CN102673031A - Fiber reinforced core panel able to be contoured - Google Patents
Fiber reinforced core panel able to be contoured Download PDFInfo
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- CN102673031A CN102673031A CN2012100659522A CN201210065952A CN102673031A CN 102673031 A CN102673031 A CN 102673031A CN 2012100659522 A CN2012100659522 A CN 2012100659522A CN 201210065952 A CN201210065952 A CN 201210065952A CN 102673031 A CN102673031 A CN 102673031A
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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Landscapes
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Abstract
A fiber reinforced core panel contains a series of adjacent, substantially parallel low density strips and a continuous fibrous reinforcement sheet threaded through the low density strips. The low density strips have at least three faces (a major face, a first edge face, a second edge face, and optionally a minor face) where the major face of each strip is disposed within the first or second side of the core panel. At least a portion of the low density strips comprise a series of cuts, where the cuts originate in the major or minor face and the cuts extend through only a portion of the thickness of the strips.
Description
Technical field
The present invention relates generally to composite construction.More specifically, the present invention relates to the fiber reinforcement central layer and by its composite construction of processing, said fiber reinforcement central layer has a series of bars that twined by the fiber reinforcement sheet, and said a series of comprise one group of otch.
Background technology
In the industry usually on cystosepiment and light wood indentation to let it center on complicated shape and bending.Indentation is included in the joint-cutting through said plate of cutting part ground on each side, and perhaps cutting runs through the joint-cutting of said plate and fully with the fixing said single part of scrim.This can cause the significant resin absorbability during the immersion liquid, and the cystosepiment and the light wood that can cause being cut have the bigger flexibility of using than reality.
Exist for forming by the low-density bar; Can be configured profile at the length direction along bar of compound, thereby and can be used for demand on the length of bar and both direction, being configured profile perpendicular to the length of bar such as the composite construction of complicated shapes such as vaulted or saddle type shape.
Summary of the invention
A kind of fiber reinforcement central layer comprises a series of adjacent, substantially parallel low-density bars and passes the continuous fiber reinforcement sheet of said low-density bar.Said low-density bar has at least three faces (interarea, first edge surface, second edge surface and optional inferior face), and wherein the interarea of each bar is set in first or second side of said central layer.At least a portion of said low-density bar comprises a series of otch, wherein said otch is created in said interarea or the inferior face and said otch extend through said thickness only a part.Also disclosed the process that is used to form said fiber reinforcement central layer.
Description of drawings
Description is only described the present invention in an exemplary fashion, and said accompanying drawing constitutes the part of the specification here, and wherein:
Fig. 1 is the perspective view according to the composite construction of an embodiment, and wherein said composite construction comprises along the bending of Y direction.
Fig. 2 is the perspective view according to the fiber reinforcement central layer of an embodiment.
Fig. 3 is the end-view of an embodiment of fiber reinforcement central layer, and this fiber reinforcement central layer has the bar of the profile of the trapezoidal shape that comprises 4 faces.
Fig. 4 is the end-view of an embodiment of fiber reinforcement central layer, and this fiber reinforcement central layer has the bar of the profile of the square shape that comprises 4 faces.
Fig. 5 is the end-view of another embodiment of fiber reinforcement central layer, and this fiber reinforcement central layer has the bar of the triangular shaped profile that comprises 3 faces.
Fig. 6 is the end-view of another embodiment of fiber reinforcement central layer, and this fiber reinforcement central layer has the bar of the profile that comprises 4 faces, and wherein 2 faces are crooked.
Fig. 7 A is the end-view with bar of different profiles with 7B.
Fig. 8 is the perspective view according to the composite construction of an embodiment, and wherein this composite construction comprises that bending along Y direction and directions X is with the formation dome-shaped.Said low-density bar is arranged the bar with trapezoidal and leg-of-mutton profile with the mode that repeats.
Fig. 9 is the end-view of another embodiment that can on directions X, be configured the fiber reinforcement central layer of profile.
Figure 10 is the perspective view that on the both sides of plate, has the low-density plate of a series of joint-cuttings, and wherein said joint-cutting forms parallel plane.
Figure 11 is the perspective view that on the both sides of plate, has the low-density plate of a series of joint-cuttings, and wherein said joint-cutting forms uneven each other plane.
Figure 12 is the outline drawing of an embodiment that in the interarea of bar and time face, comprises the bar of a series of otch, and wherein said otch forms parallel plane.
Figure 13 is the outline drawing of an embodiment that in the interarea of bar and time face, comprises the bar of a series of otch, and wherein said otch forms uneven each other plane.
Figure 14 is the outline drawing of an embodiment that in the inferior face of bar, comprises the bar of a series of otch, and the line that the lip-deep otch of wherein said face forms is not orthogonal to said longitudinal axis.
Figure 15 is the outline drawing of an embodiment that in the inferior face of bar, comprises the bar of a series of otch, and the degree of depth of wherein said otch is along said length and change.
Figure 16 is the outline drawing of an embodiment that in the inferior face of bar, comprises the bar of a series of otch, and the frequency of wherein said otch is along said length and change.
Figure 17 is the outline drawing of an embodiment that in the inferior face of bar, comprises the bar of a series of otch, wherein said otch taper.
Figure 18 is the outline drawing (not shown reinforced fabric) of an embodiment of fiber reinforcement central layer, and wherein from the bar to the adjacent strip, the frequency of the otch in the bar changes.
