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CN112248139B - 一种车厢底板用碳纤维增强的竹展平复合板及其制造方法 - Google Patents

一种车厢底板用碳纤维增强的竹展平复合板及其制造方法 Download PDF

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CN112248139B
CN112248139B CN202011101437.6A CN202011101437A CN112248139B CN 112248139 B CN112248139 B CN 112248139B CN 202011101437 A CN202011101437 A CN 202011101437A CN 112248139 B CN112248139 B CN 112248139B
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关明杰
马志远
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Nanjing Forestry University
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Abstract

本发明涉及一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，包括如下工艺步骤：1)竹展平单板接长；2)热压干燥；3)表面砂光；4)碳纤维浸胶；5)施胶组坯；6)冷压固化；7)养生。本发明的有益效果：1)提高了产品的抗弯性能和冲击韧性，能有效解决传统竹制车厢底板力学性能不足的缺陷，实现车身材料的轻量化。2)能有效的提高竹展平板的利用率和拓宽竹制产品的应用领域，响应国家节能环保的号召，利用生物质材料的可再生和循环利用的特点进行设计，符合新能源汽车的设计理念。3)该制造方法改进传统工艺，产品质量有所保证，避免热压过程中出现的鼓泡分层等现象，减少生产过程中的能耗，起到节能减排的效果。

