CN106739273A - 一种泡沫材料半填充波纹杂交夹层板及其制备方法 - Google Patents
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Abstract
本发明公开了一种泡沫材料半填充波纹杂交夹层板及其制备方法,由于泡沫材料只填满了波纹芯层一半的孔隙,由此带来的重量增量并不明显,提高了填充的增益和夹层结构的比吸能。同时,这种半填充波纹杂交夹层板结构形式简单,易于制备且制备耗材较少。泡沫填充材料一方面能通过自身的压溃变形吸收冲击能量,另一方面能提供支撑刚度的贡献,其对波纹芯层壁板的侧向支撑有利于提高芯层壁板的压溃强度和动力失稳临界载荷,使面板和波纹芯层的局部屈曲性能得以改善,能有效减小面板的塑性变形,两种材料的耦合提高了夹层结构的抗冲击性能。
Description
技术领域
本发明涉及一种金属-泡沫填充材料复合材料,具体涉及一种泡沫材料半填充波纹杂交夹层板及其制备方法。
背景技术
泡沫铝和PVC泡沫等泡沫材料具有高孔隙率,是一种轻质高强材料,在***冲击载荷下有良好的缓冲吸能特性,但其横向抗剪强度和承载能力较弱,不适合单独作为承载结构。而钢制波纹夹层板刚度和承载能力较高,但波纹芯层的支撑强度较低,芯层壁板容易发生侧向失稳,不能充分发挥波纹夹层板的冲击吸能效应。将泡沫材料填充至波纹夹层板芯层的孔隙中,形成杂交夹层板,能够给芯层壁板提供侧向支撑,提高芯层壁板的压溃强度。这种杂交夹层板能将两种材料的性能进行综合互补,并实现结构的多功能化。
目前的杂交夹层板通常为全填充,即在芯层的所有孔隙中塞满泡沫填充材料。在进行防护结构的设计时,应该尽可能减小夹层板下面板的塑性变形。而在一定的***冲击载荷下,由于泡沫填充材料对上、下面板及波纹芯层的连续支撑,上面板获得的速度和动能减小,通过泡沫填充材料传递到下面板的冲量增大,使下面板的速度和动能增大,导致下面板的塑性变形增大。最终上面板的吸能量减少,波纹芯层通过压缩变形和塑性失稳吸收的能量减少,下面板的吸能量增加。同时,由于芯层所有的孔隙中均塞满泡沫填充材料,当泡沫材料密度较大时,填充所带来的重量增量较为明显,且远离中心区域的泡沫填充材料对结构的吸能贡献不大,导致填充的增益有所下降。
如何使泡沫材料和金属材料二者优势互补,提高杂交夹层板的防护性能,同时降低结构的重量,提高杂交夹层板的比吸能,是本发明要解决的问题。
发明内容
本发明的目的在于解决波纹芯层壁板的侧向支撑强度和压溃强度低的缺点,提供一种泡沫材料半填充波纹杂交夹层板,增强芯层壁板的动力稳定性,提高夹层板的抗冲击能力和比吸能。
为解决上述技术问题,本发明提供了一种泡沫材料半填充波纹杂交夹层板,包括:上面板、波纹芯层、泡沫填充材料、以及下面板,波纹芯层位于上面板和下面板之间;泡沫填充材料制成柱状,其横截面形状尺寸与波纹芯层的孔隙形状尺寸相匹配;在波纹芯层靠近上面板一侧的所有孔隙中均塞满泡沫填充材料,或者在波纹芯层靠近下面板一侧的所有孔隙中塞满泡沫填充材料。
进一步地,波纹芯层的孔隙为梯形棱柱状;泡沫填充材料制成梯形棱柱状,其横截面形状尺寸与波纹芯层的孔隙形状尺寸相匹配。
进一步地,上面板、下面板和波纹芯层的材料为304不锈钢。
进一步地,泡沫填充材料为泡沫铝、PVC泡沫或聚氨酯泡沫。
为了实现上述目的,本发明还提供了一种泡沫材料半填充波纹杂交夹层板的制备方法,包括以下步骤:
(1)采用激光切割技术将金属板材切割成上下面板;
(2)采用模压、折叠技术将金属板材制成波纹芯层;
(3)采用激光焊接技术将波纹芯层和上下面板连接起来,形成金属夹层板;
(4)将泡沫材料加工成棱柱形状的泡沫填充材料,其横截面形状尺寸与波纹芯层中孔隙的空间形状尺寸相匹配;
(5)将泡沫填充材料***金属夹层板波纹芯层的孔隙中进行填充,将靠近上面板一侧的孔隙全部塞满,或者将靠近下面板一侧的孔隙全部塞满,形成半填充波纹杂交夹层板。
进一步地,波纹芯层的孔隙为梯形棱柱状,步骤(3)将上面板和下面板分别与波纹芯层两侧的孔隙梯形上底焊接。