Figure 19 is the outline drawing of an embodiment that in the inferior face of bar, comprises the bar of a series of otch, and wherein said otch comprises tissue layer.
Figure 20 is the outline drawing (not shown reinforced fabric) of an embodiment of fiber reinforcement central layer, and wherein the otch on the side of plate aligns.
Figure 21 is the outline drawing (not shown reinforced fabric) of an embodiment of fiber reinforcement central layer, and wherein the otch on the side of plate is staggered.
Figure 22 is the end-view of an embodiment of fiber reinforcement central layer, shows with respect to the low-density bar reinforced fabric is set.
Figure 23 is the end-view of another embodiment of fiber reinforcement central layer, and this fiber reinforcement central layer has stabilized zone onboard.
The specific embodiment
With reference now to accompanying drawing,, and particularly with reference to figure 1, show composite construction 10, this composite construction 10 comprises a plurality of low-density bar 100, continuous fiber reinforcement sheet 200, first exocuticle 300, second exocuticle 400 and polymeric matrix 500 substantially.Composite construction 10 is included in the bending on the direction of bar length of being appointed as the Y direction.Fiber-reinforced layer 200 forms fiber reinforcement central layer 11 with low-density bar 100 (having extra optional layer and material).Low-density bar 100 has parallel basically longitudinal axis.Low-density bar 100 comprises a series of otch 150 along the surface of bar, towards the first side 11a and the second side 11b of fiber reinforcement central layer 11.First exocuticle 300 is disposed on the first side 11a that strengthens central layer 11.Second exocuticle 400 also is the flexible material of arranging with first exocuticle, the 300 second opposite side 11b that across-the-grain strengthens central layer 11.Polymeric matrix 500 is resin material normally, such as thermosetting polymer.Yet, can use other fluoropolymer resin, such as thermoplastic or be aggregated in the material of correct position.Polymeric matrix infiltrates this series of cuts 150 in continuous fiber reinforcement sheet 200, first exocuticle 300, second exocuticle 400 and the low-density bar 100 at least.In Fig. 2, illustrate in greater detail fiber reinforcement central layer 11.
With reference now to Fig. 2,, low-density bar 100 has at least three faces and at least about 5: 1, is preferably at least about 10: 1 the length and the aspect ratio of width.Low-density bar 100 is arranged in the plate 11, makes that the longitudinal axis of low-density bar 100 is substantially parallel.Low-density bar 100 has the density that is lower than polymeric matrix 500, is preferably to have about 0.01 and 0.2g/cm
3Between, more preferably about 0.02 and 0.07g/cm
3Between density.
With reference now to Fig. 3-6,, and low-density bar 100 (a, cross-sectional profile b) can have any suitable profile; Profile includes but not limited to have the profile of three or four faces.Face can be straight or crooked.The face near adjacent strip 100 of the bar 100 in the central layer 11 is designated as edge surface 101 and 103. Edge surface 101 and 103 be preferably with adjacent strip in neighboring edge face 101 and 103 couplings, as shown in Fig. 3-6.Make edge surface 101 and 103 couplings form high-intensity composite construction 10.First side 11a of central layer 11 or the wideest face in the face on the second side 11b are designated as interarea 105.
In one embodiment, the bar 100 in the central layer 11 is configured such that it forms more smooth face.Bar 100 makes interarea 105 and the adjacent strip 100a of specific 100a on the opposition side of central layer 11, b, the interarea 105 of b contrast with respect to adjacent strip 100 upset (bar 100a and bar 100b compare).If bar is four sides,, be known as time face 107 with interarea 105 opposite faces as bar 100 in the trapezoidal shape shown in Fig. 3.(have at bar under the situation of square shape as shown in Figure 4, because all faces all are identical with the angle, the orientation is not important).Interarea 105 is roughly parallel with time face 107.In one embodiment, the ratio of the length of interarea and time face is greater than 2: 1, more preferably greater than 5: 1.If bar is three, triangular shaped bar does not as shown in Figure 5 have inferior face and the point opposite with interarea 105 or rib to be known as a little 109 so.The embodiment of plate 11 has been shown in Fig. 6, and its discal patch 100 has four faces, and wherein two faces are crooked.
With reference to figure 7A and 7B, it is acute angle that the angle α that is formed by edge surface 101 and interarea 105 is preferably, and means that it spends less than 90.Also preferably, the angle β that is formed by edge surface 103 and interarea 105 also is an acute angle.The summation of angle α and β is preferably less than 180 degree.If any one is not straight in the face 101,103,105, in order to confirm angle α and β, form the imaginary line of the end points of connecting line so, as in that kind shown in Fig. 7 B.All bars all can have identical cross-sectional profile or different bars has different profiles and size.In order to provide crooked on the leg-of-mutton direction crossing, can be compared to changing in the face of the triangle of second side of panel in the face of α and β angle on the triangle of first side of panel.This also may be used on the shape outside the triangle.
In one embodiment, compound 10 comprises along directions X, perpendicular to the bending (" X " direction for example, has been shown in Fig. 1) of the direction of the length of bar.In order to obtain the bending along directions X, profile between bar and the bar and size can change.In one embodiment, (a b) can be used to be formed on the plate that has the nature profile in the final products to have the bar 100 that replaces cross section.Fig. 8 shows all has crooked fiber reinforcement central layer 10 on X and Y direction, wherein through using the triangle with different α and β angle and the trapezoidal bending that forms on the directions X of alternately arranging.The nature profile allows the sagging curved shape that becomes of plate, wherein between adjacent strip, has minimum clearance and piles up to avoid too much polymeric matrix 500 (resin).The another kind of method that obtains this natural profile on the directions X is the angle that changes in the adjacent cross section.The profile that the change at the angle between the adjacent strip provides more greatly is big more.Through using the flexible foam bar, for example polyethylene or polypropylene can provide extra profile on X or Y direction.Can use the rigid foams that has alternately and flexible foam section bar 100 (a, b).
