K KK K THU THU THU THUT HO T HO T HO T HO H HH HC H C H C H C HU C U C U C U C

TS. ON TH THU LOAN

Khoa Ho-Trng i Hc Bch Khoa Nng
NI DUNG:
K THUT SN
K THUT VT LIU COMPOZIT
K THUT SN XUT BT V GIY
K THUT SN
PHN I:
Chng 1: Gii thiu chung
1.1. Lch s pht trin
-S dng hn hp nha cy, sp ong, lng trng trng,v bt mu c sn trong thin
nhin
-Sau cng nguyn, du thc vt c dng lm sn du
-My chc nm gn y, sn tng hp ra i v ngy cng a dng, phong ph
1.2. Khi nim sn/lp ph (paint/surface coating):
Khi nim: Sn l mt h phn tn, gm nhiu thnh phn nh: cht to mng, bt
mu, ph gia,trong mi trng phn tn. Sau khi ph ln b mt vt liu nn, n to
thnh lp mng u n, bm chc, c tc dng trang tr v bo v b mt vt liu nn.
*Mc ch dng sn:
-Bo v b mt vt liu nn
-Trang tr
-Cung cp thng tin, du hiu
-
1.3. Cc thnh phn ca sn:
*Pha lin tc (Cht mang-Vehicle):
a. Cht to mng (binder, film fomer)
+Gm nha thin nhin, nha tng hp, du tho mc,
+To mng lin tc, bo v b mt vt liu nn.
+Thnh phn thay i tu thuc vo mc ch s dng
b. Dung mi hoc cht pha long:
+Ho tan hoc phn tn cht to mng
+D bay hi, bay hi dn ht trong qu trnh to thnh mng sn
+Khng dng trong sn bt v h trng hp 100%
*Pha gin on
c. Ph gia
+Lng dng nh, nhng c nh hng ln
d. Bt mu
+Cung cp mu, c, hiu ng quang hc,
+Thng c dng vi mc ch trang tr
+Trong sn lt co tc dng chng n mn
+Khng dng trong vecni, sn bng
e. n
+c dng vi nhiu mc ch: gim gi thnh sn phm,cng
vi bt mu to c cho b mt sn,..
nh hng ca cc thnh phn chnh n tnh cht ca sn phm
1.4. Cht to mng
Phn loi cht to mng theo khi lng phn t
Cc phng php to mng i vi cc h polymer tiu biu
* Natural polymers (Cc polyme thin nhin)
-Gm du thin nhin, nha thng, gum,
-Cc dn xut ca xenlulo:
-Axetat xenlulo
-Butyrat xenlulo
-Nitro xenlulo
-
Xenlulo
Nitroxenlulo
Chng 2: Cc thnh phn ca sn
2.1 Cht to mng
*Du thc vt
-ng vai tr quan trng trong lp ph b mt do tnh sn c, a dng v phong ph
-L este ca glycerin vi axit bo (no, khng no), c gi l triglycerit, ngoi ra c
cha thm mt lng t cht khng bo
Cu trc c trng ca du
R
2
R
3
R
1
Cu trc mt s axit bo khng no tiu biu
Thnh phn ca mt s loi du thng c dng trong sn
*Thnh phn khng bo:
-Chim khong 0,1-1% trng lng du
-Gm sp, photphatit, cht mu,
+Sp: l este ca axit bo vi ru cao phn t. VD: ru Xerilic C
26
H
53
OH
+Photphatit: l este ca glycerin, ngoi gc axit bo cn c gc octophotphoric
CH
2
OCO R
1
CH OCO R
2
CH
2
O P
O
OH
OCH
2
CH
2
-N (CH
3
)
3
OH
CH
2
OCO R
1
CH OCO R
2
CH
2
O P
O
OH
OCH
2
CH
2
-NH
2
Lexitin Kephalin
* Phn loi du tho mc
-Da theo kh nng kh (oxi ho v khu mch) ca du
Du
Kh: -Ch s iod C
I
~ 130 200
-Cha nhiu axit bo khng no c 2,3 ni i
-Kh nhanh
-C th dng mt mnh hoc phi trn vi nha trong qu trnh gia
nhit to mng
-VD: du tru, du lanh cha trn 60% axit linoleic v linolenic
Bn kh: -C
I
~ 95 130
-Kh chm hn, d nng chy, d ho tan
-t khi s dng mt mnh, thng kt hp vi du kh, hoc bin
tnh vi nha
-VD: du u nnh cha trn 50% axit linoleic
Khng kh:
-C
I
< 95
-Khng dng sn xut sn c, thng dng lm cht ho do
-VD: du da chim 90% axit lauric no, ch 10% axit khng no
Nha Alkyd
-S kt hp du hoc axit bo t du vo cu trc nha UPE nhm:
-Tng cng tnh cht c hc
-Tng tc kh
-Tng bn lu
Alkyd
Gy: hm lng du di 40%
Trung bnh: hm lng du 40-60%
Bo: hm lng du trn 60%
2.2. Dung mi, cht pha long
Dung mi
Hydrocacbon: bo v thm
Ete, keton, este, alcol,
Hydrocacbon clo ho, nitro parafin
+Mc ch s dng: lm gim nht ca sn, to d dng cho qu trnh gia cng
*Dung mi
-L nhng cht lng (hu c thp phn t) d bay hi c kh nng ho tan cht
to mng v bay hi dn ht trong qu trnh to thnh mng sn
*Yu cu chn la dung mi:
-Kh nng ho tan
+Nhng cht c phn cc tng t nhau d ho tan vo nhau
VD: axetat Xenlulo (este) c dung mi l cc este hoc xeton nh axeton
-Nhit si: nh hng n tc bay hi
+Qu cao hay qu thp u khng ph hp:
Qu cao Chm kh
Qu thp Kh qu nhanh, khng th qut bng chi, qu trnh kh
khng hon ton
*S bay hi ca dung mi t mng sn
-Qu trnh bay hi qua 2 giai on:
+G 1 s bay hi ca dung mi xy ra trong s ph thuc p sut hi ca
dung mi v khng b nh hng bi s c mt ca polyme ho tan
+G 2: Khi mng polyme c hnh thnh, dung mi cn lu li trong
mng s c thot dn dn ra nh qu trnh khuych tn (Khi cn khong 20%
dung mi)
-Tc bay hi ca dung mi nh hng ln n s chy ca lp mng sn
-Dng hn hp dung mi:
+ nht tng nhanh nh dung mi bay hi nhanh
+Qu trnh chy cng c iu chnh nh dung mi bay hi chm hn
*Tnh tr ho hc ca dung mi
-Dung mi c dng phi tr ho hc
-S tng tc ca cc nhm chc ca dung mi vi cht to mng
-Phi tr vi mi trng hn ch ht m ca mng
*Tnh c hi
-Hu ht cc dung mi hu c u c hi
-nh hng trc tip n sc kho, nh hng n tng kh quyn
-Lng dng dung mi phi trong gii hn cho php
-Khuynh hng thay th dung mi hu c bng nc (sn nc), sn bt, h sn
trng hp 100%
*Gi thnh
-R, d kim
-Lng dung mi dung kh nhiu nn nh hng nhiu n ga thnh sn
-C th dng thm cht pha long h gi thnh
+Cht pha long: ch ho tan c cht to mng khi c mt ca dung mi
+La chn cng vi loi dung mi v t l dung mi cho ph hp
+Thng bay hi nhanh hn dung mi
-L nhng ht rn hu c, v c c mu, khng ho tan v khng b nh hng ho
hc, l hc bi cht mang
-Trong thc t:
+Mt s bt mu hu c c th ho tan trong dung mi hu c
+Bt mu v c th khng ho tan trong dung mi hu c
-Cu trc tinh th hoc v nh hnh
2.3 Bt mu (pigments)
For protection
UV protectionkolour stability/durability;
humidity resistance;
water resistance;
chemical resistance;
resistance to insect/bird effects;
mechanical properties;
distortion resistance.
Bt mu
-S hp th v phn x chon la mt vi sng ca nh sng ti b mt mng sn
to nn mu sc ca n
VD: Bt mu xanh
Bt mu trng
Bt mu en
-Mu sc ca bt mu ph thuc ch yu vo cu trc ho hc
For decoration
appearance/high gloss and smoothness;
aesthetic/customer appeal.
