Wave-shaped carbon fiber board and manufacturing method thereof

Abstract

The invention discloses a wave-shaped carbon fiber board and a manufacturing method thereof.The manufacturing method of the wave-shaped carbon fiber board comprises the following steps that S1, carbon fiber cloth is coated with phenolic resin impregnation liquid, and impregnated carbon fiber cloth is formed; s2, arranging high-temperature-resistant release layers on two opposite surfaces of the impregnated carbon fiber cloth; and S3, the impregnated carbon fiber cloth is conveyed and passes through the space between two meshed gear rollers, the two gear rollers rotate relatively, the impregnated carbon fiber cloth is rolled into a wave shape and heated to be solidified, and the wave-shaped carbon fiber board is formed. According to the invention, the carbon fiber cloth is impregnated by phenolic resin, and the wave-shaped carbon fiber board is formed by rolling, heating and curing, and has small thickness and enough strength; the phenolic resin and the carbon fiber are materials with good flame retardant property, and the prepared wave-shaped carbon fiber plate has good high temperature resistance and flame retardant property.

Description

Technical Field

[0001] The invention relates to the technical field of air purification in nuclear power plants, and in particular to a corrugated carbon fiber board and a manufacturing method thereof. Background Art

[0002] To make an activated carbon fiber filter, the activated carbon fiber felt needs to be folded into an S shape in order to greatly increase its contact area with the gas to be treated within a limited space. Through folding, the originally flat activated carbon fibers form a complex pleated structure, and the gas passes through more of the activated carbon fiber surface when passing through. In order to avoid the fibers on the adjacent sides being squeezed and pressed against each other during the folding process, affecting the airflow and causing the pressure difference to increase, it is also necessary to set up interlayer brackets between adjacent folded surfaces as guide plates to create a certain gap between them. The guide plates need to be as small as possible to reduce the flow resistance, and they need to have a certain support strength.

[0003] If the interlayer bracket is processed by injection molding, the thickness of the injection molded product cannot be too thin, otherwise the bracket will be large and the resistance will be large. Thin plates with a thickness of 0.1mm or less can be achieved by roll forming, and the bracket volume will be very small, which can meet the requirements of small volume and high strength. Aluminum foil plates or thin film stainless steel plates can be used for thin plates, but both of them cannot be burned, which does not meet the requirement that the developed filter must be able to be incinerated and reduced in volume. For raw materials, carbon fiber cloth or glass fiber cloth pre-impregnated with epoxy resin can also be selected, but the cost of pre-impregnated cloth is high, and epoxy resin is not flame retardant, which cannot meet the technical requirements of flame retardancy of the developed filter. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a corrugated carbon fiber board and a manufacturing method thereof.

[0005] The technical solution adopted by the present invention to solve the technical problem is: to provide a method for manufacturing a corrugated carbon fiber board, comprising the following steps:

[0006] S1, applying a phenolic resin impregnation liquid on the carbon fiber cloth to form an impregnated carbon fiber cloth;

[0007] S2, providing a high temperature resistant release layer on two opposite surfaces of the impregnated carbon fiber cloth;

[0008] S3, conveying the impregnated carbon fiber cloth and passing it between two meshing gear rollers, the two gear rollers rotate relatively, pressing the impregnated carbon fiber cloth into a wave shape and heating it to solidify it, thereby forming a wave-shaped carbon fiber board.

[0009] In some embodiments, the raw materials of the phenolic resin impregnation solution include phenolic resin, water and curing agent;

[0010] The mass ratio of the phenolic resin, water and curing agent is 100:100-300:2-10.

[0011] In some embodiments, the phenolic resin is a water-soluble liquid with thermosetting properties, a curing temperature of 160° C. to 185° C., less than 20% free phenol, and a solid content of 50±2%.

[0012] In some embodiments, the curing agent includes a polysilicon compound NL type curing agent.

[0013] In some embodiments, the release layer is a release paper or a release film, which has a temperature resistance of 200° C. or above.

[0014] In some embodiments, in the impregnated carbon fiber cloth, the impregnation amount of the phenolic resin impregnation liquid is as follows:

[0015] The amount of phenolic resin impregnation liquid on each square meter of carbon fiber cloth is 120 g to 200 g.

[0016] In some embodiments, the carbon fiber cloth is extended unidirectionally along the length direction, connected longitudinally by weft threads, has a thickness of 0.1 mm to 0.3 mm, and has a tensile strength greater than 3000 MPa.

[0017] In some embodiments, in step S3, before the impregnated carbon fiber cloth passes through the gear roller, the gear roller is heated to 170° C. to 200° C.

[0018] In some embodiments, the gear roller is hollow inside, and a heating rod is provided inside the hollow part, and the heating rod is powered on by a temperature controller to heat the gear roller;

[0019] One of the gear rollers is connected to a motor, and the motor drives the gear roller to rotate, thereby causing the two meshing gear rollers to rotate.

[0020] The present invention also provides a corrugated carbon fiber board, which is made by using any of the above methods for making the corrugated carbon fiber board.