In another embodiment of bending on obtaining directions X; Thereby allowing on arbitrary direction of central layer 11 in the first side 11a or the second side 11b crooked mode fixed strip 100 and to strengthen sheet 200 and form fiber reinforcement central layers 11, as in that kind shown in Fig. 9.In this embodiment, strengthen interarea 105 and edge surface 103 that sheet 200 is fixed to each bar 100.Staying edge surface 101 does not combine.In this situation, fiber reinforcement central layer 11 rotates between face 103 and the interarea 105 on the edge of, makes fiber reinforcement central layer 11 can bend to arc or angle.
Low-density bar 100 can be processed by any suitable material, includes but not limited to the plastic bottle of foam (closed pore or perforate), light wood and sealing.Foam can be, for example, and polyurethane foam, expanded polystyrene foam, expanded vinyl foam, dilatancy polypropylene foam, or its copolymer.Bar can be by rigid foams, such as PVC, styrene-acrylonitrile (SAN) or Polymethacrylimide (PMI); Fire-retardant foam is such as phenoplasts; Or process by the hollow tube that plastics, metal, paper or similar material are processed.In potential preferred implementation, bar 100 is made up of closed-cell foam.Can be based on processing parameter, like pressure, temperature or chemical resistance or other desired plate characteristic, select the type of closed-cell foam such as resistance to water or fire resistance, thermal insulation or light transmission.
Can in many ways this group otch be formed in the bar.In a preferred implementation, cut closed pore polyurethane foam plate, form the otch that crosses plate through and through.For example, above-mentioned embodiment has been shown in Figure 12 and 13.Sheet after will cutting then is cut into desired low-density bar size.Can use the cutting plate of Figure 10 to process the low-density bar 100 shown in Figure 12.Can use the cutting plate of Figure 11 to process the low-density bar 100 shown in Figure 13.Arrange then with and with these bars of well cutting of reinforced fabric 200 windings.In embodiment as shown in Figure 10, cut the foam plate and form per two inches about 0.0625 wide and about 0.625 dark otch.In the top of plate and bottom, form otch, and top and bottom slot depart from the half the of spacing distance each other, make each bottom slot in the centre of two top slot and vice versa.In another embodiment, at first obtain low-density bar and then cut each low-density bar to form one group of otch.Arrange then and use reinforced fabric 200 to twine these bars of well cutting.
In one embodiment, bar 100 only has otch on interarea or inferior face, for example shown in Figure 14-18.In another embodiment, bar 100 all has otch in interarea and time face, for example as at Figure 12,13, shown in 17 and 19.In another embodiment, the interarea of bar and time face are cut, make when bar is assembled in the central layer 11, cut surface is faced the same side (11a or 11b) of central layer 11 all.For example shown in Figure 20, its discal patch has the bar that has otch in the bar that has otch in the interarea and time face with the mode setting that replaces.
This group otch 150 forms the plane in low-density bar 100.This plane can or be not orthogonal to cut surface perpendicular to cut surface (main or inferior).From interarea to inferior face, from the low-density bar to adjacent strip, or along the length of a bar, the angle on the plane that is formed by otch can change.Figure 12 shows the low-density bar that in interarea 105 and time face 107, has one group of otch 150, and wherein otch 150 is perpendicular to cut surface.Preferably, interarea is parallel with the otch on time face.
Figure 13 shows the low-density bar that in interarea 105 and time face 107, has one group of otch 150, and wherein otch 150 is not orthogonal to cut surface.In addition, the otch in the interarea is not parallel to the otch in time face.When cutting slit, when during dipping vacuum application being arrived parts, this can allow otch closed a little angledly.Power on the otch makes gap-closing, thereby reduces the opening volume that occupied by resin.
The lip-deep line that is formed on the face (also being known as cut surface) that is cut perhaps is not orthogonal to the edge of cut surface perpendicular to the sidepiece of cut surface.Figure 12 and 13 shows the line that formed by the otch on the cut surface embodiment perpendicular to the edge of cutting (main or inferior) face, and Figure 14 shows the embodiment that line that the lip-deep otch by cut surface (being time face 107 in this situation) forms is not orthogonal to the longitudinal axis of bar.From interarea to inferior face, from a low-density bar to adjacent strip, or along the length of a bar, the angle of the line that is formed by the otch on the cut surface can change.
Select the degree of depth of otch for the desired performance in the final products, wherein the degree of depth of otch is mastered more and is often caused bending to the more ability of minor radius.In one embodiment, the otch mean depth be the thickness of low-density bar 100 about 10% and 90% between, more preferably between about 20% and 75%.Figure 12 shows the embodiment that the notch depth on all otch (in interarea and time face) all approximately equates.From interarea to inferior face, from a low-density bar to adjacent strip, perhaps along the length of a bar, the degree of depth of otch can change.The degree of depth that Figure 15 shows otch is along the length of low-density bar 100 and the embodiment that changes.
