复合材料制品成型工艺-喷射成型
日期：2023-07-17
作者：复材产业圈 浏览：
425 评论：0 核心提示： 喷射成型：将混有引发剂和促进剂的聚酯分别从喷枪两侧（或是在喷枪内混合）喷出，同时将切断的玻纤无捻粗纱，由喷枪中心喷出，使其与树脂均匀混合，沉积到模具上，当沉积到一定厚度时，用辊轮压实，使纤维浸透树脂，排除气泡，固化后成制品。
喷射成型：将混有引发剂和促进剂的聚酯分别从喷枪两侧（或是在喷枪内混合）喷出，同时将切断的玻纤无捻粗纱，由喷枪中心喷出，使其与树脂均匀混合，沉积到模具上，当沉积到一定厚度时，用辊轮压实，使纤维浸透树脂，排除气泡，固化后成制品。
1.工艺过程：
1.1 原材料准备：树脂（主要用不饱和聚酯树脂）和无捻玻纤粗纱。
1.2 模具准备 准备工作包括清理、组装及涂脱模剂等。
1.3 喷射成型设备 喷射成型机分压力罐式和泵供式两种：①泵式供胶喷射成型机，是将树脂引发剂和促进剂分别由泵输送到静态混合器中，充分混合后再由喷枪喷出，称为枪内混合型。其组成部分为气动控制系统、树脂泵、助剂泵、混合器、喷枪、纤维切割喷射器等。树脂泵和助剂泵由摇臂刚性连接，调节助剂泵在摇臂上的位置，可保证配料比例。在空压机作用下，树脂和助剂在混合器内均匀混合，经喷枪形成雾滴，与切断的纤维连续地喷射到模具表面。这种喷射机只有一个胶液喷枪，结构简单，重量轻，引发剂浪费少，但因系内混合，使完后要立即清洗，以防止喷射堵塞。②压力罐式供胶喷射机是将树脂胶液分别装在压力罐中，靠进入罐中的气体压力，使胶液进入喷枪连续喷出。安是由两个树脂罐、管道、阀门、喷枪、纤维切割喷射器、小车及支架组成。工作时，接通压缩空气气源，使压缩空气经过气水分离器进入树脂罐、玻纤切割器和喷枪，使树脂和玻璃纤维连续不断的由喷枪喷出，树脂雾化，玻纤分散，混合均匀后沉落到模具上。这种喷射机是树脂在喷枪外混合，故不易堵塞喷枪嘴。
①纤维 选用前处理的专用无捻粗纱。制品纤维含量控制在30%-40%，纤维长度一般为25mm-50mm；
②树脂含量 喷射制品采用不饱和聚酯树脂，树脂含量控制在60%左右；
③雾化压力 当树脂粘度为0.2Pa·s，树脂罐压力为0.05～0.15MPa时，雾化压力为0.3～0.55MPa，方能保证组分混合均匀；
④胶液粘度 应控制在0.3Pa·s-0.8Pa·s，触变度以1.5-4为宜；
⑤喷射量 喷射量与喷射压力和喷嘴直径有关，喷嘴直径在1.2mm-3.5mm之间选定，可使喷胶量在8g/s-60g/s之间调变；
⑥喷枪夹角 不同夹角喷出来的树脂混合交距不同，一般选用20°夹角，喷枪与模具的距离为350～400mm。改变距离，要高速喷枪夹角，保证各组分在靠近模具表面处交集混合，防止胶液飞失。
①环境温度应控制在（25±5）℃，过高，易引起喷枪堵塞；过低，混合不均匀，固化慢；
②喷射机系统内不允许有水分（要求独立管路供气，气体必须彻底除湿）存在，否则会影响产品质量；
③成型前，模具上先喷一层树脂，然后再喷树脂纤维混合层；
④喷射成型前，先调整气压，控制树脂和玻纤含量；
⑤喷枪要均匀移动，防止漏喷，不能走弧线，两行之间的重叠富庶小于1/3，要保证覆盖均匀和厚度均匀；
⑥喷完一层后，立即用辊轮压实，要注意棱角和凹凸表面，保证每层压平，排出气泡，防止带起纤维造成毛刺；
⑦每层喷完后，要进行检查，合格后再喷下一层；
⑧最后一层要喷薄些，使表面光滑；
⑨特殊部位喷射：曲面时，喷射方向始终沿曲面法线方向；沟槽时，先喷四周和侧面，然后再底部补喷适量纤维；转角时，从夹角部位向外喷射；
⑩喷射机用完后要立即清洗，防止树脂固化，损坏设备。
1.用玻纤粗纱代替织物，可降低材料成本；
2.生产效率比手糊的高2~4倍；
3.产品整体性好，无接缝，层间剪切强度高，树脂含量高，抗腐蚀，耐渗透性好；
4.可减少飞边，裁布多余下脚料及剩余胶液的消耗；
5.产品尺寸和形状不受限制。1.树脂含量偏高，制品强度一般；
2.产品只能做到单面光滑；
