植物纤维/热塑性聚合物预浸料在汽车轻量化领域的应用进展

doi:10.11707/j.1001-7488.20210917

摘要/Abstract

摘要：

作为一种天然高分子材料，植物纤维来源丰富，成本低廉，密度小，比强度、比模量高，被认为是最具前景的生物可降解再生资源，其增强复合材料利用价值高、环保无污染，既可显著减少化石燃料的使用，也可降低温室气体排放量，具有巨大的市场价值和发展前景，如何高效利用植物纤维资源、开发高附加值实用产品、拓宽应用领域已成为科研界和工业界的研究焦点。在汽车轻量化趋势下，以植物纤维替代玻璃纤维等增强复合材料，不仅能降低生产成本、减少加工能耗，还有利于汽车零部件产品绿色循环低碳生命体系的构建，从而有效推动汽车工业的可持续发展。预浸料作为先进复合材料产品的中间体，对汽车轻量化的发展具有举足轻重的作用。本研究从植物纤维/热塑性聚合物预浸料着手，概述对其研究的必要性，并介绍增强相连续植物纤维的制备技术以及连续植物纤维/热塑性聚合物预浸料常用制备技术的优缺点和关键技术难点，重点从熔融浸渍、挤出-压延、薄膜层叠、熔融沉积成型等方面阐述连续植物纤维/热塑性聚合物预浸料的新兴制备技术，同时总结植物纤维/热塑性聚合物复合材料在汽车轻量化领域的应用，对比分析汽车传统门饰板和保险杠与薄壁化门饰板和保险杠的质量和生产成本，以期为连续植物纤维/热塑性聚合物预浸料在汽车轻量化领域占据一席之地提供理论支撑。最后，对连续植物纤维/热塑性聚合物预浸料的研究趋势进行几点展望，指出在以后研究工作中，可重点研究连续植物纤维的制备技术和均匀分散，有助于更薄预浸料的开发，从而消除纤维屈曲，提高结构可设计性，进一步降低制品成本；为实现低孔隙率、质量上乘、性能优异的连续植物纤维/热塑性聚合物预浸料的稳定生产，可有效联用现有制备技术，扬长避短，还可理论实践相结合进一步研制新的制造设备，改进生产工艺，实现材料、设备和工艺的一体化发展；同时，为促进连续植物纤维/热塑性聚合物预浸料的良性发展，有必要加快建立标准化评价体系以规范市场。

关键词: 植物纤维, 热塑性聚合物, 预浸料, 制备技术, 汽车工业, 轻量化

Abstract:

Plant fibers as a macro material have the advantages of being a low cost abundant natural resource with a low density, high specific strength and high specific modulus, which is considered as the biodegradable renewable resource with the most promising research prospects. Plant fiber reinforced composite has a high use value and environmental protection without pollution, which not only significantly reduces the use of fossil fuels, but also reduces the greenhouse gas emissions, leading to huge market value and development prospects. Therefore, how to efficiently utilize the plant fiber resource, develop high-added value practical products and broaden the application fields have become key focuses of research and industry. Under the trend of automobile lightweight, substituting plant fiber for glass fiber and other reinforced composite materials will not only reduce the production cost and processing energy consumption, but also facilitate the construction of green, circular and low-carbon life system for auto parts products, effectively promoting the sustainable development of automobile industry. Prepreg, as an intermediate of advanced composite products, plays an important role in the development of automotive lightweight. Thus this study provides a brief overview of necessity of the continuous fiber reinforced thermoplastic polymer research; the preparation technology of continuous plant fiber as well as the continuous fiber/thermoplastic polymer prepregs commonly used in regards to the advantages, disadvantages and key technical problems. This review will expound upon the emerging technology of continuous plant fiber/thermoplastic polymer prepreg such as melt impregnation, extrusion-rolling, film stacking technique and fused deposition modeling. This paper also summarizes the application of continuous plant fiber/thermoplastic polymer composite materials used in automotive lightweight field, and analyzes the quality and production cost of automobile traditional and thin-walled door trim, as well as traditional and thin-walled bumper, in order to provide theoretical support for continuous plant fiber/thermoplastic prepreg for using in lightweight vehicles components. Finally, the research trend of continuous plant fiber/thermoplastic polymer prepreg is prospected. The future work will be focused on the preparation technology and evenly dispersed of continuous plant fiber, helping development of thinner prepreg, which thereby eliminates fiber buckling, improves the structure design, and further reduces the product cost. In order to achieve the stable production of continuous plant fiber/thermoplastic prepreg with lower porosity, improved quality and excellent performances, the existing preparation technology can be effectively combined so as to foster the strengths and circumvent the weaknesses, but also by combining the theory and practice further to develop the new manufacturing equipment and improve the production technology, so that the integrated development of material, equipment and process technology is expected to happen. At the same time, in order to promote the benign development of continuous plant fiber/thermoplastic prepreg, it is necessary to speed up the establishment of standardized evaluation system to regulate the market.