*Mu sc:
Bt mu
-Phn t hp th nng lng kch thch cc in t chuyn t mc nng lng
c bn (E1) sang mc nng lng cao hn (E2)
-Bc sng nh sng c hp th c xc nh bi:
E = E2 - E1 = h*c /
h : hng s Plancks
c : the velocity of light
: bc sng nh sng
Mi phn t c s orbital xc nh do vy c nng lng c trng ring ca n, do vy c
hiu nng lng E xc nh v hp th nhng bc sng nht nh
Bt mu
Bt mu
Bt mu
General properties of pigments
Bt mu
Bt mu
*Kch thc ht ca bt mu
Kch thc
bt mu
Phn tn trong h km ng nht,
mng sn thu c km bng phng
Din tch b mt ring ln, hp ph nhiu
cht to mng nh hng n gi thnh
Ln
B qu
Vn cc cc b
Kch thc va phi
Bt mu
* ngm du
-l lng cht to mng tnh bng gam ngm 100g bt mu thnh mt khi
nho
-Cng b cng tt
-Qu b cng khng tt
- ngm du ph thuc bn cht cht to mng v bt mu
-Lng dng bt mu v c thng nhiu hn bt mu hu c t n tng mu
-Lng cht to mng dng thc t thng gp i gi tr ngm du
*Kh nng ph
-l lng bt mu cn thit tnh bng gam ph ln 1 m
2
b mt sn
-Kh nng ph ln ngha l ch cn lng t bt mu v bt mu thng phi mn
Bt mu
*Bt mu ph tr (supplementary pigments)
-Kh nng to mu sc, chng n mn khng cao,
-Lm gim mnh gi thnh, nh hng n bng, cng
*n:
+Gim gi thnh sn phm
+iu chnh nht ca sn
+nh hng n tnh cht c l, lng dng nhiu lm gim mnh c tnh
Bt mu
*Chng n mn: dng kt hp vi bt mu chng n mn (Alcophor 827,
Albaex, Kelate, Anticor 70,
*Chng to bt:
-Sn khng nc thng xut hin bt kh s dng cht chng to bt
-L nhng cht c hot ng b mt cao v linh ng tt
-Lm gim sc cng b mt ca nhng bt kh nm cnh nhau to nn nhng
bt kh ln hn, km n nh v b v ra
-Dung dch ca pine oil, dibutyl phosphate, or short chain alcohols
2.4 Cc ph gia
*Cht chng lng:
-Mui kim loi ca cc axits hu c: stearat nhm, canxi, magie,..
-C tc dng nh cht hot ng b mt gip s phn tn ca bt mu, n
vo sn tt hn
-Mt s cht chng lng:
+Stearatecoated calcium carbonates (e.g. Winnofil)
+Modified hydrogenerated castor oils (Crayvallac)
+Bentones
+Perchem
+Easigel
+BYK Anti-Terra 203
+Aerosil
+Aluminium stearate
*Cht chng chy:
-Silicagel, oxyt titan, bt talc,to cu trc thixotropy
-C s tng tc vt l gia cc mch polyme v ph gia chng
chy to mng li khng gian
*Cht chng nm mc, hu h, vi khun, cht ho ho do,
2.5 Cht lm kh
-Lm tng nhanh cc qu trnh ho hc xy ra trong qu trnh kh ca mng sn
-L x phng kim loi ho tr thay i: cobalt, mangan, canxi, km, chca axit
bo, axit nha
-C ch:
+Nh s thay i ho tr m x phng kim loi ly oxy phn t t khng
kh, to thnh oxy nguyn t hot ng hn truyn cho du thc y phn ng
to mng
2 Mn(RCOO)
2
+ O
2
(RCOO)
2
MnO 2 (RCOO)
2
Mn + 2 O
-Thng s dng kt hp 2 hoc 3 loi cht lm kh
-Lng dng t, nu nhiu mng sn d b nt, chng b lo ho,..
2+ 4+ 2+
Chng 3: Sn xut sn
Mixer
Mill
Mixer
Tinting
Filter
Tank
Packaging
S
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v
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n
t
P
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g
m
e
n
t
B
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n
d
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r
S
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l
v
e
n
t
B
i
n
d
e
r
A
d
d
i
t
i
v
e
Tinter
Test
Quy trnh sn xut sn
Cc cng on sn xut sn:
1.Phi trn to paste (Mixing): Khuy trn bt mu vi mt lng thch hp dung dch
cht to mng, to hn hp dng paste c nht thch hp
2. Nghin paste (Grinding)
3.Pha trn (Mixing): pha trn paste vi cc thnh phn cn li ca n pha ch
4.Chnh mu cho t yu cu (Tinting)
5. Kim tra v hiu chnh (Testing and adjusting)
6.Lc v ng gi (Filtering and packaging)
*Nghin
-Nhm to h phn tn ng nht
-Gip cc ht t kch thc yu cu
-My nghin
+My cn (2 trc, 3 trc):
Nng sut cao
H thng h, gy c hi
Trong qu trnh nghin, khong cch thay i, nh hng n
mn, phi kim tra thng xuyn
B mt trc cn c th b mn, kh phat hin bng mt thng
+My nghin bi: h thng kn, t c hi
Chng 4: Cc phng php gia cng mng sn
-C nhiu phng php gia cng mng sn thu thuc vo iu kin
-Cc phng php sn c s dng c khuynh gim thiu s bay hi
ca dung mi
-Gm cc phng php: qut, nhng, phun, in di
-B mt phi c x l trc khi sn
4.1. Gii thiu:
B mt
Lm sch
Sn nn
Sn lt
Trt mattit v mi nhn
Sn ph
nh bng
(lm phng, nhn b mt)
(C hc, ho hc, nhit,)
(mu sc, bn)
4.2 Cc giai on ca qu trnh sn:
*Ty mng sn c
-Phng php c hc:
-Co bng tm, chi thp, my mi, ty lp sn
b trc khng bm vo b mt
-Vi mng sn bm hc, c th bng phng php
phun ct, phun bi hoc phng php ho hc, nhit
4.3 Lm sch b mt vt liu cn sn
-Phng php ho hc:
Dng ho cht ty (Dung mi, dung dch NaOH 20-30%)
Dng co st, chi thp,..co sch mng sn c
Phun nc ra sch
Lm kh
Ty mng sn c
-Phng php nhit:
n gin, t tn km
Dng n x hoc l than t chy mng sn c
Dng co st, chi thp,..co sch mng sn c
Dng vi rp hoc mi nh sch
Lau sch
Ty mng sn c
*Ty r v cht bn:
-Bng phng php c hc: my mi, nh r (chi, a nhm,)
-Bng dung mi, ho cht (phun, dng gi,..)
-Ra sch bng nc
*Chn sn
-Loi sn phi ph hp
VD: Sn bo ph hp sn cc vt dng ngoi tri
Sn gy ph hp sn cc vt dng trong nh
*K thut sn
-K thut sn nh hng rt nhiu n cht lng mng sn, nu sn khng
ng quy cch s to mng sn khng bng, nhn, nt, d trc,
4.4. Sn
Sn
Sn nn: -Bm dnh tt vo b mt vt liu nn
-C bn c hc cao
-C tc dng bo v b mt nn (chng g)
Sn ph:
-Tu thuc yu cu ngoi quan (mu sc, bng,)
-Mt hoc nhiu lp sn ph
Sn lt: -Lm cho b mt sn phng, nhn trc khi sn ph
-B mt nhn khng cn sn lt
-B mt km bng phng cn nh mattit v mi mn
(mi kh v m t)
-C th mt hoc nhiu lp lt
* Cc lp sn
+Trc khi sy v sn cc lp tip theo nn mt thi gian nht nh
*Cc phng php sn
a. Phng php qut, ln bng tay
-PP c in v ph bin
-Dng chi, con ln
-Sn yu cu nht thp
-Cht lng mng sn ph thuc nhiu vo k nng ca ngi qut
-Nng sut thp
b. Phng php nhng
-Nng sut cao hn
-K thut n gin, c th c gii ho, t ng ho
-Nguyn tc: Vt c nhng vo thng sn, ly ra, t ng sn
phm sn tha chy xung, sau lm kh
- nht nh hng rt ln n chiu dy mng sn
-Ph hp cho sn phm sn nhiu b mt
-Khng ph hp vi nhng sn phm c hnh dng phc tp
- air-fed spray, airless spray, hot spray, and electrostatic spray
-Thch hp hu ht cc loi sn, cc loi vt liu sn
-Mng sn u, phng, bng
-Tn nhiu dung mi, nh hng n mi trng
Hiu qu chuyn dch ca mt s loi sng phun nh sau:
c.Phng php phun
d. Sn in di (electrodeposition)
-Sn in di anode hoc cathode
-Thng dng gia cng lp sn nn, c tc dng chng n mn tt
-Sn in di cathode to mng sn bo v chng n mn tt hn
-Sn in di cathode chng s x phng ho tt hn
K THUT VT LIU COMPOZIT
PHN I:
1.1. Khi nim: Vt liu compozit l vt liu t hp (mc v m) ca hai
hay nhiu vt liu (VL) thnh phn nhm to ra VL mi c tnh cht tri
hn tnh cht ca tng VL thnh phn.
T hp cc tnh cht
To tnh cht mi
Si thu tinh
(bn)
Nha polyeste
(khng ho cht)
= GRP
(bn v khng ho cht)
+
Si thu tinh
(gin)
Nha polyeste
(gin)
= GRP
(do dai - tough)
+
*GRP: Glass Reinforced Plastic
Chng1: Gii thiu chung
Hp kim
Hn hp polyme
C phi l vt liu compozit?
VD1: G (xenlulo/lignin), xng(collagen/protein+mui canxi pht pht),..
VD2: Vn p, gch n tru hoc si thc vt,:
VD3: Compozit nha (UPE, epoxy,: ) v si thu tinh,si cacbon,:
Vt liu compozit
Vt liu nn + Vt liu gia cng
Polyme Si cacbon
Kim loi Si thu tinh
Ceramic Si Aramic (VD: Kevlar)
Si, ht kim loi (VD: Ti, Al)
1.2. Thnh phn ca VL compozit:
VL nn
VL gia cng
VL compozit gm mt hay nhiu pha gin on (VL gia
cng) phn b trong pha lin tc (VL nn)
-ng vai tr l cc im chu
ng sut tp trung
-Thng c tnh cht c l ho
cao hn VL nn.
-Lin kt VL nn
-Chuyn ng sut sang n khi c
ngoi lc tc dng ln VL.