Select the frequency of otch for the desired performance in the final products, wherein the frequency of otch is bigger causes bending to the more ability of minor radius usually.In one embodiment, otch on average has the average frequency between about per 10 inches 1 otch and 5 otch of per inch.Figure 16 shows the embodiment of the frequency of otch along the length variations of low-density bar 100.The embodiment that the frequency that Figure 18 shows otch changes along a side of central layer 11 from the bar to the adjacent strip (not shown continuous fiber reinforcement sheet 200, thereby more clearly see the otch 150 in the bar 100).
In one embodiment, otch is filled with a plurality of fibers or fabric.If otch is filled with fiber, then can in any suitable manufacturing step process, introduce fiber, be included in bar and form and fiber is attached in the otch before the central layer, perhaps during the dipping that floods with the resin that comprises fiber.Figure 19 shows the embodiment that otch 150 is filled with fabric.Fiber or fabric are used for further strengthening and strengthening the intensity of central layer 11.Fabric can be any suitable fabric, includes but not limited to be described to be suitable for those fabrics and the textile of continuous fiber reinforcement sheet 200.
Except providing crooked, this series of cuts 150 also can comprise extra structural advantages.When resin penetrated in the plate 11, otch was filled with resin and can helps the structural strength of plate.Otch behind the dipping forms strength bar in a lateral direction, thereby reduces the truss distortion.Also can increase otch 150 to guarantee resin infiltration completely and resin infiltration faster.
Refer back to an embodiment shown in Fig. 4, continuous fiber reinforcement sheet 200 passes low-density bar 100, makes fiber reinforcement sheet 200 be disposed in the edge surface 101 of adjacent strip 100, arrange between 103 and along the interarea 105 of low-density bar 100.In one embodiment, about at least 65 (65%) percent of the surface area of the first side 11a of enhancing sheet 200 formation fiber reinforcement central layers 11 and the second side 11b.Strengthening sheet 200 is discontinuous on the first side 11a of central layer 11 or the second side 11b.
Continuous fiber reinforcement sheet 200 can be weaven goods, braid, bonded textile, non-woven material (for example short-cut original silk silk felt) or silk sheet (sheet of strands).Fiber reinforcement sheet 200 can be unidirectional silk such as rove, and can be through on rove, combining, enroll fixed yarn, perhaps braiding fixed yarn and keeping together on rove.At weaven goods, braid, under the situation of spinning thing/weft-knitted thing, adhesive-bonded fabric or bonded textile, textile can have yarn or the tape element that is disposed in a plurality of (two or three) axial direction.The yarn or the fiber that strengthen sheet 200 can be, for example, and glass fibre, carbon, polyester, aramid fiber, nylon, natural fiber and their mixture.Preferably, continuous fiber reinforcement sheet 200 is that multiaxis is to braid.Multiaxis has high-modulus, can be oriented to the no crimped fibre that is fit to shear and compress the combination demand to braid.Fiber can be monofilament, multifilament, short fiber, strip member or their mixture.Since their low cost, high relatively modulus and with the favorable compatibility of various kinds of resin, glass rove is preferred.Be used in the fiber that strengthens in the sheet 200 and have high intensity and weight ratio.Preferably, fiber has in the time of 23 ℃ the 1GPa/g/cm at least by the standard fibers feature measurement
3Intensity and weight ratio and the modulus of 70GPa at least.
Strengthen sheet 200 and before combining, also can be combined with thermosetting or thermoplastic resin with foam strip.Resin can be infiltrated in fiber (pre-preg); Separated into the form of film (such as
of Gurit) of fibre plate, perhaps mixed (Saint Gobain
) mutually with fortifying fibre.The resin that combines in advance has the advantage that is used in the dry run with similar epidermis with reinforce.These processes have higher controlled usually to fibre resin ratio, thereby and have the potential that can be used for the low weight structure.Process is better controlled less substandard products of generation or defective.The defective that these prepreg are handled is that higher material obtains cost, needs control store usually, and should handle the common higher fund input (heating, hyperbaric chamber etc.) that needs.
Refer now to the embodiment shown in Figure 22, bar 100a and 100b are so arranged, that is, the interarea 105a of its discal patch 100a is in the first side 11a of plate, and the interarea 105 of bar 100b is in the second side 11b of plate.Each interarea 105 has the first interarea edge 102 and the second interarea edge 104.In this embodiment, fiber reinforcement sheet 200 advances from 102 to second interarea edges 104, the first interarea edge in first 11a of plate 11 along the interarea 105 of bar 100a.Fiber reinforcement sheet 200 changes directions between bar 100a and bar 100b, advancing then, appears among second 11b of plate 11 up to its 102 place, the first interarea edge at bar 100b.Then fiber reinforcement sheet 200 advances to second interarea edge 104 from the first interarea edge 102 along the interarea 105 of bar 100b in first 11b.Fiber reinforcement sheet 200 advances between bar 100b and next bar 100a then, is in slave plate 11 appearance among first 11a at the first interarea edge 102 of bar 100a up to it.Length along plate 11 continues to repeat this advancing downwards.
