所述步骤(1)中熔融纺丝的工艺参数为：纺丝温度320～370℃，纺丝速度200～300m/min。
优选地，所述步骤(2)中短纤维长度为5～30mm，直径为10～50μm。
优选地，所述步骤(2)、(3)中粘结剂为质量比为1：5～7：2～4的纳米对位芳香族聚酰胺颗粒、E51环氧树脂和聚氨酯的混合物，所述纳米对位芳香族聚酰胺颗粒的粒径为100-300nm。
优选地，所述步骤(4)中纤维毡的克重为10～30gsm，厚度为20～80μm。
优选地，所述步骤(4)中单向碳纤维带厚度为200～500μm。
优选地，所述步骤(4)中热压的工艺参数为：100～150℃下热压30-60min，压力为1-3MPa。
优选地，所述步骤(4)中复合碳纤维带为三明治结构。
本发明还提供一种上述的制备方法制备得到的复合碳纤维带。
本发明化提供一种复合碳纤维带在自动铺放液体成型中的应用。
有益效果
(1)本发明无离型纸及PE膜，生产工艺简单，成本低；
(2)制备得到的复合碳纤维带无需冷藏，室温下可储存数月；
(3)将复合碳纤维带进行自动铺放工艺得到的制品品质高、可重复性好，孔隙率低于0.5％。
具体实施方式
下面结合具体实施例，进一步阐述本发明。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。
实施例1
(1)将聚醚酰亚胺树脂与聚芳砜树脂以质量比1:1共混后在纺丝温度360℃，纺丝速度280m/min条件下进行熔融纺丝得到直径为10μm共混树脂长纤维，之后将其切割成长度为8mm的短纤维；
(2)将粒径为150nm的对位芳香族聚酰胺颗粒、E51环氧树脂和聚氨酯以质量比为1:5:2混合得到粘结剂，将短纤维利用粘结剂粘结成克重为10gsm，厚度为20μm的纤维毡；
(3)将成卷的碳纤维展纱成单向的碳纤维，之后利用步骤(2)得到的粘结剂将其粘结成厚度为300μm的单向碳纤维带；
(4)将两块步骤(2)得到的纤维毡与步骤(3)得到的单向碳纤维带形成三明治结构进行热压，其中上下表面为纤维毡，中间层为单向碳纤维带，热压工艺为在120℃，1MPa压力下热压60min；即得到可用于自动铺放液体成型的复合碳纤维带。该复合纤维带室温下可储存8个月；将复合碳纤维带进行自动铺放工艺得到的制品品质高、可重复性好，孔隙率低于0.5％。
实施例2
(1)将聚醚酰亚胺树脂与聚芳砜树脂以质量比1:2共混后在纺丝温度340℃，纺丝速度220m/min条件下进行熔融纺丝得到直径为15μm共混树脂长纤维，之后将其切割成长度为15mm的短纤维；
(2)将粒径为200nm的对位芳香族聚酰胺颗粒、E51环氧树脂和聚氨酯以质量比为1:7:3混合得到粘结剂，将短纤维利用粘结剂粘结成克重为20gsm，厚度为30μm的纤维毡；
(3)将成卷的碳纤维展纱成单向的碳纤维，之后利用步骤(2)得到的粘结剂将其粘结成厚度为400μm的单向碳纤维带；
(4)将两块步骤(2)得到的纤维毡与步骤(3)得到的单向碳纤维带形成三明治结构进行热压，其中上下表面为纤维毡，中间层为单向碳纤维带，热压工艺为在140℃，1.5MPa压力下热压30min；即得到可用于自动铺放液体成型的复合碳纤维带。该复合纤维带室温下可储存8个月；将复合碳纤维带进行自动铺放工艺得到的制品品质高、可重复性好，孔隙率低于0.5％。
Claims (10)
1.一种复合碳纤维带的制备方法，包括如下步骤：
(1)将聚醚酰亚胺树脂与聚芳砜树脂混合进行熔融纺丝，得到长纤维；
(2)将步骤(1)中长纤维，切割，得到短纤维，采用粘结剂粘结成纤维毡；
(3)将成卷的碳纤维展纱成单向的碳纤维，利用粘结剂粘结成单向碳纤维带；
(4)将步骤(2)中纤维毡作为上下层，步骤(3)中单向碳纤维带作为中间层，热压，得到复合碳纤维带。
2.根据权利要求1所述的制备方法，其特征在于，所述步骤(1)中聚醚酰亚胺树脂与聚芳砜树脂的质量比为1：1～3。
3.根据权利要求1所述的制备方法，其特征在于，所述步骤(1)中熔融纺丝的工艺参数为：纺丝温度320～370℃，纺丝速度200～300m/min。
4.根据权利要求1所述的制备方法，其特征在于，所述步骤(2)中短纤维长度为5～30mm，直径为10～50μm。
5.根据权利要求1所述的制备方法，其特征在于，所述步骤(2)、(3)中粘结剂为质量比为1：5～7：2～4的纳米对位芳香族聚酰胺颗粒、E51环氧树脂和聚氨酯的混合物，所述纳米对位芳香族聚酰胺颗粒的粒径为100-300nm。
6.根据权利要求1所述的制备方法，其特征在于，所述步骤(4)中纤维毡的克重为10～30gsm，厚度为20～80μm；单向碳纤维带厚度为200～500μm。
7.根据权利要求1所述的制备方法，其特征在于，所述步骤(4)中热压的工艺参数为：100～150℃下热压30-60min，压力为1-3MPa。
8.根据权利要求1所述的制备方法，其特征在于，所述步骤(4)中复合碳纤维带为三明治结构。
9.一种如权利要求1所述的制备方法制备得到的复合碳纤维带。
10.一种如权利要求9所述的复合碳纤维带在自动铺放液体成型中的应用。
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