Key words: plant fiber, thermoplastic polymer, prepreg, preparation technology, automobile, lightweight

中图分类号:

S784

王翠翠,李明鹏,王戈,顾少华,程海涛. 植物纤维/热塑性聚合物预浸料在汽车轻量化领域的应用进展[J]. 林业科学, 2021, 57(9): 168-180.

Cuicui Wang,Mingpeng Li,Ge Wang,Shaohua Gu,Haitao Cheng. Application Progress of Plant Fiber/Thermoplastic Polymer Prepreg in Automotive Lightweight Field[J]. Scientia Silvae Sinicae, 2021, 57(9): 168-180.

图/表 12

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表1

表2

常用制备技术比较"

制备技术 Preparation technology			优点 Advantages	缺点 Disadvantages	关键技术难点 Key technical difficulties
预浸渍 Pre- impregnation	熔融浸渍法 (应用广泛) Melt impregnation (widely used)		①工艺过程简单，成本低廉 Simple process and low cost ②挥发分含量低，无污染 Low volatile content, no pollution ③孔隙率低Low porosity ④可精确控制预浸料宽度、厚度以及纤维体积含量 Precise control the prepreg width, thickness, and fiber volume content ⑤高效稳定生产 Efficient and stable production ⑥特别适用于结晶性热塑性聚合物 Especially suitable for crystalline thermoplastic polymers	①热塑性聚合物对增强纤维的浸润性和渗透性较差 Thermoplastic polymer has poor wetting and permeability to the reinforced fibers ②对仪器设备要求高 High requirement on instrument and equipment ③浸渍时间短 Short soaking time	①纤维分散 Fiber dispersion ②完全浸润 Complete wetting
	溶剂浸渍法 Solvent impregnation		①设备简单Simple equipment ②成本低廉Low cost ③纤维浸润性和准直性好 The fiber is well infiltrated and collimated	①具有局限性Limitation ②回收费用昂贵Expensive to recycle ③孔隙含量高High pore content ④不环保，危害人体健康Carbon penance, do damage to the human health ⑤结晶性热塑性树脂难以适用 It is difficult for this method to use the crystalline thermoplastic polymers	①热塑性聚合物的溶解 The dissolution of thermoplastic polymers
	反应浸渍法 Reaction impregnation		①热塑性聚合物基体先聚合成低分子质量的预聚体，其熔体黏度低，易于浸渍纤维 The thermoplastic polymer matrix is polymerized into a low molecular mass prepolymer, whose melt viscosity is low and it is easy to impregnate the fiber ②热塑性聚合物韧性好 The thermoplastic polymer has sufficient toughness	①具有局限性Limitation ②工艺条件比较苛刻 Harsh process conditions ③反应不易控制 It is not easy to control the reaction ④不可连续生产 Noncontinuous production ⑤不具备实用价值 It has no practical value	①聚合反应的控制 The control of poly- merization reaction
后浸渍 After impregnation	粉末悬浮技术 Powder suspension technology	粉末浸渍法 Powder impregnation	①热塑性聚合物基体分子质量损失小 Low molecular mass loss of thermoplastic polymer matrix ②工艺简单、成本低廉 Simple process, low cost ③浸渍速度快 Fast soaking ④生产效率高 High production efficiency ⑤适合批量生产 Suitable for mass production	①热塑性聚合物粉末粒径要求严苛 Requirements of thermoplastic polymer powder particle size are strict ②粉末直径在5~10 μm之间为宜，而制备直径＜10 μm的粉末难度较大(Sala et al., 1996) The powder diameter is 5-10 μm, but it is difficult to prepare the powder with diameter less than 10 μm ③易形成孔隙，导致制品缺陷 Easy to form pores, resulting in product defects ④易造成污染Easy to cause pollution	①热塑性聚合物粉末的均匀分布 Uniform distribution of thermoplastic polymer powder ②纤维的均匀分散 Uniform dispersion of fibers
	粉末悬浮技术 Powder suspension technology	悬浮预浸法 Suspension preleaching	①预浸料流动性好 Prepreg has good fluidity ②适合制作几何形状复杂和薄壁结构的制品 It is suitable for making products with complex geometry and thin wall structure	①技术难度高，设备投资大 High technical difficulty and equipment investment	①热塑性聚合物纤维的制备 Preparation of thermoplastic polymer fibers ②混杂方式 Hybrid pattern
	纤维混杂技术 Fiber hybrid technique	混纤法 CN-CA 混编法 Mischen	①易控制基体含量 Easy to control matrix content ②纤维能得到充分浸润 The fibers can be fully saturated ③尺寸稳定性高 High dimensional stability ④制品形状复杂 Products with complex geometry	①纤维的屈曲和断裂损伤 Fiber buckling and fracture damage ②热塑性聚合物难以实现均匀浸润 Thermoplastic polymer is difficult to achieve uniform infiltration ③工艺复杂、生产成本高 Complicated technology, high production costs ④界面结合弱于粉末悬浮法 The interface binding state is weaker than the powder suspension method	①热塑性聚合物粉末的均匀分布 The uniform infiltration of thermoplastic polymer
	薄膜层叠法(标准技术) Film stacking technique(standard technology)		①工艺简单Simple process ②生产效率高 High production efficiency ③材料质量好 Good material quality	①成型条件苛刻，成型时间长；压力大，温度高；仅能用于模压制品的加工，加工工艺受限 Harsh molding condition, long molding time; high pressure and temperature; only be used for the processing of moulded products, processing technology is limited(Meng et al., 1995)	①温度和压力的控制 Control of temperature and pressure
熔融沉积成型 Fused deposition modeling (崔永辉等，2019)		一步法 One-step method	①可实现快速制备 Rapid preparation can be realized ②可控制增强相含量 The content of reinforcing phase can be controlled	①浸润效果不佳 Poor infiltration effect	①热塑性聚合物基体对增强相的浸润效果 Infiltration effect of thermoplastic polymer on the reinforced phase
熔融沉积成型 Fused deposition modeling (崔永辉等，2019)		二步法 Two-step method	①可进一步实现连续纤维浸渍 Further impregnation of continuous fiber can be achieved ②力学性能相对更好 The mechanical properties are relatively better	①工艺相对较为复杂 Complex process ②成本较高 Higher cost