-Bo v si khi b h hng do tn cng
ca mi trng
-Ngoi ra cn ng gp mt vi tnh
cht cn thit nh: tnh cch in,
do dai,..
Vt liu gia cng Vt liu nn
*Vai tr ca cc vt liu thnh phn
1.3. C ch gia cng ca vt liu compozit
C ch gia cng: di tc dng ca ngoi lc, vt liu gia cng (VLGC) s
l nhng im chu ng sut tp trung do mng nha truyn sang
-VLGC dng si truyn ti ng sut tt hn VLGC dng ht, do ng sut ti mt
im bt k trn si c phn b u trn ton b chiu di, do ti mi im
s chu ng sut nh hn nhiu so vi VLGC dng ht di tc dng ngoi lc
nh nhau.
-Kh nng truyn ti trng t VL nn sang VL gia cng ph thuc: VL nn, VL
gia cng, kt dnh ti b mt tip xc ca VL nn v VL gia cng.
Kt dnh ti b mt tip xc ca VL
nn v VL gia cng c hnh
thnh trn c s:
+ Lc hp th v thm t
+ Lc tnh in
+ Lc tng tc c hc
+ Lc lin kt ho hc
VL gia cng
Vng tip xc
VL gia cng/VL nn
VL nn
: Vng tip xc rt nh (b mt tip xc pha) ng vai tr quan trng
trong quyt nh tnh cht c, l ca VL compozit
L thuyt kt dnh ti b mt tip xc VL gia cng/VL nn
1.4. Phn loi:
1.4.1. Phn loi theo hnh dng vt liu gia cng: gm compozit ct si
v compozit ct ht.
Compozit
ct si
Si lin tc (si di, vi: ): t l chiu di / ng knh (l/d)
rt cao, d =3-200 m
Si gin on (si ngn, vn: ): 5 < l/d < 1000, d = 0,02-100
m
* Compozit ct si: l compozit c gia cng bi si, n c bn ring
v modun n hi cao. VD: Compozit si thu tinh, cacbon, xenlulo:
Fibre aspect ratio: L/D
Mt s loi compozit ct si
Si di n
hng
Si di
dng lp
Si ngn sp
xp hn n
Si ngn
nh hng
* Compozit ct ht: l compozit c gia cng bi cc ht vi cc dng v
c kch khc nhau. VD: B tng, g p:
Mt s ct ht nh: vy mica, ht cao lanh, CaCO
3
, bt hoc vy st, ng,
nhm., bt g,...
Mc ch dng ht lm VL gia cng trong compozit:
-c dng trong nhng ng dng yu cu v bn khng cao thng c
s dng lm gim gi thnh sn phm.
-Trong mt s trng hp ht c dng ci thin mt s tnh cht ca VL
compozit nh: tng kh nng chu nhit, chu mi mn, gim co ngt
-Khc phc mt s kh khn khi gia cng
Vy, mnh
Compozit ct ht
Ht
1.4.2. Phn loi theo bn cht VL nn
Compozit nn hu c (nha): vi VL gia cng dng
-Si hu c: si polyamit, Kevlar, xenlulo,...
-Si khong: si thu tinh, cacbon, basalt,...
-Si kim loi: si bo, nhm,...
Compozit nn kim loi (hp kim nhm, hp kim titan..) vi VL gia
cng dng:
-Si kim loi: bo,...
-Si khong: si cacbon,...
Compozit nn gm: vi VL gia cng dng:
-Si kim loi: bo,...
-Ht kim loi: cht gm kim...
* Kh nng chu nhit ca VL compozit
-nn hu c: n khong 300
0
C
-nn kim loi: n 600
0
C
-nn gm: trn 1000
0
C
1.5. Tnh cht chung ca vt liu compozit
-Khi lng ring b do vy tnh nng c l ring cao hn thp v cc VL
truyn thng khc (thu tinh, gm s, g,.. ) rt nhiu
-Gi thnh khng cao
-Chu mi trng, khng ho cht cao, khng tn km trong bo qun v
chng n mn, khng cn sn bo qun nh VL kim loi, g,...
-Cch In cch nhit tt
-Bn lu (thi gian s dng di hn VL kim loi, g 2-3 ln)
-Gia cng ch to n gin, nhanh, a dng, d to hnh, thay i v sa cha
-Chi ph u t thit b gia cng thp
-Bn cht VL ct
-Bn cht VL nn
- bn lin kt b mt tip xc pha
-T l VL gia cng/VL nn trong compozit
-Hnh dng, kch thc ca VL gia cng
-nh hng, s phn b ca VL gia cng
(nu l si)
Nha
Compozit
Si
Bin dng

n
g
s
u

t
k

o
*Cc yu t nh hng n tnh nng gia cng
Khi lng ring (Density) ca mt vi vt liu cu trc ph bin
bn ko ring (Specific Tensil Strength) ca mt vi
vt liu cu trc ph bin
M un ko ring (Specific Tensile Modulus) ca
mt vi vt liu cu trc ph bin
1.6. ng dng ca vt liu compozit
- Giao thng vn ti: v cano, tu thuyn, xe hi, cabin,...
- VL xy dng: cu kin nh lp ghp, gn dm chu lc, p lt, tm lp,...
- VL in: tm cch in, v cc thit b in, my bin th,...
- VL chu ho cht: bn cha, ng dn, van, b in phn,...
- VL gia dng: bn, gh, t, gi, tm trn, bn tm, lavabo, tm cch m,..
- chi
-VL compozit cao cp: dng trong hng khng, v tr, dng c th thao cao
cp,...
Compozit l vt liu ca ngy mai, n ang thay th dn cc VL
truyn thng: kim loi, g, s,..
Cc b phn lm bng compozit trong my bay Airbus A 380
ng dng ca vt liu compozit
Cc b phn lm bng compozit si Graphite/nha epoxy trong my bay
AV-8B
ng dng ca vt liu compozit
Compozit si lanh/nha polypropylen thay th compozit si thy tinh trong
mt s b phn phn thn ca xe hi (Mercedes Benz A -Class)
ng dng ca vt liu compozit
Compozit si t nhin dng lm nh lp ghp
ng dng ca vt liu compozit
Compozit si ci dng lm gi, t
ng dng ca vt liu compozit
Vt liu xy dng t compozit si t nhin
ng dng ca vt liu compozit
Tu nh c trn c s compozit si
thu tinh v nha epoxy
Gung trong thit b x l nc thi trn c
s compozit si thu tinh v nha epoxy
(Owens-Corning Fiberglas Corp.)
ng dng ca vt liu compozit
Cc b phn lm bng compozit si Kevlar/nha epoxy
trong xe chy trn tuyt
ng dng ca vt liu compozit
Lp t ng ln t compozit si thu tinh di nc
ng dng ca vt liu compozit
Mi cho ca thuyn ua t
compozit Kevlar/epoxy
Bo qun mt s v tri n mn ca ng
dn bng compozit thu tinh/epoxy
ng dng ca vt liu compozit
2.1. Gii thiu chung
2.1.1. Thnh phn
Nha nn
Nhit do Nhit rn
Si
polyme
Si
cacbon
Kim loi
PP
Aramic
Si t nhin
...
TT E
TT S
TT C
...
Al
Ti
...
EP
UPE
PF
UF
...
PP
PE
PET
PVAx
...
VL gia cng
Si
T.tinh
Polyme
compozit
Ceramic
-Modul cao
-Modul thp
CHNG 2: VT LIU THNH PHN CA POLYME COMPOZIT
-Tnh cht c hc tt (chu ti trng)
-Tnh cht thm t, kt dnh tt (truyn hiu qu ti trng)
-Bn do dai tt (chng li s pht trin vt nt)
-Bn di tc dng ph hu ca mi trng (nc, cc tc nhn t
mi trng, c bit mi trng nc bin)
2.1.2. Yu cu i vi VL nn
Vt liu nn
Polyme
Nha nhit
rn
Nha nhit
do
Cao su
Kt tinh
V nh hnh
Vt liu nn
Polymer = poly (nhiu) + mer (phn, n v)
VD: -CH
2
-CHCl-CH
2
-CHCl-CH
2
-CHCl-CH
2
-CHCl- (PVC)
Vit tt: -CH
2
-CHCl -
Polyme l nhng hp cht m phn t ca chng gm nhng nhm nguyn
t c ni vi nhau bng lin kt ho hc v lp di lp li nhiu ln to
thnh nhng mch di v c khi lng phn t ln
n
-mng li, mt ni
ngang dy c, t 10 n
1000 ln cao hn trong
cao su
-mch thng, gia cc
mch c rt t lin kt
ngang
Cu trc:
-mch thng hoc nhnh
EP, UPE, PF, UF,: -cao su thin nhin, cao
su tng hp: BR, ABR,:
PP, PE, PVC,:
-Khng c kh nng nng
chy
-Khng c kh nng ho
tan
-Khng c kh nng nng
chy
-Khng c kh nng ho
tan
-C kh nng trng
-C kh nng nng chy
nhiu ln
-C kh nng ho tan
nhiu ln
Nha nhit rn Cao su Nha nhit do
Mt vi im khc bit gia nha nhit do, nhit rn v cao su
2.1.3 Cc yu t nh hng n tnh cht vt liu nn
-Bn cht ho hc, s phn b cc nhm chc, phn cc,:
-Phn t lng, phn nhnh, a phn tn
-Trng thi pha: tinh th hay v nh hnh
-iu kin ng rn (nha nhit rn):
+Loi cht ng rn
+ Nhit
+ Thi gian
+...