A key factor of some embodiments are fortifying fibre sheet 200 beginnings the point of advancing between bar 100a and the 100b with up to its arrival the opposite side place of plate 11 go out to give me a little between the angle.For this angle is shown, draw first imaginary line 151 from the second interarea edge 104 of bar 100b and the first interarea edge 102 of bar 100a.Draw second imaginary line 152 from the second interarea edge 104 of bar 100b and the first interarea edge 102 of bar 100b.Angle between the interarea 105 of first imaginary line 151 and bar 100a is Θ
a, and the angle between the interarea 105 of bar 100a and second imaginary line 152 is Φ
a, the angle between the interarea 105 of bar 100b and second imaginary line 152 is Θ
b, and the angle between the interarea 105 of bar 100b and first imaginary line 151 is Φ
bIn one embodiment, select angle Θ
bAnd Θ
aMake them add up to less than 180 degree.Equally, in one embodiment, select angle Φ
aAnd Φ
bIt is added up to less than 180.As angle Θ
aAnd Φ
aWhen total is spent less than 180 and as angle Θ
bAnd Φ
bAlso add up to when spending, also help to realize this configuration less than 180.In order to design the crooked plate 11 about first surface 11a, angle Θ
aAnd Φ
aTotal is less than angle Θ
bAnd Φ
bSummation.In order to realize the bending of plate 11 on second surface 11b, angle Θ
bAnd Φ
bTotal is greater than angle Θ
aAnd Φ
aSummation.
In order to form the winding structure of plate 11, strengthen sheet 200 and be oriented to cross edge surface 101, move and cross interarea 105, the edge surface 103 (it also is the edge surface 101 of adjacent strip) that crosses article one then moves.Fortifying fibre 200 continues to advance around the interarea 105 of adjacent strip, and advances around edge surface 103 (it also is the edge surface 101 of next bar) then.Repeat this advancing along the length of fiber reinforcement central layer 11 with the situation on the surface 101,105,103 that forms fiber reinforcement sheet 200 cover strips 100.In one embodiment, strengthen surface area about at least 65 (65%) percent that sheet forms the first side 11a and the second side 11b of central layer 11, and provide the angle between first surface 11a and the second surface 11b to support.In addition, if inferior face is arranged, the surface area that strengthens the interarea 105 of sheet 200 coverings will be greater than the surface area of inferior face 107.In second embodiment, first side 11a of fiber reinforcement sheet 200 overlays 11 and the surface area of the second side 11b about at least 80 (80%) percent perhaps is preferably about at least 90 (90%) percent.
The bar 100 of fiber reinforcement central layer 11 possibly be fixed in other component-assembled with composite construction 10 with enhancing sheet 200 before together sometimes.Refer now to Figure 23, fiber reinforcement central layer 11 is fixed through increasing by first stabilizer 600, and this first stabilizer 600 strengthened the first surface 11a of central layer 11 and be fixed to enhancing sheet 200 and bar 100 by across-the-grain.In addition, second stabilizer 700 can be fixed to by the second surface 11b that across-the-grain strengthens central layer 11 and strengthen sheet 200 and bar 100.Second stabilized zone 700 can be by processing with first stabilized zone, 600 identical or different material and structures.Routinely, face stabilizer 600 and 700 is the fabrics of very loose (open), for example lax ramie cotton fabric.Stabilized zone 600,700 also can be fibrage, unidirectional fibre, thermoplastic film, adhesive layer or its mixture.Binder material can be used to face stabilizer 600,700 is fixed to bar 100 and strengthens sheet 200.Binder material can be the extra layer that is added between stabilized zone and the plate 11, perhaps can be incorporated in the stabilized zone 600,700.In one embodiment, face stabilizer 600,700 can be film, be preferably and have open pore, flows through composite constructions 10 before cured resin matrix 500, to allow resin matrix 500.Face stabilizer 600,700 can be processed by elastomeric yarn or fiber.In addition, fiber reinforcement central layer 11 can comprise the only stabilized zone on a side of core 11.The face stabilizer is the material that loosens, and has little surface area, and to be preferably be light material, and is for example light than appearance cortex 300,400.
In another embodiment, be attached to the fiber reinforcement central layer 11 that bar 100 forms integral body through before polymeric matrix being arranged in the composite construction 10, strengthening sheet 200.In this embodiment, can will strengthen sheet with bonding agent and be fixed to bar 100, and binding agent for example can be arranged to or the form put so that the part of opening of fortifying fibre 200.In another embodiment, strengthen sheet and can be fixed to bar through comprising non-woven binding agent net.
Return with reference to figure 2, in one embodiment, composite construction 10 comprises first exocuticle 300 and second exocuticle 400.In another embodiment, composite construction only can comprise an exocuticle 300 or 400.First exocuticle 300 can be by processing with second exocuticle, 400 identical or different material and/or structures.Epidermis can be processed by one or more layers fiber.Preferably, the appearance cortex is processed by two-layer at least fiber.Any suitable fiber can be used in the exocuticle 300,400; Include but not limited to organic or inorganic structure reinforced fabric; For example glass fibre, carbon fiber, such as the aramid fiber of commodity
by name; Linear polyethylene or polypropylene fibre such as commodity
by name; The thermoplasticity ribbon fiber; Polyester fiber, nylon fiber or natural fiber.Material and structure also can change between the layer in epidermis 300,400.