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表4

表5

木 & 麻纤维增强热塑性聚合物复合材料在汽车工业中的应用"

材料 Material		减重效果 Mass loss	应用案例 Application case	使用部位 Use the parts	优点 Advantages	缺点 Disadvantages
麻纤维复合材料 Hemp fiber composite	黄麻/PP Jute/PP	20%~30%	Mercedes, Benz, Ford, Chery中小型汽车 Small and medium-sized cars of Chery	吸噪板、备用轮罩、发动机护罩、前后保险杠 Noise protection sheet, spare wheel cowling, engine hood, bumper beams	①可减轻整车质量 Reducing the mass of the vehicle ②麻纤维是众多植物纤维中最适合作复合材料的增强体 ① Hemp fiber is the most suitable reinforcement for composite materials among many plant fibers(Zakriya et al., 2017; Premkumar et al., 2017)	挥发性有机物的释放Release of volatile organic compounds
	洋麻/PP Kenaf/PP		Volvo, Saab, Renault, Ford, SAAB9S	汽车装饰部件、车门面板、座椅、靠板、顶棚、行李盘 Automobile decorative parts, door panel, seat, backup plate, roof board, luggage bearing board
	亚麻/PP Flax/PP		Audi A4, BMW 3, Reynolds Twingo, Chevy Impala, Mercedes M, GM, Ford	后备箱盖、车门衬板、冷却器架、后窗台饰板、后隔板的装饰衬板、座椅后背、引擎挡板 Trunk lid, door panel, cooler racks, rear window plaque, decorative plate of the back partition, back seat, engine damper
	剑麻/PP Sisal/PP		Mercedes M, Ford, GM,	座椅后背、车门面板 Back seat, door panel
	大麻/PP Hemp/PP		Ford Focus, Ford Mondeo, SAAB9S	车门面板、发动机护罩 Door panel, engine hood
	黄 & 洋 & 苎麻/PP & PC & PE Jute & Kenaf & Ramie/PP & PC & PE		济南重汽斯太尔王、豪沃、江淮风商务车等 Jinan sinotruk steyr king, Howo, Jianghuai wind commercial vehicle, etc	—
木纤维复合材料 Wood fiber composite		20%~40%	华晨宝马 Brilliance BMW	门板Door panel	①可减轻整车质量 Reducing the mass of the vehicle ②木纤维成本低廉，约1 000 yuan·t^-1 Wood fiber is cheap, about 1 000 yuan·t^-1	木材供不应求 Demand for wood exceeds supply
			VW XL1	包括通风管道在内的汽车内饰件 Automotive interior including ventilation ducts
			Audi A1	行李箱承重板 Luggage bearing board