-Trng thi rn trc gia cng (do khi lng
phn t cao)
-Gia cng nhit chy mm ( trng thi
nng chy vi nht cao) to hnh dng
v sn phm c ho rn nh lm ngui
-Cc sn phm c c th c gia cng thay
i hnh dng l u im hiu qu kinh
t
-Chi phi u t thit b gia cng tng i cao
hn, tuy nhin gi thnh sn phm thp hn
do thi gian gia cng ngn hn nha nhit rn
- Trc gia cng, nha
thng trng thi lng
-Trong qu trnh gia cng
trng thi rn, vi cu
trc mng li khng gian
3 chiu nh cc phn ng
ho hc
- Thi gian gia cng di
hn nha nhit do.
Gia cng nha nhit do Gia cng nha nhit rn
Vt liu nn
2.1.4 c im gia cng ca nhit do v nha nhit rn
2.2. Nha nhit rn
2.2.1 Nha polyester khng no (UPE)
-L loi nha ph bin nht, c bit trong cng nghip hng hi (thn tu,
cnh bum...)
-c tng hp t cc polyacid v polyol khc nhau tnh cht thay i kh
rng
-Polyacid, polyol hoc c hai c cha ni i
-L cht lng nht, mu sng, dng dung dich nha UPE trong monome
(thng l Styren)
-Nha c thi gian bo qun gii hn (gel ho qua thi gian bo qun lu di)
thng phi dng cht c ch
-Nha trc khi gia cng phi thm cht xc tc, xc tin v cc ph gia
thch hp
-Cht xc tin t nh hng n nha trong trng hp khng c mt cht xc
tc cho vo ngay sau khi nha mi c sn xut
-Cht xc tc cho vo nha ngay trc khi s dng (gia cng compozit)
khi mo phn ng khu mch
ng rn nha UPE
Nha nhit rn
ng rn
+ styren
-Lng cht xc tc v xc tin o lng chnh xc
- Xc tc thm vo thay i mu ca nha UPE
ng rn
ng rn nha UPE
-Qu nhiu xc tc thi gian gel ho qu
nhanh
-Qu t cht xc tc qu trnh ng rn
khng hon ton
-Trong qu trnh ng rn, co ngt nhiu (4-8%)
gy bin dng, to nhng tim nng gy h
hng trong vt liu
Nha nhit rn
-Cho vo trc khi cho cht xc tc v phi khuy trn u trnh hnh thnh
bt kh nh hng n sn phm cui cng.
-Mc ch s dng n nhm:
-Gim gi thnh
-To d dng cho qu trnh gia cng
-Tc ng n mt vi tnh cht ca sn phm
-n c th c thm vo n 50% so vi lng nha v s nh hng
n bn un, ko ca sn phm
-Trong mt s trng hp n thm vo cn tng kh nng chng chy,
chy,... ca sn phm
Ph gia, n dng trong gia cng compozit nha UPE
Nha nhit rn
Tnh cht chung ca nha UPE
-C l tnh cao
-D gia cng iu kin thng
-Gi thnh thp
Thng dng nha UPE trong dung mI styren do:
-Styren lm gim nht, d Iu chnh nht thch hp cho qu trnh gia cng
-Styren l tc nhn khu mch nha UPE khng to ra sn phm ph
-ng rn nhit thng, p sut thng nn gi l nha p sut thp
-D dng Iu chnh qu trnh ng rn
-Gi thnh thp
-Tnh thm t VL gia cng, n cao
Nha nhit rn
-l loi nha c xem l c tnh nng cao nht
-Gm 2 thnh phn: nha lng v cht ng rn (hoc cht xc tc), nhit
ng rn t 5
o
C n 150
o
C tu thuc cht ng rn, xc tc.
-Nha lng khng mu nu, nhit thng c th tn ti nhiu nm
trong bnh cha kh m khng phn ng vi nhau
- bn kt dnh cao
-Bn c hc (cng, do dai), nhit tt. Do cha cc vng thm gia mch
phn t gip hp th ng sut c, nhit tt
-Bn ho cht
-Cch in tt
O
CH
2
CH
CH
2
O
CH CH
2
O O CH
2 C
CH
3
CH
3
2.2.2 Nha Epoxy
Nha nhit rn
Diglycidyl ete ca bisphenol F (DGEBF)
Polyglycidyl ete ca
nha PF Novolac
N,N,N: ,N: ,-
tetraglycidyl
metylendianilin
Triglycidyl p-amino phenol
Vng thm trong cu trc to cng, bn c hc v n nh nhit ca
epoxy mng li
Mt s nha epoxy thng dng
Nha nhit rn
Cht ng rn
-Lng dng nhiu
-Phn ng vi nha epoxy to
cu trc mng li.
-Cht ng rn thng l cc
amin thng, thm, anhydric,..
ng rn Nha Epoxy
Cht xc tc
-Lng dng t
-Xc tc phn ng xy ra trc
tip gia cc phn t epoxy
(phn ng homopolyme ho)
Nha nhit rn
-Vng epoxy c m to lin kt cng ho tr vi cht ng rn amin
-Lng cht ng rn dng thch hp, nu khng cn i nhm chc khng
phn ng s tn ti, cu trc mng li khng pht trin hon ton.
- So vi nha UPE, co ngt khi ng rn thp (1-5%)
-Trong qu trnh ng rn khng thI ra sn phm ph
ng rn Nha Epoxy
Phn ng ng rn gia nha epoxy v amin
Nha nhit rn
(DETA) Dietylentriamin
(TETA) Trietylentriamin
(TEPA) Tetraetylenpentamin
M-Phenyldiamin (MPDA)
(DDS) 4,4: - Diamindiphenylsulfo
(DICY) Dicyandiamit
Mt s cht ng rn amin thng dng
Nha Epoxy
Tc nhn ng rn
anhydric
Anhydric
(xc tc)
Epoxy lng
Nha Epoxy ng rn
Phn ng xy ra c mt cht
xc tin (c th yu cu nhit
cao)
To lin kt esten nh tt
nhit cao v hu ht mi
trng khc nghit (tr mI
trng kim)
Lng anhydric dng phi ph
hp pht trin h thng mng
li
Nha Epoxy
Mt s tc nhn ng rn anhydric thng dng
Dodecenyl succinic
andydric (DDSA)
Nadic methyl anhydrric (NMA) Phtalic anhydric (PA)
3,3: ,4,4: -
Benzophenol-
tetracacboxylic
dianhydric (BTDA)
Nha Epoxy
ng rn nh cht xc tc
-Xc tc l cc axit Lewis hoc baz Lewis to cc cation (axit Lewis)
hoc anion (baz Lewis)
-Phn ng to lin kt etebn nhit cao v mI trng khc nghit
Nha Epoxy
Boron Trifluoric-monoetylen amin
(BF
3
MEA)
2,4,6-Tri (dimetyl amino metyl) phenol 2-etyl-4-metylimidazol (EMI)
Benzyldimetylamin (BDMA)
Mt s xc tc ng rn thng dng
Nha Epoxy
Cht pha long
-Dng trong mt vi phng php gia cng
-Thng l cc cht lng c nht thp, cha nhm epoxy, n chc
-Tuy nhin cng c mt s cht pha long tham gia tao mng li ca cu trc
nha
P-t-butyl phenyl glycidyl ete
Phenyl glycidyl ete (PGE)
Butyl glycidyl ete (BGE)
Nha Epoxy
2.2.3 Nha Vinylester
-Ging nha polyester, nhng v tr nhm phn ng nm cui mch v t nhm
ester hn
-Bn nc v ho cht hn UPE do c t nhm ester hn c dng nhiu
trong sn xut ng ng v cc thng cha ho cht, tu thuyn
-Nha Vinylester ng rn bn hn UPE ng rn dng lm lp ph cho
compozit nha UPE
Nha nhit rn
Vinylester cha ng rn
Vinylester ng rn
Nha Vinylester
ng sut-bin dng
Nha nhit rn
t hn nha Vinylester (3-15 euro/kg)
Epoxy
-Tnh cht c l, nhit cao
-Bn nc cao
-Bn nhit c th n 140
o
C(t)/
220
o
C(kh)
-Co ngt khi ng rn thp
-Yu cu ng rn hon ton (Postcure)
trng hp yu cu tnh nng cao
-Hm lng Styren cao
-Gi thnh cao hn UPE (2-4 euro/kg)
-Co ngt khi ng rn cao
Vinylester
-Bn ho cht v mi trng rt cao
-Tnh cht c hc cao hn UPE
-Tnh cht c hc trung bnh
-Styren thot ra nhiu trong khun m
-Co ngt khi ng rn cao
-Gii hn thi gian lm vic
UPE
-D s dng
-R (1-2 euro/kg)
Nhc im u im
So snh tnh cht ba loi nha UPE, Vinylester v epoxy
2.2.4 Nha Phenolic
-L mt trong nhng nha nhit rn c s dng rng ri nht, ch yu l
nha Phenol-formaldehyt (PF)
-Ngoi ra cn c nha: phenol-fufural, resorcinol-formaldehyt,...
