A crimped basalt fiber composite material and a preparation method and application thereof

Abstract

The application discloses a kind of crimped basalt fiber composite material and its preparation method and application, belong to the field of automotive interior and exterior materials.The application is prepared by crimping basalt filament in the process of basalt fiber drawing by increasing rotating high-temperature rod to basalt filament, with a certain curvature basalt fiber, thereby avoiding the influence of high stiffness basalt fiber on the toughness of composite material, solve the problem of insufficient tensile strength and local fracture of fiber composite material in the process of large tensile deformation, with higher tensile strength and elongation at break, suitable for preparing the workpiece with large tensile deformation.Meanwhile, basalt fiber composite material also has excellent environmental protection and flame retardant performance, in addition to can be applied in automotive interior or exterior materials, also can be applied in building materials and aerospace materials, widen the application range of basalt fiber composite material, has very broad application prospect.

Description

Technical Field

[0001] This invention relates to the field of automotive interior and exterior materials technology, and in particular to a curled basalt fiber composite material, its preparation method, and its application. Background Technology

[0002] Basalt fiber composite hot-pressed sheets are characterized by low odor, environmental friendliness, and excellent flame retardant properties. Currently, they are used in the automotive industry as materials for interior and exterior products, replacing traditional injection-molded parts and hemp fiber composites. Due to their superior environmental and flame-retardant properties, basalt fiber composite hot-pressed sheets hold promise for applications in other vehicles.

[0003] Basalt fiber is a brittle material with a theoretical tensile strength ranging from 3000 MPa to 4840 MPa, an elastic modulus of 90 GPa to 110 GPa, and an elongation at break of approximately 3.2%. However, the tensile strength of commercially available basalt fiber is generally between 2000 MPa and 2500 MPa, significantly lower than its theoretical tensile strength. Furthermore, the tensile strength of commercially available basalt fiber composite hot-pressed sheets is only 8 MPa to 30 MPa, with an elongation at break of 8% to 10%, both relatively low. Therefore, basalt fiber composite hot-pressed sheets can currently only be used for parts with small tensile deformation.

[0004] To improve the mechanical properties of basalt fiber composite hot-pressed plates, it is necessary to improve existing products to enhance the tensile strength and elongation at break of the composite material, so as to adapt to the process of large tensile deformation and further broaden its application scenarios. Summary of the Invention

[0005] This invention addresses the problem of low tensile strength and elongation at break of existing basalt fiber composite hot-pressed sheets by proposing a crimped basalt fiber composite material, its preparation method, and its application.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows.

[0007] In a first aspect, the present invention proposes a crimped basalt fiber composite material, comprising the following raw materials in parts by weight: 50-70 parts of basalt fiber with curvature and 30-50 parts of polypropylene fiber; wherein the radius of curvature of the basalt fiber with curvature is in the range of 4-6 mm, the length of the basalt fiber with curvature is 40-60 mm, and the length of the polypropylene fiber is 50 mm; the basalt fiber with curvature and the polypropylene fiber are loosely mixed, needle-punched into felt, and hot-pressed into a board to prepare a fiber composite material.

[0008] Furthermore, the method for preparing the basalt fiber with curvature includes the following steps:

[0009] Step 1: After the basalt fibers are formed, they fall into a cylindrical shaping device under the action of gravity. Through the horizontal circular motion of the central column inside the cylindrical shaping device, the basalt fibers are wound around the central column, and the central column heats the basalt fibers.

[0010] Step 2: Remove the central column and basalt fiber filaments, and cool them to obtain basalt fiber filaments with curvature;

[0011] Step 3: Cut the cooled basalt fiber filaments with curvature to the specified length to obtain basalt fiber with curvature.

[0012] Furthermore, the temperature of the central column is 250~350℃.

[0013] Furthermore, the horizontal circular motion of the central column has a rotational speed of 25 rpm and a radius of motion of 3 mm.

[0014] Furthermore, the central column is a metal tube with an inner diameter of 2 mm and an outer diameter of 4-6 mm.

[0015] Furthermore, the pressure of the hot press is 10 MPa, the hot pressing temperature is 100℃~180℃, and the hot pressing time is 35~60 minutes.