[0021] The beneficial effects of the present invention are as follows: the carbon fiber cloth is impregnated with phenolic resin, and then rolled, heated and cured to form a corrugated carbon fiber board with a small thickness and sufficient strength; both phenolic resin and carbon fiber are materials with good flame retardant properties, and the resulting corrugated carbon fiber board has good high temperature resistance and flame retardant properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments, in which:

[0023] Figure 1 It is a schematic diagram of the process of rolling the impregnated carbon fiber cloth into a wavy shape by a gear roller in the present invention;

[0024] Figure 2 Schematic diagram of the structure of a corrugated carbon fiber board according to an embodiment of the present invention. DETAILED DESCRIPTION

[0025] In order to have a clearer understanding of the technical features, purposes and effects of the present invention, specific embodiments of the present invention are now described in detail with reference to the accompanying drawings.

[0026] refer to Figure 1 and Figure 2 The method for making the corrugated carbon fiber board of the present invention may include the following steps:

[0027] S1. Coat the carbon fiber cloth with phenolic resin impregnation liquid to form an impregnated carbon fiber cloth 10.

[0028] The raw materials of the phenolic resin impregnation liquid include phenolic resin, water and curing agent. The phenolic resin impregnation liquid is prepared by mixing the phenolic resin, water and curing agent in a predetermined mass ratio.

[0029] In some embodiments, the mass ratio of phenolic resin, water and curing agent is 100:100-300:2-10.

[0030] Phenolic resin is a water-soluble liquid, which can be a brown or orange-red transparent liquid. Phenolic resin is thermosetting, with a curing temperature of 160°C to 185°C, less than 20% free phenol, and a solid content of 50±2%. The viscosity of the phenolic resin measured by a Tu-4 viscometer is 15 seconds to 40 seconds.

[0031] The curing agent includes a polysilicon compound NL type curing agent. The water is preferably neutral purified water.

[0032] In some embodiments, the carbon fiber cloth is unidirectionally extended along the length direction, connected longitudinally by weft lines, has a thickness of 0.1 mm to 0.3 mm, and a tensile strength greater than 3000 MPa. The width of the carbon fiber cloth can be set according to the filter requirements.

[0033] In the impregnated carbon fiber cloth 10 formed by impregnating the phenolic resin impregnation liquid, the impregnation amount of the phenolic resin impregnation liquid is as follows: the phenolic resin impregnation liquid on each square meter of the carbon fiber cloth is 120 g to 200 g.

[0034] S2, disposing a high temperature resistant release layer 11 on two opposite surfaces of the impregnated carbon fiber cloth 10.

[0035] The high temperature resistant release layer 11 covers the surface of the impregnated carbon fiber cloth 10 to prevent the phenolic resin impregnation liquid on the impregnated carbon fiber cloth 10 from adhering to the gear roller.

[0036] In some embodiments, the release layer 11 is a release paper or a release film, which has a temperature resistance of more than 200°C.

[0037] S3, the impregnated carbon fiber cloth 10 is transported and passed between two meshing gear rollers 30, the two gear rollers 30 rotate relatively, the impregnated carbon fiber cloth 10 is rolled into a wavy shape and heated to solidify it, so as to form a wavy carbon fiber board 20.

[0038] In step S3, the roll pressing of the impregnated carbon fiber cloth 10 can be achieved by using a roll pressing device, which includes two gear rollers 30 arranged opposite to each other and meshing with each other, a driving mechanism, and a temperature control mechanism.

[0039] The driving mechanism includes a motor, which is connected to one of the gear rollers 30. The gear roller 30 connected to the motor is used as the active roller, and the other gear roller 30 is used as the driven roller. When the motor is started, the gear roller 30 used as the active roller is driven to rotate, and the rotation of the gear roller 30 drives the other gear roller 30 meshing with it to rotate, so that the two gear rollers 30 rotate synchronously.

[0040] The temperature control mechanism includes a heating rod and a temperature controller connected to the heating rod. Each gear roller 30 is hollow inside, and the heating rod is arranged inside the hollow inside of the gear roller 30. The temperature controller controls the heating rod to be energized to heat the gear roller.

[0041] In a preferred embodiment, the parameters of each gear roller 30 are selected as follows:

[0042] The diameter of the gear roller 30 is 60 mm to 100 mm, and the length is 300 mm to 400 mm; the tooth height of the gear roller 30 is 7 mm to 12 mm, the tooth top angle is 70° to 85°, and the tooth bottom angle is 100° to 115°.

[0043] In some embodiments, step S3 further comprises:

[0044] S3.1. The heating rod is energized and heated by the temperature controller to heat the gear roller 30 to 170° C. to 200° C.

[0045] S3.2, the impregnated carbon fiber cloth 10 is conveyed to the front end of the gear roller 30, passes between two gear rollers 30, is rolled into a wave shape and is output from the rear end of the gear roller 30.

[0046] The gear roller 30 heats the impregnated carbon fiber cloth 10 during the rolling process, so that the phenolic resin impregnation liquid on the impregnated carbon fiber cloth 10 is heated and solidified to form a corrugated carbon fiber board 20 .