Description

一种车厢底板用碳纤维增强的竹展平复合板及其制造方法
技术领域
本发明是一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，属于车厢底板技术领域。
背景技术
目前，新能源汽车行业发展迅猛汽车轻量化之所以成为推动汽车行业发展的滚滚洪流,是与现代社会对环保节能的迫切需求紧密结合在一起的。研究数据显示,汽车整车重量降低10％,燃油效率可提高6％～8％；汽车整车质量,每减少100kg,百公里油耗可降低0.3～0.6L,CO2排放量可减少约5g/km。目前,轻量化无疑是新能源汽车行业发展的重中之重。轻量化新能源汽车可以通过优化结构设计和在汽车工程中使用轻量化材料，有效地降低能源消耗和环境污染。碳纤维是纤维状的碳素材料，含碳量大于90％，具有加工能耗低、轻质高强、耐腐蚀、容易成型等优点，其成为汽车轻量化的理想材料。碳纤维复合材料应用在汽车中车门、座舱、制动片、燃料储罐、座椅、传动轴和轮毂等方面的应用。目前，碳纤维在车厢底板领域的应用还比较少。传统用竹篾胶合板作为车厢底板，用竹篾作为胶合板单元，表面竹篾间出现阶差、缝隙，影响地板革铺设表观效果，板面平整度不佳，还容易出现脱层鼓包、厚度不均等问题。竹帘、竹篾等竹制品单元，存在竹材利用率低，生产耗能大等问题，不利于车厢底板用竹胶合板的发展。竹展平单板是竹筒经软化、展开、定型等工序将圆形竹筒展开成矩形截面的板材。竹展平单板是竹筒的板材化应用，不仅保留了竹材自身的纹理，且提高了竹材的利用率。与制备竹集成材的规格竹条相比，竹展平单板尺寸远大于规格竹条，以此为单元制备竹集成材等板方材，可降低胶黏剂的使用量，便于组坯、铺装和热压的机械化操作。但是，竹材仍然存在缺乏横向组织从而导致横向力学性能较差，无法满足新能源汽车车厢底板的要求，于是本发明采用结构增强的方式，相邻两层竹纤维方向相互垂直的结构，同时用碳纤维在表层或胶层进行复合增强提高产品的力学性能。在当前绿色、生态、环保、低碳的环境发展理念下，竹材资源丰富，竹展平单板保留了竹材纹理和性能，与我国速生材复合制备结构和非结构用产品，对充分利用国产资源、促进竹林可持续发展、提高竹材和国产速生材的附加值都有重要作用。不仅提高了竹材的利用率还提高了，还拓宽了竹材的应用领域。
发明内容
本发明提出的是一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，其目的在于针对传统竹制车厢底板力学强度较差，传统竹制单元无法满足新能源汽车车厢底板要求等缺陷，提出一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，可有效利用竹展平单板宽度方向拼宽制成的竹展平板为加工单元，采用正交组坯的方式，相邻两层竹纤维方向相互垂直，将碳纤维作为增强组有效的复合在胶层或表层，加强新复合材料的力学性能和胶合性能。所制新型车厢底板具有生态环保、防腐防霉，力学性能优异，胶合性能良好，满足性能源汽车车厢底板的具体要求。
本发明的技术解决方案：一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，包括如下工艺步骤：
一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，其特征包括以下工艺步骤：
S1竹展平单板接长：将厚度3.0以上的竹展单平板沿长度方向接长为2.4m以上的的竹展平单板；
S2热压干燥：将接长的竹展平单板平铺层叠在热压机上，加热加压整平干燥，降低含水率；
S3表面砂光：将干燥后的竹展平单板进行砂光处理，并进行表面活化；
S4碳纤维浸胶：用环氧树脂对碳纤维进行浸渍处理，使碳纤维完全没入环氧树脂中，沥干，并进行二次浸胶；
S5施胶组坯：处理之后的竹展平单板宽度方向拼宽形成竹展平板，车厢地板用碳纤维增强的竹展平复合板采用多层竹展平板正交复合，用环氧树脂作为胶黏剂，碳纤维在表层或胶层增强或表层和胶层同时增强；
S6冷压固化：将复合板坯放在冷压机中进行冷压，控制时间和压力；
S7养生：压制成型的车厢底板用碳纤维增强的竹展平复合板需放在阴凉干燥的地方陈放，并进行调制调湿处理。
优选地，所述S1，所述车厢底板用碳纤维增强的竹展平复合板采用去青去黄的竹展单平板为构成单元，是有背面展开裂隙或完全无宏观展开裂隙,只有微观展开裂隙的展开竹片,但展开裂隙深度厚度方向上不能穿透总厚度的1/3，接长采用指接、斜接或采用衬布加强接长等方式，接长胶采用结构胶为主。
优选地，所述S2，所述的热压干燥处理总共分为两步。第一步为加热加压软化整形，温度控制在90℃，压力控制在2.0～3.0MPa，时间为9h，干燥到含水率为10％～15％，第二步为加压冷却定型，不再加热，继续加压，压力控制在2.0～3.0MPa，等单板自然冷却到常温取出，防止单板翘曲变形。
优选地，所述S3，所述表面砂光处理，是对竹展单平板竹青竹黄两面都进行砂光处理，使竹展平单板表面平整；然后对竹展平单板进行表面活化处理，碱处理处理剂是0.02mol/LNaOH溶液，处理时间为1h，酸处理处理剂是0.01mol/L硫酸溶液，处理时间为1h。
优选地，所述S4，所述碳纤维采用碳纤维布，用环氧树脂进行浸渍处理，环氧树脂A、B两个组分按照质量比3﹕1进行混合搅拌，浸胶量0.3～0.5kg/m2,浸渍时间为2h，沥干之后进行二次浸胶，浸胶量0.3～0.5kg/m2,浸渍时间为0.5h，陈放时间为0.5h。
优选地，所述S5，所述施胶组坯采用的是多层竹展平板的正交复合结构，组坯时，采用的是竹展单板平板宽度方向拼宽制成的竹展平板，多层竹展平板上下叠加，相邻两层竹纤维方向相互垂直的正交结构，碳纤维可在胶层或表层进行增强，碳纤维施胶量为0.2～0.3kg/m2，并用消泡刷进行滚涂排气。