[0016] Secondly, the present invention provides a method for preparing the above-mentioned curled basalt fiber composite material, comprising the following steps:

[0017] Step 1: After the basalt fibers are formed, they fall into a cylindrical shaping device under the action of gravity. Through the horizontal circular motion of the central column inside the cylindrical shaping device, the basalt fibers are wound around the central column, and the central column heats the basalt fibers.

[0018] Step 2: Remove the central column and basalt fiber filaments, and cool them to obtain basalt fiber filaments with curvature;

[0019] Step 3: Cut the cooled basalt fiber filaments with curvature to the specified length to obtain basalt fiber with curvature;

[0020] Step 4: The curved basalt fibers and polypropylene fibers are loosely mixed, needle-punched into felt, and then hot-pressed into boards to prepare fiber composite materials; the pressure of the hot press is 10 MPa, the hot pressing temperature is 100℃~180℃, and the hot pressing time is 35~60 minutes.

[0021] Thirdly, the present invention provides the application of the above-mentioned curled basalt fiber composite material in building materials.

[0022] Fourthly, the present invention provides the application of the above-mentioned curled basalt fiber composite material in automotive interior or exterior materials.

[0023] Fifthly, the present invention provides the application of the above-mentioned curled basalt fiber composite material in aerospace materials.

[0024] Compared with the prior art, the technical effects of the present invention are as follows:

[0025] This invention proposes a crimped basalt fiber composite material and its preparation method. By adding a rotating high-temperature rod (central column) during the basalt fiber drawing process to crimp the basalt fibers, basalt fibers with a certain curvature are prepared. This avoids the influence of the high stiffness of basalt fibers on the toughness of the composite material, and solves the problems of insufficient tensile strength and local fracture of fibers in fiber composites during large tensile deformation. Experiments have shown that basalt short-cut fiber composites with a curvature radius in the range of 4-6 mm have higher tensile strength and elongation at break than straight fiber composites, making them suitable for manufacturing parts with large tensile deformation. Simultaneously, basalt fiber composites also possess excellent environmental protection and flame-retardant properties. Besides applications in automotive interior or exterior materials, they can also be used in building materials and aerospace materials, broadening the applicability of basalt fiber composites and demonstrating a very broad application prospect. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0027] Figure 1 The figures show the mechanical property test results of the curled basalt fiber composite materials provided in Examples 1-10 of this invention. In the two bar charts corresponding to each example, the left bar represents tensile strength (MPa), and the right bar represents elongation at break (%). Detailed Implementation

[0028] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to embodiments and accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Unless otherwise specified, the experimental methods described in the following examples are conventional methods.

[0030] Unless otherwise specified, all experimental materials used in the following examples were purchased from conventional biochemical reagent stores. Example 1

[0031] Fiber Preparation: After basalt fibers are formed, they fall into a cylindrical shaping device under gravity. The device has an inner cavity and a central column located within it. A motor drives the central column in a horizontal circular motion, allowing the basalt fibers to wind around it. The central column is a hollow metal tube (for easy water cooling), with an inner diameter of 2 mm and an outer diameter of 4 mm. The temperature of the central column is 300℃, the horizontal circular motion speed is 25 rpm, and the radius of motion is 3 mm. After the fibers are wound, the central column and fibers are removed and cooled using water cooling to obtain basalt fibers with a radius of curvature of 4 mm.

[0032] Fiber cutting and mixing: The cooled basalt fibers were cut into 50mm lengths to obtain chopped fibers. Then, 60 parts of basalt fibers with curvature (curvature radius of 4mm) and 40 parts of polypropylene fibers were loosened and mixed.

[0033] Hot pressing into sheets: The mixed fibers are needle-punched into felt and then placed in a hot press. The pressure of the hot press is set to 10 MPa, the hot pressing temperature is 150℃, and the hot pressing time is 45 minutes.

[0034] Finished product: Basalt fiber composite material board with good mechanical properties (see Table 1) is obtained, which is suitable for automotive interior and exterior materials as well as building materials. Example 2

[0035] Fiber preparation: Same as in Example 1, but with a central column outer diameter of 5 mm and a temperature of 250 °C, resulting in basalt fibers with a radius of curvature of 5 mm.