[0047] Alternatively, a conveyor belt is provided at the front end of the gear roller 30 , and the impregnated carbon fiber cloth 10 is transported to the front end of the gear roller 30 on the conveyor belt.

[0048] The motor is controlled by a speed controller to achieve the change of state between rotation and stop. In one embodiment, by regulating the motor, the gear roller 30 is driven to rotate in a mode of: rotating one tooth (about 2 seconds), stopping for 12 seconds to 20 seconds to heat the rolled impregnated carbon fiber cloth 10. This rotation mode has a good curing effect on the impregnated carbon fiber cloth.

[0049] The control of the wave height in the corrugated carbon fiber board 20 can be achieved by adjusting the distance between the two gear rollers 30 .

[0050] After rolling, the release layer 11 on the corrugated carbon fiber board 20 can be removed. Alternatively, the release layer 11 remains on the surface of the corrugated carbon fiber board 20 to protect it, and the release layer is removed before the corrugated carbon fiber board 20 is installed in the filter.

[0051] like Figure 2 As shown, the corrugated carbon fiber board 20 obtained by the manufacturing method of the present invention is corrugated as a whole. The corrugated carbon fiber board 20 comprises carbon fiber cloth and phenolic resin impregnated and cured thereon.

[0052] Phenolic resin and carbon fiber are both materials with good flame retardant properties. The corrugated carbon fiber board 20 made of the materials has good high temperature resistance and flame retardant properties. Compared with aluminum foil or stainless steel sheets, the carbon fiber board 20 can be incinerated to reduce volume and has low solid waste production. Compared with carbon fiber or glass fiber prepregs pre-impregnated with epoxy resin, the cost is low.

[0053] The corrugated carbon fiber sheet 20 is applied to the filter and is arranged in the folded layer of the fiber felt in the filter to separate two adjacent fiber surfaces of the folds to prevent the two fiber surfaces from being closely attached to each other and affecting the circulation of airflow.

[0054] The corrugated carbon fiber board 20 has high strength, can effectively support the filter fiber felt, and form a uniform gap. Each square meter of the corrugated carbon fiber board can bear a pressure of 100 to 150 kilograms.

[0055] The thickness of the corrugated carbon fiber board 20 is only 0.1 mm to 0.3 mm, and the ventilation resistance is small. Compared with other types of filters, the filter using the corrugated carbon fiber board has a resistance of about 50 Pa less under the same air volume.

[0056] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for manufacturing a corrugated carbon fiber board, characterized in that: The following steps are involved: S1, applying a phenolic resin impregnation liquid on the carbon fiber cloth to form an impregnated carbon fiber cloth; S2, providing a high temperature resistant release layer on two opposite surfaces of the impregnated carbon fiber cloth; S3, conveying the impregnated carbon fiber cloth and passing it between two meshing gear rollers, the two gear rollers rotate relatively, pressing the impregnated carbon fiber cloth into a wave shape and heating it to solidify it, thereby forming a wave-shaped carbon fiber board.

2. The method for manufacturing a corrugated carbon fiber board according to claim 1, characterized in that: The raw materials of the phenolic resin impregnation solution include phenolic resin, water and curing agent; The mass ratio of the phenolic resin, water and curing agent is 100:100-300:2-10.

3. The method for making a corrugated carbon fiber board according to claim 2, characterized in that: The phenolic resin is a water-soluble liquid with thermosetting properties, a curing temperature of 160° C. to 185° C., less than 20% free phenol, and a solid content of 50±2%.

4. The method for manufacturing a corrugated carbon fiber board according to claim 2, characterized in that: The curing agent includes a polysilicon compound NL type curing agent.

5. The method for manufacturing a corrugated carbon fiber board according to claim 1, characterized in that: The release layer is a release paper or a release film, and has a temperature resistance of more than 200°C.

6. The method for manufacturing a corrugated carbon fiber board according to claim 1, characterized in that: In the impregnated carbon fiber cloth, the impregnation amount of the phenolic resin impregnation liquid is as follows: The amount of phenolic resin impregnation liquid on each square meter of carbon fiber cloth is 120 g to 200 g.

7. The method for manufacturing a corrugated carbon fiber board according to claim 1, characterized in that: The carbon fiber cloth is extended unidirectionally along the length direction, connected by weft lines in the longitudinal direction, has a thickness of 0.1 mm to 0.3 mm, and a tensile strength greater than 3000 MPa.

8. The method for manufacturing a corrugated carbon fiber board according to any one of claims 1 to 7, characterized in that: In step S3, before the impregnated carbon fiber cloth passes through the gear roller, the gear roller is heated to 170° C. to 200° C.

9. The method for manufacturing a corrugated carbon fiber board according to claim 8, characterized in that: The gear roller is hollow inside, and a heating rod is arranged inside the hollow part, and the heating rod is energized by a temperature controller to heat the gear roller; One of the gear rollers is connected to a motor, and the motor drives the gear roller to rotate, thereby causing the two meshing gear rollers to rotate.

10. A corrugated carbon fiber board, characterized in that: The corrugated carbon fiber board is prepared by the method for preparing the corrugated carbon fiber board according to any one of claims 1 to 9.

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