本发明具有的优点和积极效果是:泡沫填充材料一方面能通过自身的压溃变形吸收冲击能量,另一方面能提供支撑刚度的贡献,其对波纹芯层壁板的侧向支撑有利于提高芯层壁板的压溃强度和动力失稳临界载荷,使面板和波纹芯层的局部屈曲性能得以改善,能有效减小面板的塑性变形,两种材料的耦合提高了夹层结构的抗冲击性能。由于泡沫材料只填满了波纹芯层一半的孔隙,由此带来的重量增量并不明显,提高了填充的增益和夹层结构的比吸能。同时,这种半填充波纹杂交夹层板结构形式简单,易于制备且制备耗材较少。
附图说明
图1为波纹夹层板的结构示意图;
图2为梯形棱柱状泡沫填充材料的结构示意图;
图3为靠上面板一侧芯层孔隙填充的半填充波纹杂交夹层板的结构示意图;
图4为靠下面板一侧芯层孔隙填充的半填充波纹杂交夹层板的结构示意图;
图5为半填充波纹杂交夹层板制备工艺流程图。
其中:1.上面板,2.波纹芯层,3.下面板,4.泡沫填充材料。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。此外,下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。
如图3和图4所示是本发明半填充波纹杂交夹层板的结构示意图,为了进一步了解本发明的内容和特点,下面结合附图5及实施案例对本发明作进一步的详细说明。
实施案例1:1)首先,采用模压、折叠技术将304不锈钢板材制成波纹芯层,再用电火花线切割(EDM)方法切割成设计尺寸,面内尺寸长300mm,宽288mm,将304不锈钢板材采用激光切割技术制成上、下面板,其面内尺寸长452mm,宽440mm,将制成的波纹芯层和面板清洗去除加工过程中残留的油污,采用激光焊接技术连接起来,制成无填充的波纹夹层板;2)然后,根据波纹芯层孔隙的尺寸,将泡沫材料板材用切割机切割成与孔隙尺寸相匹配的梯形棱柱;3)最后,将梯形棱柱状的泡沫材料填充到所有靠近上面板一侧的波纹芯层孔隙中,得到半填充波纹杂交夹层板。
实施案例2:1)首先,采用模压、折叠技术将304不锈钢板材制成波纹芯层,再用电火花线切割(EDM)方法切割成设计尺寸,面内尺寸长300mm,宽288mm,将304不锈钢板材采用激光切割技术制成上、下面板,其面内尺寸长452mm,宽440mm,将制成的波纹芯层和面板清洗去除加工过程中残留的油污,采用激光焊接技术连接起来,制成无填充的波纹夹层板;2)然后,根据波纹芯层孔隙的尺寸,将泡沫材料板材用切割机切割成与孔隙尺寸相匹配的梯形棱柱;3)最后,将梯形棱柱状的泡沫材料填充到所有靠近下面板一侧的波纹芯层孔隙中,得到半填充波纹杂交夹层板。
采用下述实验验证本发明效果:
试件编号TP-1和TP-2为全填充波纹杂交夹层板,由上面板、波纹芯层、泡沫填充材料和下面板构成,其中上面板厚度为1.38mm,芯层厚度为0.7mm,下面板厚度为1.38mm,材料均为304不锈钢,泡沫填充材料密度为0.25g/cm3,材料为PVC泡沫材料。
试件编号TP-3和TP-4为靠上面板一侧芯层孔隙填充的半填充波纹杂交夹层板,由上面板、波纹芯层、泡沫填充材料和下面板构成,其中上面板厚度为1.38mm,芯层厚度为0.7mm,下面板厚度为1.38mm,材料均为304不锈钢,泡沫填充材料密度为0.25g/cm3,材料为PVC泡沫材料。
试件编号TP-5和TP-6为靠下面板一侧芯层孔隙填充的半填充波纹杂交夹层板,由上面板、波纹芯层、泡沫填充材料和下面板构成,其中上面板厚度为1.38mm,芯层厚度为0.7mm,下面板厚度为1.38mm,材料均为304不锈钢,泡沫填充材料密度为0.25g/cm3,材料为PVC泡沫材料。
将本实验中的试件进行空中***实验,其中编号为TP-1、TP-3和TP-5的试件***距离为50mm,编号为TP-2、TP-4和TP-6的试件***距离为100mm。
实验在海军工程大学实验中心的***筒中完成,在***实验中直接采用TNT***引爆后产生的高强度冲击波进行加载。实验中采用的TNT***为圆柱体形状,装药密度约为1.61g/cm3,爆速为6.95×103m/s,爆热为6.74×106kJ/m3,装药重量为55g,对应直径R=35.0mm,高度h=37.2mm。各夹层板的重量统计如表1所示。
表1