-C sn trn th trng dng dung dch nc, dung dch trong dung mi hu
c hoc dng bt
-c ng rn nh gia nhit v p sut, khng s dng xc tc hoc cht
ng rn
Nha nhit rn
n
ng rn nha Phenolic
Nha phenolic
Novolac Resol
-F/P>1
-Xc tc kim
-Nha nhit rn
-F/P <1
-Xc tc axit
-Nha nhit do
+ Phenol
Nha Phenolic
Resol (trang thi A)
Nha c kh nng nng chy v ho tan
Resitol ( trng thi B)
Nha rn nng chy, ho tan km
Rezit (trng thI C)
Nha rn khng ho tan, khng nng chy, bn ho cht
Giai on 1
Giai on 2
Giai on 3
Nhit
Nhit
Nhit
* Di tc dng nhit phn ng ngng t xy ra, c to sn phm ph (nc, HCHO)
Nha nhit rn
*u im:
- Chng chy tt
- Duy tr tnh cht nhit cao trong thi gian di
-Bn ho cht tt c bit i vi nhiu axit
-Tnh cht in tt, bn nhit rt tt v bn c hc cao (c bit cng
cao)
-R hn nha UPE
*Nhc im:
-Qu trnh ng rn nhit cao c thot bay hi (nc v formaldehyt) nn
sn phm c nhiu l bt v vt hng b mt, c hi
-Gin, dng cht ho do nh hng n qu trnh ng rn
-p sut ng rn cao, thi gian ng rn di hn nha UPE, thi gian sng
ngn (Khong 90 ngy dng lng)
-Gii hn mu hn ch
Nha Phenolic
2.3. Nha nhit do
2.3.1 u im ca compozit nha nhit do
-Gia cng nhanh hn compozit nha nhit rn, gm cc cng on: gia nhit,
to hnh, lm ngui, khng c phn ng ng rn xy ra
- bn tch lp cao, hp th m thp v bn ho cht ca polyme kt tinh
mt phn rt tt
-Di nh sng ca mi trng, compozit nha nhit do c nhng u im:
c hi rt thp, do khng cha cc tc nhn phn ng, thi gian sng v
hn
-C th c ti sinh do c kh nng nng chy v ho tan tr li
*Hm lng si thp
-Gia cng d dng
-Sn phm c cng v bn thp.
*Hm lng si cao:
-Sn phm c cng v bn cao
-Gia cng chm
-Kh to hnh dng vi nhng sn phm c cu trc hnh dng phc tp.
-Nn gia cng bn thnh phm trc khi to thnh phm
* Cc phng php gia cng: Injection molding, Extrusion, Press-moulding,
Pultrusion, resin Injection,...
* c im gia cng cua nh a nhit deo
2.4. Vt liu gia cng
2.4.1 Yu cu i vi Vt liu gia cng
-Tnh gia cng c hc tt
-Tnh khng ha cht, mi trng, nhit tt
-T trng b
-Phn tn vo nha tt (tnh tng thch)
-Truyn nhit, gii nhit tt
-Thun li cho qu trnh gia cng
-Gi thnh h
-nh hng tt n mi trng, vn hin nay rt c quan tm
Tu thuc vo yu cu ca tng loi sn phm c th m
chn la VL thch hp
Si
Si t nhin
Si ha hc
Hu c
V c T polyme
thin nhin
T polyme
tng hp
Khng
phi
polyme
Thc vt
-Coton
-ay
-Da
-G
ng vt
-Lng
-Tc
-T
-Thu
tinh t
nhin
(Basalt)
-Si
khong
(amiang)
-Cao su
-Visco
-Axetat xenlulo
-Ceramic
-Thu tinh
-Basalt
-PP
-PA
-Teflon
-Polyeste
-Aramic
-Wolfram
-Al
-Thp
2.4.2 Phn loi si
-ng knh si
-nh hng ca mch phn t
trong si
-Chiu di si
-Kiu an, dt vi
2.4.3 Cc yu t nh hng n tnh cht si
nh hng ca ng knh n bn si
Hnh dng mt ct ngang mt s loi si
Si tng hp
Si t nhin
S nh hng ca mch phn t
(Plain weave) (Twill weave)
(Unidirectional cloth)
Cc dng vt liu gia cng
Vi cho go
La trn
Vi n hng
Vi la (thu tinh)
Vi th (thu tinh)
Hng phn b ca si trong vt liu compozit
2.5.1 Si cacbon
Cu trc tinh th, gm nhng lp cacbon dng lc din
C th c sn xut t PAN (ph bin nht), rayon hoc nha (Pitch),
loi nguyn liu nh hng nhiu n cu trc v tnh cht ca si cacbon
Nh
Compozit nn polyme c cng v bn cao
Duy tr tnh cht trong mi trng khc nghit (Nhit cao, tip xc vi
dung mi v cc cht lng, mi trng m t)
Dn in, dn nhit tt
n nh kch thc
Tng i t
Tng i dn
Kh nng chng li s ph hu khng cao lm
*Compozit si cacbon/nn cacbon chu nhit cao, dng lm a phanh, chi tit
l nhit, ng gi, VL ph chng oxy ho, compozit nn nha (Epoxy) dng
trong ngnh hng khng, v tr
2.5 S lt mt s loi si
8-9
1,6
150 6
Cacbon t si Rayon
8-11
1,9-2,15 200-450
25-110
Cacbon(t pitch)
4-8 1,75-1,9 350 -1000 30-50 Cacbon ( t PAN)
ng
knh si
( m)
Khi lng
ring
(g/cm
3
)
bn
ko (ksi)
Mun ko
(Msi)
So snh tnh cht ca cc loi si cacbon
Loi si
Sn xut si cacbon
Oxy ho
Ko si t pitch
nng chy
Cun si
PAN
Ko
Cacbon ho
Graphit ho
X l b mt
Sy kh
Cun si
Cacbon/
Graphit
200-400
o
C
250-2500
o
C
1500-3000
o
C
: X l nhit nguyn liu
th c cha cacbon,
thng l si polyme
R
Ph bin, a dng
L loi VL gia cng c s dng rng ri nht
Kh nng gia cng c l tnh cho VL nn cao
T s c l tnh/gi c rt cao hn cc loi si khc, tnh cht va p tt
Dn in thp
Bin dng ph hu cao hn si cacbon
Tng i nng
C khuynh hng hp th m
2.5.2 Si thu tinh
S sn xut si thu tinh
TT E -Bn, cng, chu thi tit, dng cho VL cch In (chim t l cao
nht)
TT A : C hm lng kim cao, khng m km
TT S-Modun v bn ko cao, dng cho mc ch c bit (hng
khng, kt cu c bn c hc cao)
TT C-Bn ho cht, ph chi tit my, kt cu chng n mn ho hc
YM-31A- trn c s si TT E, dng ci thin mm do cho vt liu
Mt s loi si thu tinh
2.5.3 Si Aramic
Bn ko cao
Modun v do dai cao
Nh
Dn in thp
Bn ho hc cao
Gin n nhit thp
n nh kch thc tt
Bn ct cao
Chng chy tt
C khuynh hng hp th nc (a nc)
bn nn, un kh thp
bn b mt tip xc vi VL nn khng cao
*Dng hn hp Thu tinh-kevlar, cacbon-kevlar ch to TB chng phng
x, chng nhit v dng c th thao
Tnh cht vt liu
7,8
2,6
1,9
1,8
1,45
2,5
600-2000
70-80
2500
3200
2800
1700
203
75
340
230
124
76-86
Thp
Nhm
Si C (modun cao)
Si C ( bn cao)
Si Aramic
Si thu tinh
KLR (g/cm
3
)
bn(MPa)
Modun
(GPa)
Vt liu
CHNG 3
CC PHNG PHP GIA CNG
VL gia cng
Nha
Con ln
Gel coat
Khun
VL gia cng
Nha
Ln bng tay
Khun
4.1 Hand Lay-up (Phng php gia cng bng tay)
-VL lp c gia cng bng tay theo PP t
-Mng cht do (nilon) bc ln khun v khng kh c tho ra nh bm chn khng
-Lng nha tha c loi b di tc dng ca bm chn khng.
4.2 Phng php ti chn khng (Vacuum bagging)
4.3 Spray Lay-up (Phng phap phun)
Nguyn tc: S i c ct ngn trong sung (gi bng tay) c bn ng th i v i
nh a vao khun. ong rn hoan toan tr c khi thao san ph m
4.4 Resin Transfer Moulding (c chuyn nha)
Khun
Nha vo
Khun
VL gia cng
Khun
Nha vo Nha ra
VL gia cng
Keo 2 mt
Tm ph
Keo 2
mt
Nha chy
qua VL gia
cng di CK
Ti CK
VL gia
cng
Nha
n bm
CK
Khun
4.5 Phng php c chuyn nha c s tr gip ca chn khng
(Vacuum Asisstant Resin Transfer Moulding-VARTM)
4.6 Phng php qun si (Filament Winding)
Si
B nha
Trc
Si c Iu chnh gc
cun thch hp
C kh
nng di
chuyn
Trng
quay
S i T m nh a
Qu n ong rn
Qu n t
Qu n kh
S i a c
t m nh a
-T
cao, th ng
4.7 Extrusion process (Phng phap un)
-Trong qua trnh i qua truc vt, nh a nong chay, th m t vao s i, c ct ngn
-H n h p nh a s i c ep qua u tao hnh, ap l c c tao nn b i quay truc vt
-Th ng dung i v i nh a nhit deo
-Phng phap san xu t lin tuc
-San xu t compound, compozit s i ngn (t m, thanh, ng...)