优选地，所述S6，所述冷压固化，压力为3.0～5.0MPa，时间为14h，温度为常温。
优选地，所述S7，,压制成型的车厢地板用碳纤维增强的竹展平复合板在调湿调质环境中进行湿热平衡，时间7天以上，经调湿调质后含水率控制在10～12％。
优选地，以竹展平单板为构成单元，采用结构用冷压环氧树脂作为胶黏剂进行正交组坯压制而成。其增强类型包括：
1)表层增强，在正交组坯的多层竹展平复合板任意上下表层增加一层或多层碳纤维增强层；
2)胶层增强，在正交组坯的多层竹展平板任意胶层增加一层或多层碳纤维增强层；
3)表芯层同时增强，在正交组坯的多层竹展平复合板上下表面和各胶层同时进行碳纤维增强。
本发明的有益效果：
1)本发明技术方案适用于新能源汽车车厢底板，有效的解决了传统工艺和制备条件下，车厢底板存在翘曲、鼓泡以及分层等问题，在降低产品自身重量的同时，提高了产品的抗弯性能和冲击韧性，能有效解决传统竹制车厢底板力学性能不足的缺陷，实现车身材料的轻量化。
2)能有效的提高竹展平板的利用率和拓宽竹制产品的应用领域，响应国家节能环保的号召，利用生物质材料的可再生和循环利用的特点进行设计，符合新能源汽车的设计理念。
3)该制造方法改进传统工艺，竹展平单板干燥采用加压加热干燥，可有效的保证板坯平整，不翘曲不变形，固化方式采用冷压固化，产品质量有所保证，避免热压过程中出现的鼓泡分层等现象，减少生产过程中的能耗，起到节能减排的效果。
附图说明
图1是一种车厢底板用碳纤维增强的竹展平复合板的表层增强组坯方式示意图。
图2是一种车厢底板用碳纤维增强的竹展平复合板的胶层增强组坯方式示意图。
图3是一种车厢底板用碳纤维增强的竹展平复合板的表芯层增强组坯方式示意图。
图4是一种车厢底板用碳纤维增强的竹展平复合板的表层增强三层结构实物图。
图5是一种车厢底板用碳纤维增强的竹展平复合板的胶层增强三层结构实物图。
图6是一种车厢底板用碳纤维增强的竹展平复合板抗弯强度的测试过程图。
图7是一种车厢底板用碳纤维增强的竹展平复合板表层增强三层结构抗弯强度的测试结果图。
图8是一种车厢底板用碳纤维增强的竹展平复合板胶层增强三层结构抗弯强度的测试结果图。
其中，浅色代表竹展平板，黑色代表碳纤维，箭头代表竹纤维方向，黑色省略号代表多层竹展平板。
具体实施方式：
实施例1，一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，包括如下工艺步骤：
1)竹展平单板接长：以厚度为5.0的竹展单平板沿长度方向接长为2.4m的的竹展平单板；
2)热压干燥：将截断的竹展平单板平铺在热压机上，第一步为加热加压，温度控制在90℃，压力控制在2.5MPa，时间为9h，干燥到含水率为15％，第二步为加压冷却定型，不再加热，继续加压，压力控制在2.5MPa，等单板自然冷却到常温取出，防止单板翘曲变形；
3)表面砂光：用砂光机对竹展单平板竹青竹黄两面都进行砂光处理，使竹展平单板表面平整。然后对竹展平单板进行表面活化处理，将0.02mol/L NaOH溶液均匀涂布到竹展平单板两面，处理时间为1h；
4)碳纤维浸胶：将碳纤维布用环氧树脂进行浸渍处理，环氧树脂A、B两个组分按照质量比3﹕1进行混合搅拌，浸胶量0.5kg/m2,浸渍时间为2h，沥干之后进行二次浸胶，浸胶量0.5kg/m2,浸渍时间为0.5h，沥干0.5h；
5)施胶组坯：处理后的竹展平单板板先采用指接的方式进行宽度方向的拼宽，制作成竹展平板，按照示意图1的组坯方式进行组坯，一层碳纤维复合在三层正交组坯碳纤维的上下表面，胶粘剂使用环氧树脂，施胶量为0.3kg/m2，碳纤维层用消泡刷进行滚涂排气复合在表层或者胶层；
6)冷压固化：将复合板坯放在冷压机中进行冷压，压力为3.0MPa，时间为14h，温度为常温即可；
7)养生：压制成型的车厢底板用碳纤维增强的竹展平复合板需放在阴凉干燥的地方陈放，时间7天以上，经调湿调质后含水率控制在12％；
8)后期处理：调湿调质后的复合板砂光、开槽、油漆、包装工序制备成车厢底板用碳纤维增强的竹展平复合板成品如图4所示。
实施例2：一种车厢底板用碳纤维增强的竹展平复合板及其制造方法，包括如下工艺步骤：
1)竹展平单板接长：以厚度为5.0的竹展单平板沿长度方向接长为2.4m的的竹展平单板；
2)热压干燥：将截断的竹展平单板平铺在热压机上，第一步为加热加压，温度控制在90℃，压力控制在2.5MPa，时间为9h，干燥到含水率为15％，第二步为加压冷却定型，不再加热，继续加压，压力控制在2.5MPa，等单板自然冷却到常温取出，防止单板翘曲变形；
3)表面砂光：用砂光机对竹展单平板竹青竹黄两面都进行砂光处理，使竹展平单板表面平整。然后对竹展平单板进行表面活化处理，将0.01mol/L硫酸溶液均匀涂布到竹展平单板两面处理时间为1h；
4)碳纤维浸胶：将碳纤维布用环氧树脂进行浸渍处理，环氧树脂A、B两个组分按照质量比3﹕1进行混合搅拌，浸胶量0.5kg/m2,浸渍时间为2h，沥干之后进行二次浸胶，浸胶量0.5kg/m2,浸渍时间为0.5h，沥干0.5h；
5)施胶组坯：处理后的竹展平单板板先采用指接的方式进行宽度方向的拼宽，制作成竹展平板，按照示意图2的组坯方式进行组坯，一层碳纤维复合在三层正交组坯碳纤维的上下两个胶层，胶粘剂使用环氧树脂，施胶量为0.3kg/m2，碳纤维层用消泡刷进行滚涂排气复合在表层或者胶层；
6)冷压固化：将复合板坯放在冷压机中进行冷压，压力为3.0MPa，时间为14h，温度为常温即可；
7)养生：压制成型的车厢底板用碳纤维增强的竹展平复合板需放在阴凉干燥的地方陈放，时间7天以上，经调湿调质后含水率控制在12％；
8)后期处理：调湿调质后的复合板砂光、开槽、油漆、包装工序制备成车厢底板用碳纤维增强的竹展平复合板成品如图5所示。