Appearance cortex 300,400 can comprise woven fabric layer, braid layer, bonded textile layer, fibrous nonwoven layer or silk sheet such as roving layer.The fiber reinforcement sheet can be a for example rove of unidirectional silk, and unidirectional silk can combine, enroll fixed yarn through crossing rove, perhaps crosses rove braiding fixed yarn and can be maintained at together.In the situation of woven fabric, braid, warp braiding/weft-knitted fabric, non-woven material or bonded textile, textile can have yarn or the strip member that is arranged in a plurality of (two or three) axial direction.The yarn or the fiber that strengthen sheet can be glass fibre, carbon fiber, polyester fiber, aramid fiber, natural fiber, with and composition thereof.Preferably, continuous fiber reinforcement sheet is that multiaxis is to braid.Multiaxis has high-modulus to braid, and the no crimped fibre that can be oriented to the requirements of combination that is fit to shearing and compression.Fiber can be monofilament, multifilament, short silk, strip member, or its mixture.
The profile or the crooked composite plate of any some place structure composite plate that can be during manufacture.In one embodiment, during resin dipping and solidification process, in mould, construct the profile of composite plate.In another embodiment, before the application table cortex, construct the profile (when it is the fiber reinforcement central layer) of plate.
In one embodiment, composite plate 10 can be processed by two or more adjacent enhancing central layers 11.Strengthening central layer 11 can so be arranged, that is, and and 100 parallel or 90 degree that rotate relative to one another of the bar in each plate 11 wherein.Being similar to the extra enhancement layer that is used in the exocuticle 300,400 can be added between the enhancing central layer 11.Then appearance cortex 300 and 400 is added to top and the bottom that strengthens central layer 11.
Infiltrate or dipping composite construction 10 with resinous polymer matrix 500, it is preferably in pressure reduction current downflow at least a portion through (strengthening sheet 200, exocuticle 300,400 and optional stabilized zone 600,700).Preferably, resin flow is through all reinforcing materials (strengthen sheet 200, exocuticle 300,400 and optional stabilized zone 600,700) and solidify to form the support structures of rigidity.Can use resin, for example the thermoplasticity monomer of polyester, vinylester resin, epoxy resin, di maleimide resin, phenolic resin, melmac, silicone resin or PBT or nylon (Nylon) etc.Because its moderate cost, favorable mechanical performance, good operation time and curing characteristics, vinyl acetate is preferred.Fortifying fibre also can twine before and resin-bonded around foam strip.For the thermosetting prepreg, resin can comprise B stage thermosetting resin, and perhaps for perhaps unidirectional of band yarn, hybrid yams, resin can comprise thermoplastic resin.
Through the for example method of vacuum-bag technique method, resin transfer moulding method or vacuum-assisted resin transfer method of molding (VARTM), can be implemented in and make resin flow cross the porous fortifying fibre under the pressure reduction.In the VARTM method of molding, core and epidermis are sealed in the sealed mold that has a flexible die face usually, and air is by being found time from mould, thereby atmospheric pressure applies through flexible face, so that composite construction 10 is consistent with mould.Catalytic resin is drawn onto in the mould via resin distribution media or the lip-deep groove net that is arranged on plate through vacuum substantially, and curable.Composite construction 10 can have flow enhancement means, for example, but is not limited to: the groove or the groove that in the first type surface of bar and subsurface, cut; Groove net on all sides of bar; Additional element in reinforced fabric is the space or the enhancing yarn that flows for example.Extra fiber or layer such as the surface current moving medium also can be added to composite construction to help to be convenient to the dipping of resin.One group of thick yarn for example weighs the axis that rove or monofilament can be evenly spaced apart one or more reinforces, thus the resin dipping speed of adjustment composite plate.In one example, monofilament polyester is spaced apart out about 20mm along the length that strengthens sheet.Then sheet is twined around foam strip and impregnated on the direction of foam strip resin is arranged.Obviously want fast when the dipping speed ratio uses reinforce under the situation of not adding monofilament.
Embodiment
The process that is used to form fiber reinforcement central layer and composite construction begins from closed pore polyurethane foam plate.Cut one inch thick foam plate then, form per two inches about 0.0625 wide and about 0.625 dark otch.Form otch at the top of plate and bottom, and top and bottom slot depart from distance half, thus each bottom slot in the centre of two top slot, and vice versa.Show the diagrammatic sketch of the plate after cutting like Figure 10.
Next, the foam plate is cut into has 1 inch thick, 1.28 inches wide master, ten six (16) inches long bars of 0.125 inch inferior side and trapezoidal shape.The trapezoidal angle from the bottom to the sides adjacent is 60 degree.Show the accompanying drawing of the low-density bar that is formed with this series of cuts like Figure 12.Bar has 65g/m on master and time side
2Glass fibre non-woven surfaces material.The profile of trapezoidal shape has 2 parallel faces.Long one in these faces is designated as interarea and short one and is designated as time face.Other two faces are known as edge surface.
Be arranged side by side said, wherein their longitudinal axis so arrange so that every at a distance from a bar interarea towards on and face down between replace.The edge surface of bar presses close to be close to the edge surface of that bar.
By the E-glass rove with 12oz/yd
2The structure of double offset (+/-45 degree) is (from Vectorply Corporation's
) the continuous fiber reinforcement sheet processed passes said.Strengthening sheet is so passed so that strengthen sheet and edge surface and interarea adjacent, as shown in Figure 3.Form the fiber reinforcement central layer like this.
Stabilized zone is added to the either side of plate and handles up to next step so that bar is remained on suitable position with the enhancing sheet.Stabilized zone is light weight glass fibre scrim (from Milliken & Company
).Use the non-woven adhesive of light weight hot melt (from
of Spunfab) coating stabilized zone.