Solid conveying
Plasticating or melting Melt pumping
un 1 truc vt un 2 truc vt
-Thit b un 2 truc vt, qua trnh tr n h p, ct s i t t hn
-Hai truc vt co th quay cung chiu ho c ng c chiu
Extrusion process (Phng phap un)
Schematic diagram of extrusion procedure
- i v i s i kem bn nhit, nn cho vao vung nh a nong chay
Extrusion process (Phng phap un)
Polymer
Fibre
Nozzle
Cooling
Product
Extruder die
Hnh dang u tao hnh co th la:
-Khe hep T m ph ng
-Hnh tru Thanh
-Hnh khuyn ng
4.8 Injection moulding (uc tim)
*Qua trnh:
-Nguyn liu (nh a + VLGC ho c hat compound) c nap vao phiu
-Truc vt chuyn nguyn liu rn qua vung gia nhit, nh a nong chay chuyn sang
trang thai long
-Ch t long c ep (tim) vao khun, lam ngu i tao dang san ph m
-M khun va thao san ph m
Materials
Khun tr c khi nap liu Nap liu vao khun
Thao san ph m
Injection moulding (uc tim)
Injection moulding (uc tim)
-Nng su t l n
-Dung i v i compozit nh a nhit deo
-San xu t compozit s i ngn
-San xu t cac san ph m co hnh dang ph c tap
-Tr ng h p nh a va s i kho th m t vao nhau
-Nguyn liu cho nection moulding la compound
- Compound c tao nn bng phng phap Extrusion ho c Mixer
-Tranh tr ng h p may un va uc qua dai
*Nguyn liu compound:
njection moulding (uc tim)
Tao compound
4.9 uc tim nh a (Resin Injection Moulding)
Resin
- t VL gia c ng gi a 2 chi tit khun uc (Khun trn va d i)
-D i ap l c nh a c phun vao khun va th m vao VLGC
-ong rn co th nhit th ng ho c nhit cao
-Ch tao c cac san ph m co hnh dang ph c tap
-Phng phap nay ti l VLGC cao nn tnh nng c ly cao
-VLGC co th la vai, mat, s i dai,..
uc tim nh a
Ho p ch t duc - ban thanh ph m
-La h p ch t uc, ban thanh ph m dang cu n ho c dang t m, day khoang 3mm
-T l s i th p (30% kh i l ng), t l hat trong nh a cao (50% kh i l ng)
4.10 Sheet Moulding Compound (SMC)
-S i dai
- ng phng
-S i ct ngn
- ng phng
-S i ct ngn (25-50mm)
-Phn b ng u nhin
SMC-C SMC-D SMC-R
-SMC h n h p: SMC-D/R, SMC-C/R
-H p ch t uc co t l s i cao (30-50%), co c tnh cao goi la HMC
M t s loai h p ch t uc SMC
Sheet Moulding Compound (SMC-R)
Ho p ch t duc - ban thanh ph m
-V t liu gia c ng: s i thuy tinh, cacbon, kevlar
-Nh a: th ng dung nh a polyester
4.11 uc ep (Press moulding)
-Nh a + s i trn u ho c ban thanh ph m c cho vao khun
-D i ap su t va nhit , nh a hoa long va in y khun, san ph m c
nh hnh theo 3 chiu
-Co th san xu t compozit nh a nhit deo s i dai
San ph m
uc ep (Press moulding)
4.12 Pultrusion process (Phng phap keo nh hnh)
S i
B nh a Tao hnh
Ct San ph m
T m nh a ln s i
-Nh a c ong rn
-Tao hnh dang SP
S i dai
Mat, vai
* c im cua phng phap keo nh hnh
-Sn xut sn phm dai lin tuc, din tch ph n ct ngang khng i (Panel, t m,
dy th ng,..)
-Ga thanh th p, ch t l ng t t, san l ng cao
-Th i gian ong rn c iu chnh b i t c keo
-Th ng dung i v i nh a nhit rn
Pultrusion process (Phng phap keo nh hnh)
-V c ban gi ng nh a nhit rn, co m t s im khac:
-Nhit gia cng cao (m t s san ph m dung
trong nganh hang khng n 750
o
F)
- nh t cao > 1.10
6
cP, th m t kho
-Nhit gia cng th p
(250-400
o
F)
- nh t th p (vai trm cP)
Nh a nhit deo Nh a nhit rn
-San xu t cac t m l p t cac t m ban thanh ph m (prepreg sheets) r t mong trn c
s nh a nhit deo.
-Lam nong chay b m t cac t m nay, va ep chung lai v i nhau d i ap l c trong
qua trnh lam ngu i san ph m
* i v i nh a nhit deo
Pultrusion process (Phng phap keo nh hnh)
*u im:
-Nhanh (t m nh a va ong rn) do v y kinh t
-Ham l ng nh a c iu chnh chnh xac
-Tnh ch t san ph m l p r t t t, do s i th ng va ham l ng s i cao
-Vung t m nh a kn, han ch cac ch t bay hi
*Nh c im:
-Gi i han i v i nh ng san ph m co din tch ph n ct ngang khng i ho c
g n nh khng i
-Chi ph u t khun ( u nh hnh) co gia nhit cao
Pultrusion process (Phng phap keo nh hnh)
K THUT SN XUT BT V GIY
PHN III:
Chng 1: M U
1.1. Lch s pht trin
-Nhng t giy u tin c t cc lp mng ca thn cy (di 30cm -
45 cm) an li vi nhau.
Cc lp mng ca thn cy an li
-Khong 100 nm sau cng nguyn, giy c sn xut t huyn ph ca
s si, tre na hoc cy du tm ( Trung Quc)
-Vi th k sau, cng ngh lm giy n vng Trung ng, Chu u,
-Th k 20, ngnh giy pht trin mnh vi cc k thut hin i
-Ngy nay, hu ht cc qu trnh cng ngh c t ng ho
1.2. Khi nim v bt v giy
*Giy: l t kt li ca s si c hnh thnh trn sng mn t huyn ph
bt nc.
*Bt: l nhng th si thc vt c thnh phn ho hc ph hp cho vic lm
giy
Nguyn liu
giy
G
Cy h trc
Cy h tho
Cy ngn ngy
Ph phm, th phm cng nghip
Chng 2: NGUYN LIU SN XUT GIY
2.1. Nguyn liu: tt c cc thc vt u c th dng lm giy, tuy nhin
vic la chon nguyn liu da vo cc yu t:
-Yu cu cht lng sn phm ( bn, mu sc,)
-Ngun nguyn liu
-Quy trnh cng ngh
90-95%
85-90%
40-50%
45-55%
B g
B g
Mnh
Mnh
G mm
G cng
2 loi
2 loi
G mi
G mi ho
Kraft
Sunfit
Hiu sut Dng g Loi g
Phng php
bt
Mt vi cng ngh bt
*Nguyn liu rm
Sau khi thu hoch:
-Phi kh ( m di 18%)
-ng bnh khong 25kg
-Bo qun trong kho phi cao ro, cm la
X l rm chun b nu bt
Bnh rm
Ph bnh
Ct ngn Lm sch
Nu
20-30mm
My sng
Qut thi v phn ly gi lc
t, ct, phn b nh vn
Phn rm c ct ngn
Phn rm cha c ct ngn
5mm
40*40mm
Nguyn liu rm
Sng nghing chn ng
nghing: 20-30
o
Tn s 700 ln/pht
*Qut thi v phn ly gi lc:
-Dng qut thi a rm vo xyclon phn ly theo ng tip tuyn v xoy trn:
+Rm tt nng hn theo thnh phn ly rt xung ay dng nu bt
+Phn nh gm l b xoy tt gia, theo ng v gi bay ln nh phn ly ra
ngoi
*Nguyn liu tre na
-Cy di 2 tui tt cho sx giy
-Sau khi cht h phi rc ht mu cnh
-Thi gian bo qun khng nn qu lu do s ph hu ca sinh vt, vi sinh
vt
-Ct : di 25-35mm, rng 5-15mm, trc khi ct phi p, cn dp (C th cng
vi my ct)
*Nguyn liu g
G Ct ngn Bc v Cht mnh Sng mnh Ni nu
Kho cha
My mi
Mnh qu kch thc
Di: 10-30mm
Dy: 2-5mm
2.2. Cu trc v thnh phn s si
*Cu trc g:
Cu trc g gm:
1-Lp v cht bn ngoi (outer dead bark)
2-Lp v sng bn trong (inner living bark)(Libe)
3-Cambium: sn sinh si v g
4-G gic (Sapwood)
5-G li (hearwood)
*Tc sinh trng thay i theo ma, ta c cc vng cy
-G sm: thnh s si mng, c cc l trn thnh (ma xun)
-G mun: thnh s si dy, cht hn (ma thu)
G sm G mun
*Cc loi t bo:
+Si: t bo tng i di, ng knh b, to bn v nhng tnh cht vt l
ca g (15-60% TT g)
+Cc ng: t bo thnh mng, rng, ngn hn (di 0,3-0,4mm, rng 30-
130m), cc t bo thng nhau, dn cht dinh dng v nc t r ln l tt
(chim n 60% th tch g)
Thc n c cha trong cc t bo Parenchyma ng knh thay i t g
sm n g mun trong mt vng hng nm.