Claims (5)

1.一种车厢底板用碳纤维增强的竹展平复合板的制造方法，其特征在于，包括以下工艺步骤：
S1竹展平单板接长：将厚度3.0以上的竹展单平板沿长度方向接长为2.4m以上的竹展平单板；
S2热压干燥：将接长的竹展平单板平铺层叠在热压机上，加热加压整平干燥，降低含水率；
S3表面砂光：将干燥后的竹展平单板进行砂光处理，并进行表面活化；
S4碳纤维浸胶：用环氧树脂对碳纤维进行浸渍处理，使碳纤维完全没入环氧树脂中，沥干，并进行二次浸胶；
S5施胶组坯：处理之后的竹展平单板宽度方向拼宽形成竹展平板，车厢地板用碳纤维增强的竹展平复合板采用多层竹展平板正交复合，用环氧树脂作为胶黏剂，碳纤维在表层或胶层增强或表层和胶层同时增强；
S6冷压固化：将复合板坯放在冷压机中进行冷压，控制时间和压力；
S7养生：压制成型的车厢底板用碳纤维增强的竹展平复合板需放在阴凉干燥的地方陈放，并进行调制调湿处理；
所述S2，所述的热压干燥处理总共分为两步，第一步为加热加压软化整形，温度控制在90℃，压力控制在2.0～3.0MPa，时间为9h，干燥到含水率为15％，第二步为加压冷却定型，不再加热，继续加压，压力控制在2.0～3.0MPa，等单板自然冷却到常温取出，防止单板翘曲变形；
所述S3，所述表面砂光处理，是对竹展单平板竹青竹黄两面都进行砂光处理，使竹展平单板表面平整；然后对竹展平单板进行表面活化处理，碱处理处理剂是0.02mol/LNaOH溶液，处理时间为1h，酸处理处理剂是0.01mol/L硫酸溶液，处理时间为1h；
所述S6，所述冷压固化，压力为3.0～5.0MPa，时间为14h，温度为常温；
所述S7，压制成型的车厢地板用碳纤维增强的竹展平复合板在调湿调质环境中进行湿热平衡，时间7天以上，经调湿调质后含水率控制在12％。
2.根据权利要求1中一种车厢底板用碳纤维增强的竹展平复合板的制造方法，其特征在于：
所述S1，所述车厢底板用碳纤维增强的竹展平复合板采用去青去黄的竹展单平板为构成单元，是有背面展开裂隙或完全无宏观展开裂隙,只有微观展开裂隙的展开竹片,但展开裂隙深度厚度方向上不能穿透总厚度的1/3，接长采用指接、斜接或采用衬布加强接长等方式，接长胶采用结构胶为主。
3.根据权利要求1中一种车厢底板用碳纤维增强的竹展平复合板的制造方法，其特征在于：所述S4，所述碳纤维采用碳纤维布，用环氧树脂进行浸渍处理，环氧树脂A、B两个组分按照质量比3﹕1进行混合搅拌，浸胶量0.3～0.5kg/m2,浸渍时间为2h，沥干之后进行二次浸胶，浸胶量0.3～0.5kg/m2,浸渍时间为0.5h，陈放时间为0.5h。
4.根据权利要求1中一种车厢底板用碳纤维增强的竹展平复合板的制造方法，其特征在于：
所述S5，所述施胶组坯采用的是多层竹展平板的正交复合结构，组坯时，采用的是竹展单板平板宽度方向拼宽制成的竹展平板，多层竹展平板上下叠加，相邻两层竹纤维方向相互垂直的正交结构，碳纤维可在胶层或表层进行增强，碳纤维施胶量为0.2～0.3kg/m2，并用消泡刷进行滚涂排气。
5.根据权利要求1至4中任一项所述的制造方法制备得到的车厢底板用碳纤维增强的竹展平复合板，其特征在于：
以竹展平单板为构成单元，采用结构用冷压环氧树脂作为胶黏剂进行正交组坯压制而成；其增强类型包括：
1)表层增强，在正交组坯的多层竹展平复合板任意上下表层增加一层或多层碳纤维增强层；
2)胶层增强，在正交组坯的多层竹展平板任意胶层增加一层或多层碳纤维增强层；
3)表芯层同时增强，在正交组坯的多层竹展平复合板上下表面和各胶层同时进行碳纤维增强。
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