[0036] Fiber cutting and mixing: Basalt fibers are cut to a length of 50 mm, and then 55 parts of basalt fibers with curvature (curvature radius of 5 mm) and 45 parts of polypropylene fibers are mixed.

[0037] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 180℃, and the hot pressing time is 35 minutes.

[0038] Finished product: The obtained composite material board has good mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as building materials. Example 3

[0039] Fiber preparation: Same as in Example 1, but with a central column outer diameter of 6 mm and a temperature of 250 °C, resulting in basalt fibers with a radius of curvature of 6 mm.

[0040] Fiber cutting and mixing: The basalt fibers were cut to a length of 60 mm, and 70 parts of basalt fibers with curvature (curvature radius of 6 mm) and 30 parts of polypropylene fibers were mixed.

[0041] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 100℃, and the hot pressing time is 60 minutes.

[0042] Finished product: The resulting composite material sheet has excellent mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as aerospace materials. Example 4

[0043] Fiber preparation: Same as in Example 1, but the temperature of the central column is 200℃, resulting in basalt fibers without curvature.

[0044] Fiber cutting and mixing: Cut basalt fibers to a length of 60 mm, and mix 70 parts of basalt fiber (without curvature) with 30 parts of polypropylene fiber.

[0045] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 120℃, and the hot pressing time is 50 minutes.

[0046] Finished product: The mechanical properties of the obtained composite material plate are poor (see Table 1). Example 5

[0047] Fiber preparation: Same as in Example 1, but the temperature of the central column is 350℃, resulting in basalt fibers with a radius of curvature of 4mm.

[0048] Fiber cutting and mixing: Basalt fibers were cut to 40mm lengths, and 60 parts of basalt fiber (radius of curvature of 4mm) and 40 parts of polypropylene fiber were taken. Mixed.

[0049] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 110℃, and the hot pressing time is 55 minutes.

[0050] Finished product: The obtained composite material board has good mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as building materials. Example 6

[0051] Fiber preparation: Same as in Example 1, but the temperature of the central column was 350℃, resulting in basalt fibers with a radius of curvature of 4mm.

[0052] Fiber cutting and mixing: The basalt fiber was cut to a length of 60 mm, and 65 parts of basalt fiber (with a radius of curvature of 4 mm) and 35 parts of polypropylene fiber were mixed.

[0053] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 130℃, and the hot pressing time is 45 minutes.

[0054] Finished product: The obtained composite material board has good mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as building materials. Example 7

[0055] Fiber preparation: Same as in Example 1, but with a central column outer diameter of 6 mm and a temperature of 250 °C, resulting in basalt fibers with a radius of curvature of 6 mm.

[0056] Fiber cutting and mixing: Cut basalt fibers to a length of 50 mm, and mix 50 parts of basalt fiber (radius of curvature of 6 mm) with 50 parts of polypropylene fiber.

[0057] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 150℃, and the hot pressing time is 40 minutes.

[0058] Finished product: The resulting composite material sheet has excellent mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as aerospace materials. Example 8

[0059] Fiber preparation: Same as in Example 1, but with a central column outer diameter of 6 mm and a temperature of 250 °C, resulting in basalt fibers with a radius of curvature of 6 mm.

[0060] Fiber cutting and mixing: The basalt fiber was cut to a length of 40 mm, and 70 parts of basalt fiber (radius of curvature of 6 mm) and 30 parts of polypropylene fiber were mixed.

[0061] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 160℃, and the hot pressing time is 40 minutes.

[0062] Finished product: The obtained composite material board has good mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as building materials. Example 9

[0063] Fiber preparation: Same as in Example 1, but with a central column outer diameter of 6 mm and a temperature of 300 °C, resulting in basalt fibers with a radius of curvature of 6 mm.

[0064] Fiber cutting and mixing: The basalt fibers were cut to a length of 40 mm, and 65 parts of basalt fibers (with a radius of curvature of 5 mm) and 35 parts of polypropylene fibers were mixed.