3.喷射工作台环境污染比较严重，需要做好防护措施。喷射成型主要适合于汽车配件，船体制作，大型浮雕，机械外壳，浴盆，浴缸，整体卫生间等制作。nceid="16937613928621706988" data-type="video" data-mediatype="undefined" data-authiconurl="" data-from="new" data-width="1080" data-height="1920" data-id="export/UzFfAgtgekIEAQAAAAAAubMvrUuwuwAAAAstQy6ubaLX4KHWvLEZgBPE54M4IXcZd7uDzNPgMIsivyh77dkn9Uke1wyRGt4g" data-isdisabled="0" data-errortips="" data-parentwidth="677" data-maxwidth="677" data-index="0" data-flag="0" data-feedfullcoverurl="https://findermp.video.qq.com/251/20304/stodownload?encfilekey=oibeqyX228riaCwo9STVsGLPj9UYCicgttvicunFyQbicN4McYZY0pbs3Ldr9gymGARyx1vEPRwJu9EXaicIDaEXfuTIL37cIbqwdNJlC7icFxocJRcy3WKMWsGibPUChOuf0ePCibCAgrFHRfDM&adaptivelytrans=0&bizid=1023&dotrans=0&hy=SH&idx=1&m=e7dfb88a1d1358b92585d39e56e4e676&token=x5Y29zUxcibCQF9L5q8RSK8UFPC3VnZ7KPeeg5t5xsVRlPfMB7WxIHaticm6cZKDia8OqrJMlBH0VU" data-feedthumburl="https://findermp.video.qq.com/251/20350/stodownload?encfilekey=WTva9YVXqXcSUicrMCercmDHmKYPBXC7eQlS3TicqsMeavwIm28TRobqDXqGm8239TTjXG1Gwc6ypyum9orzmY4h4OfM7Zgia3eaFFyXRzzQV9ibJR1ibibq49uWbcbvdVDeNyK7dhXhG1fqE&adaptivelytrans=0&bizid=1023&dotrans=0&hy=SH&idx=1&m=5f9316bbcaa272045bc8ad92f266e067&token=AxricY7RBHdUtkD9N53fp4NiaLXS6BzGuLBCvjHLh2ic6qF5XHMX2FCvalLqSyNxH9aHRCNKGdOsyc" data-feedcoverurl="https://findermp.video.qq.com/251/20304/stodownload?encfilekey=WTva9YVXqXcSUicrMCercmDHmKYPBXC7eMc1HQWQ6nlWcFqTfLsicOSpcOPQibfPJP26Cw1mFwVL6NEEBOxrQ3zKQ6pfvziboXQHhUl2wGBWO6lLKI9xyuVnQVRdJhGfczqfwIMPdxeM7To&adaptivelytrans=0&bizid=1023&dotrans=0&hy=SH&idx=1&m=3de3cebb1bdd1702c1346e33c51f25ab&token=AxricY7RBHdUtkD9N53fp4Ipffx5PyIL6RIecIK9A8cFTP1QLN017n1AneMt1Jc9NMutMzHpPY50" data-isnews="0" data-likenum="2" style="color: initial; 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