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类型Type	捻度Twist/m^-1	线密度Linear density/tex	断裂强力Breaking force/cN	EAB(%)
1# (细Fine)	175	1 266.0×1	2 363	1.41
2#(中细Mid-fine)	99	3 232.3×1	4 069	2.47
3#(粗Rough)	112	4 607.8×1	5 926	3.57
麻纱线Hemp yarn(细Fine)	107	838.9×1	10 357	2.69

类型 Types	长度 Length/mm	直径 Diameter/μm	拉伸强度 Tensile strength/GPa	弹性模量 MOE/GPa	断裂伸长率 Elongation (%)	横截面面积 Cross area/μm²
毛竹Moso bamboo	1~4	10~50	1.710(0.17)	27.1(0.18)	7.0(0.16)	113(0.24)
杉木Chinese fir	1~4	10~50	1.258(0.23)	19.9(0.23)	6.6(0.18)	231(0.21)
洋麻Kenaf	1~4	10~50	1.019(0.18)	30.8(0.17)	3.2(0.18)	97(0.23)
苎麻Ramie	40~140	30~40	1.001(0.15)	11.4(0.17)	8.9(0.18)	337(0.23)

热塑性聚合物 Thermoplastic polymer	形态 Morphology	密度Density/(g·cm^-3)	玻璃化温度 Glass transition temperature/℃	熔点 Melting point/℃	热变形温度 Thermal deformation temperature/℃	加工温度 Processing temperature/℃	参考价格 Reference price (＄·kg^-1)
聚丙烯PP	结晶Crystal	0.89~0.93	-10	165	102	200~260	0.62
聚乳酸PLA	结晶Crystal	1.20~1.30	54	155~185	67	170~230	3.37
高密度聚乙烯HDPE	结晶Crystal	0.93~0.97	-120	120	80	177~230	0.86
聚酰胺PA	结晶Crystal	1.00~1.20	50	265	75	270~325	2.87~7.26
聚对苯二甲酸乙二酯PET	结晶Crystal	1.37~1.40	81	245~260	85	260~290	0.81
丙烯腈-丁二烯-苯乙烯ABS	无定形Amorphism	1.04~1.18	100	—	85	163~274	1.91
聚碳酸酯PC	无定形Amorphism	1.20~1.22	150	—	135	250~310	3.42

材料Material	弯曲强度 Flexural strength/MPa	弯曲模量 Flexural modulus/GPa	冲击强度 Impact strength/(kJ·m^-2)	气味等级 Odour level	VOCs/(μgC·g^-1)
PP	42.5	1.46	4.1	≤3.5(40 ℃) ≤3.5(80 ℃)	32
麻纤维(50wt%)/PP Hemp fiber(50wt%)/PP	52	3.42	23		80 40
木纤维(80wt%)/PET Wood fiber(80wt%)/PET	62	3	17

类别Type	传统门饰板 Traditional door trim	薄壁化门饰板1 Thin-walled door trim 1	薄壁化门饰板2 Thin-walled door trim 2
厚度Thickness/mm	2.5	2.3	2.0
质量Mass/kg	1.94	1.78	1.55
材料价格Price of material/(yuan·kg^-1)	16	16	18
单件产品材料成本Material cost of single product/yuan	31.02	26.54	27.92
单件产品成型周期Cycle time of single product/s	65	60	55
单件产品加工费用Processing cost of single product/yuan	8.45	7.8	7.15
单件产品总成本Total cost of single product/yuan	47.14	44.01	43.07