[0065] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 150℃, and the hot pressing time is 40 minutes.

[0066] Finished product: The obtained composite material board has good mechanical properties (see Table 1) and is suitable for automotive interior and exterior materials as well as building materials. Example 10

[0067] Fiber preparation: Same as in Example 1, but the temperature of the shaping device was room temperature, resulting in basalt fibers without curvature.

[0068] Fiber cutting and mixing: Cut basalt fibers to a length of 60 mm, and mix 60 parts of basalt fiber (without curvature) with 40 parts of polypropylene fiber.

[0069] Hot pressing into plates: The pressure of the hot press is 10 MPa, the hot pressing temperature is 170℃, and the hot pressing time is 35 minutes.

[0070] Finished product: The resulting composite material plate has poor mechanical properties (see Table 1).

[0071] Table 1 Mechanical properties of basalt fiber composites

[0072] Example Temperature of the setting device (°C) Radius of curvature of basalt fiber (mm) Basalt fiber length (mm) Tensile strength (MPa) Elongation at break (%) Example 1 300 4 50 59.45 12.19 Example 2 250 5 50 62.33 15.15 Example 3 250 6 60 68.01 16.8 Example 4 200 - 60 47.21 8.73 Example 5 350 4 40 57.21 11.73 Example 6 350 4 60 60.01 10.67 Example 7 250 6 50 67.28 16.3 Example 8 250 6 40 61.37 15.9 Example 9 300 5 40 60.27 15.8 Example 10 - - 60 42.32 9.32

[0073] The mechanical property tests of each embodiment are shown in Table 1. In Embodiments 4 and 10, the basalt fibers obtained were without curvature due to the low temperature of the setting device, resulting in lower tensile strength and elongation at break during tensile testing. Embodiments 3 and 7, with suitable setting temperatures, radii of curvature, and fiber lengths, exhibited tighter interweaving between fibers during needle punching and hot pressing, resulting in higher tensile strength, significantly superior to other embodiments. Furthermore, the basalt fibers possess a certain degree of curvature, allowing them to straighten first and then break during stretching, thus achieving a higher elongation at break. Additionally, a setting device temperature of 250°C to 350°C is sufficient to curl the basalt fibers, and higher temperatures would also cause curling but would result in greater resource waste; therefore, the setting device temperature was set at 250°C to 350°C. Temperatures below 250°C would prevent the basalt fibers from curling.

[0074] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A curled basalt fiber composite material, characterized in that, The raw materials include the following parts by weight: 70 parts of curved basalt fiber and 30 parts of polypropylene fiber; the curved basalt fiber has a radius of curvature of 6 mm, a length of 60 mm, and a length of 50 mm; the curved basalt fiber and polypropylene fiber are opened and mixed, needle-punched into felt, and then hot-pressed into a board to prepare a fiber composite material; the pressure of the hot press is 10 MPa, the hot-pressing temperature is 100℃, and the hot-pressing time is 60 minutes. The method for preparing the basalt fiber with curvature includes the following steps: Step 1: After the basalt fibers are formed, they fall into a cylindrical shaping device under the action of gravity. Through the horizontal circular motion of the central column inside the cylindrical shaping device, the basalt fibers are wound around the central column, and the central column heats the basalt fibers. Step 2: Remove the central column and basalt fiber filaments, and cool them to obtain basalt fiber filaments with curvature; Step 3: Cut the cooled basalt fiber filaments with curvature to the specified length to obtain basalt fiber with curvature.

2. The curled basalt fiber composite material according to claim 1, characterized in that, The temperature of the central column is 250~350℃.

3. The curled basalt fiber composite material according to claim 1, characterized in that, The central column rotates at a speed of 25 rpm in a horizontal circular motion with a radius of 3 mm.

4. The curled basalt fiber composite material according to claim 1, characterized in that, The central column is a metal tube with an inner diameter of 2mm and an outer diameter of 6mm.

5. The application of the curled basalt fiber composite material according to claim 1 in building materials.

6. The application of the curled basalt fiber composite material according to claim 1 in automotive interior or exterior materials.

7. The application of the coiled basalt fiber composite material according to claim 1 in aerospace materials.

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