The plate that comprises stabilized zone under it self weight, causes the bending radius of about 1.7m.Form plate, wherein in bar, do not form a series of otch, the measurable bending that makes plate have a little does not perhaps have measurable bending.
Next, comprise 4 layers by the E-glass rove with 12oz/yd
2The structure of double offset (+/-45 degree) is (from Vectorply Corporation's
) the appearance cortex processed is placed on the either side of plate.
At last, the plate that has an exocuticle is placed in the mould and under vacuum bag is handled and is fixed on together.Air is evacuated and catalyzed ethylene ester resin (can be from Composites One; The CCP ARMORSTAR
that LLC obtains) is impregnated into whole central layer and exocuticle, till not having tangible air space.
Take away mould from composite construction.The sandwich finished product can be used in the multiple application, wind turbine blade for example, boat deck, other structure that train floor or high rigidity and light weight are very important.
Here all references of being quoted; Comprise that publication, patent application and patent combine as a reference at this, as pointing out to be combined as a reference each reference to be combined by reference individually and particularly and integrally having set forth each reference at this.
The use of describing (in the context of the claim especially) term " " and " said " and similar deictic words in the context of invention will be interpreted as and cover odd number and plural number, unless otherwise indicated herein or obvious and context contradict.Term " comprises ", " having ", " comprising ", " containing " etc. will be interpreted as open term (just, meaning " including, but are not limited to "), only if point out in addition.The narration of the number range here only is intended to be used as individually with reference to the simple expression that falls into each the independent value in this scope; Only if here additionally pointed out, and each separation value has been narrated involved suchly in specification here as it individually.Can carry out described all methods here with any suitable order, only if here additionally pointed out or obviously and context contradict.Here any and all examples that provided, or the use of exemplary language (for instance, " such as ") only is intended to illustrate better the present invention and do not cause the qualification to scope of the present invention, only if advocate in addition.The language that does not have in the specification should be interpreted as any element of not advocating of indication not as the key element of execution of the present invention.
Here described preferred implementation of the present invention, comprised that known being used to of inventor carry out best model of the present invention.Concerning those of ordinary skills, will to become be conspicuous in the variation of those preferred implementations after the description of having read the front.The inventor expects that the skilled worker uses this variation as required, and the inventor is intended to the present invention and can carries out with the alternate manner different with the specific description here.Therefore, all modifications that the present invention includes the theme of narrating in the appended claim here be equal to, as be suitable for law allowed.In addition, above described element any combination in might changing in the present invention involved, only if additionally pointed out here or obviously and context contradict.
Claims (17)
1. fiber reinforcement central layer with first side and opposite second side comprises:
A series of adjacent low-density bars; Said low-density bar has at least three faces and has at least 5: 1 length-width ratio; The longitudinal axis of wherein said low-density bar is substantially parallel; Wherein the cross section of each bar has interarea, first edge surface, second edge surface and optional inferior face, and wherein the said interarea of each bar is disposed in said first side or said second side of said central layer, and at least a portion of wherein said low-density bar comprises a series of otch; Wherein said otch is created in said interarea or said the face, and wherein said otch extends through the only part of said thickness; With
Continuous fiber reinforcement sheet wherein passes said low-density bar with said continuous fiber reinforcement sheet, makes said fiber reinforcement sheet be disposed between the adjacent strip and adjacent with said interarea or said face of said low-density bar.
2. fiber reinforcement central layer as claimed in claim 1, wherein this series of cuts forms the plane, and this plane is perpendicular to perhaps being not orthogonal to said interarea and said face.
3. fiber reinforcement central layer as claimed in claim 1; Wherein said continuous fiber reinforcement sheet is passed said low-density bar; Make said fiber reinforcement sheet be disposed between the adjacent strip and adjacent with the interarea of said low-density bar, and form said central layer said first side surface area about at least 65 (65%) percent and said central layer said second side surface area about at least 65 (65%) percent.
4. fiber reinforcement central layer as claimed in claim 1, at least a portion of wherein said otch comprises fiber collection or tissue layer.
5. fiber reinforcement central layer as claimed in claim 1, the degree of depth of the otch on the low-density bar in the said interarea of wherein said central layer or said the face perhaps change from a low-density bar to adjacent low-density bar along the length of said low-density bar and change.
6. fiber reinforcement central layer as claimed in claim 1, the frequency of the otch on the low-density bar in the said interarea of wherein said central layer or said the face perhaps change from a low-density bar to adjacent low-density bar along the length of said low-density bar and change.
7. fiber reinforcement central layer as claimed in claim 1, wherein said fiber reinforcement central layer has along the bending of the direction of the longitudinal axis that is parallel to said low-density bar.
8. composite construction comprises:
Fiber reinforcement central layer as claimed in claim 1;
Be positioned at the first appearance cortex on said first side of said fiber reinforcement central layer;
Be positioned at the second appearance cortex on said second side of said fiber reinforcement central layer; With
Resin, it infiltrates at least a portion of one in said first exocuticle, the said second appearance cortex and the said continuous fiber reinforcement sheet.