试件编号 | TP-1 | TP-2 | TP-3 | TP-4 | TP-5 | TP-6 |
试件总重量/kg | 5.02 | 5.08 | 4.95 | 4.94 | 4.90 | 4.88 |
实验后夹层板上、下面板中心最大变形值以及结构总的吸能量如表2所示。
表2
试件编号 | TP-1 | TP-2 | TP-3 | TP-4 | TP-5 | TP-6 |
上面板最大挠度/mm | 38.24 | 22.51 | 39.99 | 25.93 | - | 28.22 |
下面板最大挠度/mm | 30.95 | 11.70 | 29.40 | 15.50 | - | 14.24 |
结构总的吸能量/kJ | 2.36 | 1.36 | 2.36 | 1.39 | 2.38 | 1.65 |
结构抗冲击性能改善的两个重要指标是结构最大变形极小化和能量吸收最大化。通过对夹层板中心凹陷深度的测量可获得夹层板结构上下面板的变形情况,通过有限元计算可获得结构总的吸能量,表2为试件各个面板变形值实测值以及各试件总吸能量的数值结果。当爆距为50mm时,试件TP-1和TP-3上下面板均产生塑性大变形,TP-5上下面板中心区域产生破口,而各试件总的吸能量基本一致,TP-3的结构总重量和下面板中心最大挠度值均小于TP-1,因此若以下面板中心最大挠度值为衡量标准,靠上面板一侧芯层孔隙填充的半填充波纹杂交夹层板抗爆性能最好,相比较全填充波纹杂交夹层板塑性变形降低5%,同时重量还减轻1.4%。当爆距为100mm时,各试件上、下面板均产生塑性大变形,其中,TP-6结构总重量最小,而总的吸能量最多,结构单位质量的吸能比最大,因此若以结构的吸能比为衡量标准,靠下面板一侧芯层孔隙填充的半填充波纹杂交夹层板抗爆性能最好,相比较全填充波纹杂交夹层板吸能量增加21.3%,并且重量减轻2.8%。
综上所述,由于泡沫填充材料的支撑,波纹芯层的侧向失稳现象减少,芯层壁板的失稳波长减小,而泡沫填充材料主要产生压缩大变形,吸收了较多的能量,证明了半填充波纹杂交夹层板有着良好的冲击防护性能,可作为一种新型的防护结构发挥吸能作用。在实际应用中,建议根据具体的载荷工况和功能需求,选用合适的半填充杂交夹层板结构。
本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (6)
1.一种泡沫材料半填充波纹杂交夹层板,其特征在于,包括:上面板、波纹芯层、泡沫填充材料、以及下面板,波纹芯层位于上面板和下面板之间;泡沫填充材料制成柱状,其横截面形状尺寸与波纹芯层的孔隙形状尺寸相匹配;在波纹芯层靠近上面板一侧的所有孔隙中均塞满泡沫填充材料,或者在波纹芯层靠近下面板一侧的所有孔隙中塞满泡沫填充材料。
2.如权利要求1所述的一种泡沫材料半填充波纹杂交夹层板,其特征在于,波纹芯层的孔隙为梯形棱柱状;泡沫填充材料制成梯形棱柱状,其横截面形状尺寸与波纹芯层的孔隙形状尺寸相匹配。
3.如权利要求1或2所述的一种泡沫材料半填充波纹杂交夹层板,其特征在于,上面板、下面板和波纹芯层的材料为304不锈钢。
4.如权利要求1或2所述的一种泡沫材料半填充波纹杂交夹层板,其特征在于,泡沫填充材料为泡沫铝、PVC泡沫或聚氨酯泡沫。
5.一种泡沫材料半填充波纹杂交夹层板的制备方法,其特征在于,包括以下步骤:
(1)采用激光切割技术将金属板材切割成上下面板;
(2)采用模压、折叠技术将金属板材制成波纹芯层;
(3)采用激光焊接技术将波纹芯层和上下面板连接起来,形成金属夹层板;
(4)将泡沫材料加工成棱柱形状的泡沫填充材料,其横截面形状尺寸与波纹芯层中孔隙的空间形状尺寸相匹配;
(5)将泡沫填充材料***金属夹层板波纹芯层的孔隙中进行填充,将靠近上面板一侧的孔隙全部塞满,或者将靠近下面板一侧的孔隙全部塞满,形成半填充波纹杂交夹层板。
6.如权利要求5所述的一种泡沫材料半填充波纹杂交夹层板的制备方法,其特征在于,波纹芯层的孔隙为梯形棱柱状,步骤(3)将上面板和下面板分别与波纹芯层两侧的孔隙梯形上底焊接。
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