+Parenchyma thng ng, nm theo trc si gm nhiu ngn nh(1-24% TT
g)
+T bo Parenchyma nm ngang thn cy gi l tia g (rays) (17 -30% TT g),
c th vn chuyn cc cht ho tan sang cc th g ln cn
Chiu di s si
ng knh
1,5 mm
25m
3,5 mm
35 m
G cng (l rng) G mm (l kim)
S khc nhau gia g mm v g cng
3 2 %
28 3%
27 %
42 2%
5 3 %
204%
30 5%
45 2%
Cenlulo
Hemicenlulo
Lignin
Cc cht chit
G mm
G cng
Thnh phn trung bnh ca
g mm v g cng
nh hng tui sinh hc
n chiu di TB ca si
Ch.di si
Tr.bnh
20 60
100
1
2
3
4
0
G cng
G mm
Lp gia (ML): Lin kt gia cc s si
Thnh s cp (P)
Thnh th cp (S): gm 3 lp khc bit
+ S1: lp ngoi ca thnh th 2 (0,1-0,2 m)
+ S2: phn thn chnh ca s si (2-10 m)
+ S3: Lp trong ca thnh th 2 (~0,1 m)
Lumen (L): ng trung tm ca s si (rng)
ML
P
S1
S2
S3
L
Cu trc vi si thc vt
Cu trc vi si thc vt
Thnh phn ho hc ca si thc vt
G
Lignin
Cacbohydrat
Cht chit
Cenlulo
Hemicenlulo
*Cenlulo
-L mt cacbonhydrat, gm nhng n v D-anhydro-glucopyranose ni vi
nhau bng -1, 4-glucosidic bonds
-CTHH: (C
6
H
10
O
5
)
n
-n: trng hp, thay i theo ngun cung cp v cch x l
5000- 10000
1000-3000
600-1500
200-600
Cenlulo t nhin
Si vi bng tinh ch
Cc loi bt thng phm
Cenlulo ti sinh (VD: t nhn to)
n Ngun cenlulo
Mt s gi tr trng hp
-Cenlulo trong s si thc vt c mc nh hng cao (vng kt
tinh), nh hng ln n bn s si
-Vng kt tinh: dung mi hoc cc cht phn ng kh thm nhp
-Vng v nh hnh: dung mi hoc cc cht phn ng d thm nhp
Cu trc xenlulo
Lin kt hydro ni v ngoi phn t Mch cng
Hemicenlulo
Lignin
Chng 3: SN XUT BT
3.1. Khi qut phng php sn xut bt:
-Lm bt giy : l qu trnh lm t cc lin kt trong g, bin i g thnh s
si
Bt
Bt c hc
Bt ho hc
Bt bn ho hc
Bt g mi
Bt c hc my nghin (RMP)
Bt Kraft (kim)
Bt sulfit (axit)
*Mt s phng php sn xut bt
3.2. Sn xut bt c hc:
-Cho n 1960 hu ht tt c bt c hc u c sn xut bng cng
ngh g mi (SGW)
-1975 cng ngh SGW vn chim 90% sn lng bt ca Bc M
-1980 gn 50% bt c hc c sn xut bng phng php my nghin
do mt s u im cua pp my nghin:
+S dng mnh, mn ca,
+Gim chi ph lao ng
-Tuy nhin bt g mi vn c duy tr nh u im tiu th nng lng
thp hn
-Ni chung, pp bt c hc cho hiu sut cao: 80-95%
Mt s loi bt c hc:
+Bt g mi (GW-Groundwoood)
+Bt g mi chu p lc (PGW-Presurised Groundwood)
+Bt c hc my nghin (RMP-Refiner Mechanical Pulping)
+Bt nhit c (TMP- Thermomechanical Pulping)
+Bt c nhit ho (CTMP-Chemithermomechanical Pulping)
G
Thanh chn
Vi phun nc
Thng
g
H cha bt p trn
+Nguyn tc: khi g c p theo chiu dc t vo b mt l mi nhm,
khi l quay, si b x ra khi g v tch thnh cc s si cn nguyn vn.
3.2.1. SN XUT BT G MI
+L phng php sn xut bt c hc c nht
My mi
Sng th
B bt
Sng s b
B bt
My c c
B c c
Thp ty
G
My xay
B my xay
Thng ph phm
T.b tho nc
My nghin
B bt nghin
Sng th cp
B bt sng th cp
Ph liu
Dy chuyn g mi tiu biu
mi
-Cc khc mi c ch to ring r v gn vo li b tng ct thp
-Khc mi c lm t nhng vin mi oxyt nhm hoc cacbua silic
-Lp mi dy ~7 cm (khong 2 nm thay mt ln, khi nhm hu ch b mn)
-Mi nh k
Hnh ren
Thng
Hnh xon c
Hnh thoi
Cc hnh dng g khc nhau ca thit b lm nhm mi
-Lm sc mi bng cch di ng g (dng trc ln nh d~7,5cm, l~7,5cm) qua b
mt l
-Xon c v hnh thoi c s dng rng ri nht
Mt s loi my mi
My mi kiu xch
My mi kiu ba ti
My mi kiu bung cha My mi kiu vng trn
-Khng ch nhit rt quan trng
Nc qu nhiu: cn tr s lm mm
Nc qu t: hin tng chy thnh than
C ch mi
-S cn v x ca cc vin li ra tch s si ra khi g
-Hin nay cho rng, c ch gm hng lot hnh ng xy ra ng thi.
+Ch yu l p vi tn s cao v gim p b mt khi cc vin tip xc
vi g, lm cho s si bung ra.
+ng thi lng nhit sinh ra ln do ma st /g, g/g, lng nhit ny
lm mm Lignin gip cc s si tch ra khi khi g.
Cc yu t nh hng n mi g
-p lc t vo l * -Tc ngoi bin ca mi*
-Mc ngm trong nc ca
-Ho cht thm vo
Vn hnh
-Vn tc dng nc -Nhit nc*
-p lc nc
-S lng, kch thc, v tr vi phun
Phun nc
-Loi -Kch thc vin
-Kiu lin kt - nhm l mi*
- su ca rnh
mi
-Loi g
-Tui th
-Hm lng m trong g
G
* Khng ch cn thn trong qu trnh vn hnh
3.2.2. SN XUT BT C HC MY NGHIN
-Bt c hc my nghin thng phm du tin nm 1960
-Nguyn liu: mnh g, mn ca
-Qu trnh bin i c hc mnh g hoc mn ca xy ra trong a ca my
nghin a
*u im ca phng php nghin:
-S dng phn cn li ca cc nh my x g
- bn bt cao hn (s si bt di hn bt g mi)
-Gim chi ph lao ng (t ng ho)
Tuy nhin: mu ti hn bt g mi
-Trung tm ca my nghin l b phn a nghin:
+1 a kp: gm 2 a quay theo 2 hng ngc nhau
+1 a quay , 1 a c nh
+ 1 a kp quay gia 2 a c nh
*C ch nghin:
+Lignin b lm mm bi s nn p v ma st ca g/g v g/a thp
+Cc mnh bung ra thnh cc phn nh hn v cui cng thnh s si
+S si va mi sn xut b xon li, phi lm r bt trong nc nng
Phn rng
nghin nh
Phn rng
nghin
trung bnh
Phn rng x
Mt phn ca tm a nghin
+Vng x gm cc thanh rng ph
dy, x mnh, to lc ly tm di
chuyn v sp xp mnh g
+Vng nghin gm cc thanh v rnh
hp dn
Phin a giai on mt
Phin a giai on hai
+Rng x ngn hn, sp xp
mnh v to lc ly tm
+B mt nghin rng hn
Phn rng
nghin nh
Phn rng
nghin
trung bnh
Phn rng
x
*Nghin 2 giai on:
Cc yu t nh hng n nghin mnh
-p sut vo -Nhit vo
-Nng - h gia cc a
-Tc quay ca a
-Ho cht thm vo
Vn hnh
-Loi vt liu lm a
-Hnh dng - cn
-ng knh a -Ngoi bin kn hay h
Phin a
-Loi v cht lng nguyn liu
-Hm lng m trong g
Nguyn liu
Mnh
Tb tch kim loi
Bng ti tch nc
Mnh
ra ra
Nc i tch ct
v tun hon tr li Kim loi ra
T.b tch ct
H thng ra mnh Defibrator
B bt c c
B cha
ph sng
th cp
B cha
ph sng s
cp
Sng s
cp
Sng
th cp
My ph liu
B cha bt xon
My
nghin a.p.