9. method that is used to form the fiber reinforcement central layer comprises:
(a) acquisition has the low density material plate of first direction, the second direction perpendicular to said first direction, thickness, upside and downside;
(b) on the said first direction at least one side, at said plate, repeatedly cut said low density material plate, wherein joint-cutting extends through the only part of the thickness of said plate;
(c) on the second direction of said plate, said plate is divided into a series of low-density bars; Said low-density bar has at least three faces and has at least 5: 1 length-width ratio; Wherein the cross section of each bar has interarea, first edge surface, second edge surface and optional inferior face, and the said joint-cutting in the wherein said plate forms a series of otch in the said interarea of said low-density bar or said face;
(d) arrange this series low-density bar has first side and opposite second side with formation central layer; Make that the longitudinal axis of said low-density bar is substantially parallel; And the said interarea of each bar is disposed in said first side or said second side of said central layer, and wherein the said interarea of each bar is disposed in the face opposite with interarea said adjacent strip said central layer; And,
(e) continuous fiber reinforcement sheet is passed said low-density bar, make said fiber reinforcement sheet be disposed between the adjacent strip, and adjacent with said interarea or said face of said low-density bar.
10. method as claimed in claim 9, this series of cuts in the wherein said low-density bar forms plane, this plane perpendicular to or be not orthogonal to said interarea or said face of said low-density bar.
11. method as claimed in claim 9; Joint-cutting in the wherein said plate forms a series of otch in the said interarea of said low-density bar and said face, and the plane parallel that is wherein formed by this series of cuts on the interarea of said low-density bar is in the plane that is formed by this series of cuts on the inferior face of said low-density bar.
12. method as claimed in claim 9; Wherein continuous fiber reinforcement sheet is passed said low-density bar; Make said fiber reinforcement sheet be disposed between the adjacent strip; And adjacent with the interarea of said low-density bar, and form said central layer said first side surface area about at least 65 (65%) percent and said central layer said second side surface area about at least 65 (65%) percent.
13. method as claimed in claim 9, further be included in step (b) and (c) between at least a portion that tissue layer is inserted into the said joint-cutting in the said low-density plate in step.
14. method as claimed in claim 9 further is included in step (e) afterwards along the crooked said fiber reinforcement central layer of the direction of the longitudinal axis that is parallel to said low-density bar.
15. method as claimed in claim 9 further comprises:
(f) the first appearance cortex is placed on first side of said fiber reinforcement central layer;
(g) polymeric matrix is flow at least a portion of one in said first exocuticle and the said continuous fiber reinforcement sheet; With,
(h) solidify said polymeric matrix.
16. a method that is used to form the fiber reinforcement central layer comprises:
(a) acquisition has the low density material plate of first direction, the second direction perpendicular to said first direction, thickness, upside and downside;
(b) on the second direction of said plate, said plate is divided into a series of low-density bars; Said low-density bar has at least three faces and has at least 5: 1 length-width ratio; Wherein the cross section of each bar has interarea, first edge surface, second edge surface and optional inferior face, and the joint-cutting in the wherein said plate forms a series of otch in the said interarea of said low-density bar or said face;
(c) on said interarea or inferior face, repeatedly cut at least a portion of said, wherein joint-cutting extends through the only part of said thickness;
(d) arrange this series low-density bar has first side and opposite second side with formation central layer; Make that the longitudinal axis of said low-density bar is substantially parallel and the interarea of each bar is disposed in said first or said second side of said central layer, wherein the interarea of each bar is disposed in the face opposite with interarea adjacent strip said central layer; With,
(e) continuous fiber reinforcement sheet is passed said low-density bar, make said fiber reinforcement sheet be disposed between the adjacent strip and adjacent with said interarea or said face of said low-density bar.
17. method as claimed in claim 16, further be included in said step (c) and (d) between tissue layer is inserted into the step at least a portion of the said joint-cutting in the said low-density bar.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/065,087 US8646183B2 (en) | 2011-03-14 | 2011-03-14 | Process for forming a fiber reinforced core panel able to be contoured |
| US13/065,093 | 2011-03-14 | ||
| US13/065,087 | 2011-03-14 | ||
| US13/065,093 US20120238168A1 (en) | 2011-03-14 | 2011-03-14 | Fiber reinforced core panel able to be contoured |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN102673031A true CN102673031A (en) | 2012-09-19 |
Family
ID=45563575
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2012100659522A Pending CN102673031A (en) | 2011-03-14 | 2012-03-14 | Fiber reinforced core panel able to be contoured |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN102673031A (en) |
| WO (1) | WO2012125224A1 (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20090324932A1 (en) * | 2006-06-14 | 2009-12-31 | Huntsman International Llc | Composite panel |
| CN101946051A (en) * | 2008-02-12 | 2011-01-12 | 美利肯公司 | Fiber reinforced core panel |
| CN202517767U (en) * | 2011-03-14 | 2012-11-07 | 美利肯公司 | Fiber reinforced core plate capable of being shaped with contour |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19715529C1 (en) * | 1997-04-14 | 1998-08-06 | Daimler Benz Aerospace Airbus | Composite sandwich structure for use in structural components of aircraft |
-
2012
- 2012-01-23 WO PCT/US2012/022166 patent/WO2012125224A1/en active Application Filing
- 2012-03-14 CN CN2012100659522A patent/CN102673031A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20090324932A1 (en) * | 2006-06-14 | 2009-12-31 | Huntsman International Llc | Composite panel |
| CN101946051A (en) * | 2008-02-12 | 2011-01-12 | 美利肯公司 | Fiber reinforced core panel |
| CN202517767U (en) * | 2011-03-14 | 2012-11-07 | 美利肯公司 | Fiber reinforced core plate capable of being shaped with contour |
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| WO2012125224A1 (en) | 2012-09-20 |
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Application publication date: 20120919 |