kh quyn
My c
c
B hn hp
Mnh
Thng cha
T.b tch
nc v
sng
My ra
My thi
Nghin p lc
Bnh iu
tit
Van quay
Cyclon thi
S dy chuyn cng ngh bt nhit c
Thng cha
Bt ti my xeo
3.2.3. SN XUT BT NHIT C
3.3. SN XUT BT SUNFIT
*Tm tt lch s pht trin:
-Nm 1857 Khm ph ra phng php sx
-Nm 1867 ng Benjamin Tilghman c cp bng sng ch M
-Nm 1874 bt sunfit thng phm u tin c sx Thu in
-Nm 1890 PP sx bt sunfit canxi axit quan trng nht
-Nm 1930 cng ngh Kraft chim u th
-Nm 1950 mt s ci tin v thit b v vn hnh
-n nay, nhng nghin cu tp trung vo: vic thu hi ho cht, x l mi
trng
L t
Bung t
T,b lm lnh
Qut
Kh l
Thp hp th
B cha T.b lc kh
T.b ngng t p sut thp
T.b ngng t p sut cao
Axit nu
Ni nu
H phng
Mnh g
Bt Thu hi dch nu
Khng kh Lu hunh
Amoniac Nc
Cng ngh nu sunfit vi bazo amoniac
M t cng ngh nu
*iu ch SO
2
: t chy lu hunh (hoc FeS
2
) trong khng kh
S + O
2
SO
2
(FeS
2
+ 11/2 O
2
Fe
2
O
3
+ 4 SO
2
)
+Phn ng to nhit c duy tr nhit trn 1100
o
C
+Khng ch lng oxy d trong khng kh cha (10% O
2
d)
*Hp th SO
2
trong dung dich bazo kim
SO
2
+ H
2
O H
2
SO
3
*Phn ng trng ngng ligin xy ra mnh nu dng mt mnh H
2
SO
3
+To bisunfit canxi t vi
CaCO
3
+ 2 H
2
SO
3
Ca(HSO
3
)
2
+ CO
2
+H
2
O
Qua 2 phn ng trung gian:
CaCO
3
+ H
2
SO
3
CaSO
3
+ CO
2
+H
2
O
CaSO
3
+ H
2
SO
3
Ca(HSO
3
)
2
Dch nu sunfit l: hn hp ca SO
2
t do v SO
2
lin kt dng ion bisunfit
(HSO
-
3
)
HSO
3
-
SO
2
+ OH
-
H
+
+ HSO
3
-
H
2
O + SO
2
SO
3
2-
+ H
2
O HSO
3
-
+ OH
-
H
2
O +
SO
2
Nhit
p sut
*Cc bazo c tc dng nh l dung dch m lm ngn chn phn ng trng
ngng lignin:
+To bisunfit magie:
MgO + H
2
O Mg(OH)
2
Mg(OH)
2
+ 2 H
2
SO
3
2 Mg(HSO
3
)
2
+ H
2
O
+To bisunfit natri:
Na
2
CO
3
+ H
2
SO
3
2NaHSO
3
+ CO
2
+ H
2
O
+To bisunfit amoni:
NH
3
+ H
2
O NH
4
OH
NH
4
OH + H
2
SO
3
NH
4
HSO
3
+ H
2
O
-Hp th SO
2
bng bazo tan: NH
4
OH, Mg(OH)
2
hoc Na
2
CO
3
+Cc loi vt liu m tr tng din tch tip xc trong thp hp th
Berl saddle
Intalox saddle Tellerette
Pall ring
Raschig ring
-Axit nu bao gm axit th b sung SO
2
h p t cc ni nu ti cc thit b
ngng t p sut cao v thit b ngng t p sut thp
*B sung SO
2
6,0-8,0
5,0-6,8
1,0-1,2
4-4,2
2,8-2,5
1,2-1,7
Tng SO
2
SO
2
t do
SO
2
kt hp
Axit nu Axit th
Nng axit trc v sau khi b sung SO
2
(theo % khi lng)
M t b sung kh SO
2
ca h thng axit chu p lc
*Nu bt
-Ni nu chu p lc, bng thp hoc thp khng r vi lp ph bn axit
-Ni nu c np y mnh, y np, cho axit nng t thit b ngng t p
sut cao vo, gia nhit, tun hon cng bc dch nu qua 1 thit b trao i
nhit
-Ni c tng p n mc yu cu
-Khi nhit v p sut tng, mnh hp th nhanh axit nng
-Phn ng xy ra :
+ Nhit trn : 110
o
C
+ Nhit cc i: 130-140
o
C
+Thi gian: 6-8 gi
-Khng ch iu kin nu da vo mc tch lignin
-im dng nu ca tng m khc nhau:
+Da vo mu ca dch nu
+Kim tra nh k SO
2
d
+Khi thi gian nu cn li 1-1h30 th gia nhit khng lin tc
+ Khi p sut gim xung cn khong 20-25 Psi th lng cht ni
nu c phng vo h phng, kh c a di lm sch thu hi
+Bt c tch khi dch nu, ra, ty
-Cc phn ng ho hc ch yu xy ra trong qu trnh nu bt:
+ Axit sunfuaro t do kt hp vi lignin to lignosulfonic acid khng tan
+Vi s c mt ca bazo, mui lignosulfonic c to thnh, d ho tan
hn
+Lignin sulfonat ho b tch thnh thnh nhng on phn t nh hn
+Hemicenlulo b thu phn thnh ng ho tan
Cc yu t nh hng n tc nu bt sunfit
Cao Thp
Thp Cao
Thp Cao
Ca Na Mg NH
4
pH
Nng SO
2
Nhit
Bazo
Tc thp Tc cao
*Cc yu t nh hng n nu sunfit
-Mc tch lignin
-Mu dch nu -SO
2
tha
-Mc gim trng ngng
Cc thng s
kim tra
-Mc dng ho cht (%SO
2
/g)
-T l dch/g
-p sut vo -Chu k nhit
-Nng -Thi gian nu
Khng ch nu
- Loi bazo
-T s SO
2
t do/SO
2
lin kt
Axit nu
-Loi v cht lng nguyn liu
-Hm lng m trong mnh
Nguyn liu
3.4. SN XUT BT KRAFT
-Cc loi kim: NaOH, Ca(OH)
2
, KOH,la chn ph thuc hot
tnh, tnh kinh t,
-Phn ng:
ROH + NaOH RONa + H
2
O
(Lignin) (Lignin kim)
RCOOH + NaOH RCOONa + H
2
O
3.4.1. Cng ngh bt s dng xt
*Nu:
- loi Lignin trit , phi ngm dch kim qu trnh thm thu vo
nguyn liu tt hn
-Nguyn l: Cht lng chy t ni cao n ni thp, p sut cao n p sut
thp
+Dch nu khuych tn t ni c nng kim cao n thp
+To p sut chnh lch gia bn ngoi v bn trong mnh nguyn
liu, p sut ln th tc thm thu mnh
-Nu di p sut
-Nguyn liu phi c hm m xc nh
*Cng ngh bt s dng xt
-Nng xt: qu cao s gy tn hi holoxenlulo
-Nhit :
+Cao: ho tan Lignin cao, nhng thu phn Holoxenlulo cng cao
+Thp: phn ng chm, thi gian ko di, loi lignin km trit ,
nhng t tn hi xenlulo
*nh hng ca nhit n ho tan v thu phn xenlulo
12,8
8,7
1
160
170
220
T s tc p. ho tan lignin/xenlulo Nhit (
o
C)
3.4.2. Cng ngh Kraft (sulfat)
Dch nu l: dung dch (NaOH + Na
2
S):
+Tc kh lignin nhanh hn
+Bt cha t lignin hn (to SNa)
+Phn ng a t lignin t hn
Na
2
S + H
2
O NaOH + NaSH
S nh my bt sulfat tiu biu
*Quy trnh:
1. Bc v, ct mnh v sng
2. Nu:
T l mnh/dch nu ph hp
Nng dch nu
Hm m ca mnh
iu chnh qu trnh nu (nhit , p sut)
Thi gian nu: 2-4h
p sut nu: 100-110 psi, h n 60 psi trc khi x
Turpentin v cc cht bay hi c bay hi
3. X bt vo h phng, dch en c a i thu hi ho cht
4. Ra bt, sng, ty trng v a n my xeo
Thit b nu bt gin on
Thit b nu bt lin tc
S thu hi v kim ho dch nu
Quy trnh thu hi ho cht t dch nu:
1. C c dch en long t my ra c bng thit b chng bc
(Multiple-effect vaporator) (16% 50% hm lng rn) v x phng
c tch ra
2. C c trn thit b chng bc tip xc trc tip (60% hm lng rn)
3. t dch c trong l thu hi
Lignin b t chy
Ho cht nu b chy
Natri sulfat c thm vo phn ng vi Cacbon to sulfua natri
Na
2
SO
4
+ 2 C Na
2
S + 2 CO
2
4. Cht nng chy c ho tan to dch xanh gm: Na
2
S, Na
2
SO
4
, Na
2
CO
3
5. Xt ho dch xanh to dch trng:
Ca(OH)
2
+ Na
2
CO
3
CaCO
3
+ 2 NaOH
6. Nung canxi cacbonat
CaCO
3
CaO + CO
2
7. Ti vi
CaO + H
2
O Ca(OH)
2
8. Hydroxyt natri c a v ni nu cng vi sulfua natri (dch trng)
Chng 4: SN XUT GIY
Bt
Ra
Sng
C c
Ty trng
Ra
Nghin
Tinh lc
Xeo giy
4.1. S sn xut giy t bt
Sy
p quang
Cun
p
Li
Hp phun
Bt
My xeo li
4.2. TY BT
-Bt khng ty c trng thay i trong gii hn rng
-C 2 phng php ty c dng:
+Ty thc (true bleaching)
+Ty chn lc (brightening)
*Phng php ty
-Clo ho (C) -Trch ly kim (E)
-Hypoclorit (H) -Clodioxit (D)
-Peoxyt (P) -Oxy (O)
-Dc hoc Cd
-Giai on clo ho v trch ly kim thng i km vi nhau:
+Clo ho to hp cht lignin clo ho
RH + Cl
2
RCl + HCl
C=C + Cl
2
C C
Cl Cl
H
2
O + Cl
2
O + 2 HCl
+Hp cht lignin clo ho b ho tan giai on trch ly kim
-Nng : 12-15%
-Nhit : 60-80
o
C
-Thi gian : khong 2h