CN113547765A - 高强度复合板材及其制备方法 - Google Patents
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Abstract
本发明属于复合板材的制备领域,公开一种高强度复合板材及其制备方法。包括上下面板层以及位于两者之间的骨架支撑层,骨架支撑层包括第一和第二支撑骨架;第一支撑骨架为网格状结构,包括至少两层横向支撑架和若干个纵向支撑架,每层横向支撑架由若干个横向支撑架间隔平行排列组成,纵向支撑架自下面板层向上依次纵向贯穿每层横向支撑架直至上面板层下表面,纵向支撑架之间呈前后、左右间隔均匀分布;第二支撑骨架设置在上面板层与最上层的横向支撑架之间以及下面板层与最下层的横向支撑架之间;骨架支撑层的空隙中填充有树脂泡沫层。本发明骨架支撑层分布更密实,具有更强的抗冲击性,当板材受到撞击时,不易坍塌,整个板材的使用寿命得到延长。
Description
技术领域
本发明属于复合板材的制备领域,具体涉及一种高强度复合板材及其制备方法。
背景技术
常见的轻质复合板材,是以纤维增强复合材料作为面板层,泡沫材料作为夹心层,通过粘结的方式制成,虽实现了轻质、保温的特性,但面板层与夹心层常出现因结合强度较低而分层的现象,且这种车厢板材因没有承力结构,导致抗压抗冲击性能较差,从而影响使用。随着不断研究,现有的在车厢板材中增加承力结构的方法是设置支撑柱做骨架支撑层,这种方式虽一定程度上起到提高板材承力性能的作用,但往往骨架支撑结构在板材中分布较少,导致车厢板的力学性能分布不均衡,同样易发生因夹心层与面板层结合强度低,且无承力结构而出现分层和局域板材坍塌现象。
发明内容
针对上述现有技术的缺陷与不足,本发明的目的在于提供一种高强度复合板材及其制备方法。
为实现上述目的,本发明采取的技术方案如下:
高强度复合板材,包括上下面板层以及位于两者之间的骨架支撑层,所述骨架支撑层包括第一支撑骨架和第二支撑骨架两部分;第一支撑骨架为网格状结构,所述网格状结构包括至少两层横向支撑架和若干个纵向支撑架,每层横向支撑架由若干个横向支撑架间隔平行排列组成,纵向支撑架自下面板层上表面开始向上依次纵向贯穿每层横向支撑架直至上面板层下表面,纵向支撑架之间呈前后、左右间隔均匀分布;第二支撑骨架设置在上面板层与最上层的横向支撑架之间以及下面板层与最下层的横向支撑架之间;骨架支撑层的空隙中填充有树脂泡沫层;所述上下面板层和骨架支撑层为纤维增强树脂基复合材料,所述树脂泡沫层中的树脂和纤维增强树脂基复合材料中的树脂相同。
较好地,所述第二支撑骨架的纵截面为矩形或拱形。
较好地,纤维增强树脂基复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶,树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
制备方法,制备步骤如下:
(1)、裁切出1#纤维毡、2#纤维毡、3#纤维毡,1#纤维毡、2#纤维毡、3#纤维毡的数量、形状和尺寸分别与横向支撑架、纵向支撑架、第二支撑骨架相对应;然后按照第一支撑骨架和第二支撑骨架的组成形式拼接1#纤维毡、2#纤维毡、3#纤维毡,形成框架结构;1#纤维毡、2#纤维毡、3#纤维毡中的纤维与纤维增强树脂基复合材料中的纤维相同;
(2)、在模具底板上由下至上依次铺放一层离型膜、一层预浸料,然后将步骤(1)所得框架结构放置在预浸料上方,并在其顶部依次铺放一层预浸料、一层离型膜,放置完毕后,闭模;所述预浸料为与纤维增强树脂基复合材料对应的纤维增强树脂基预浸料;
(3)、配制树脂泡沫浆料,采用真空灌注方式将树脂泡沫浆料并从模具侧面的进料口注入框架结构的空格中;树脂泡沫浆料中的树脂与纤维增强树脂基复合材料中的树脂相同;
(4)、加压固化,即得高强度复合板材。
较好地,步骤(2)中,所述离型膜为PET膜、PE膜、PI膜或OPP膜。
较好地,步骤(4)中,0.5-5 Mpa、50-150 ℃条件下加压固化1-10 h。
较好地,步骤(3)中,所述树脂泡沫浆料由树脂、固化剂、空心微珠、可膨胀微球发泡剂、稀释剂按照100∶(2-70)∶(5-30)∶(1-5)∶(1-5)的质量比例混合均匀;所述固化剂为甲基四氢苯酐、甲基六氢苯酐、十二烯基琥珀酸酐、双氰胺及其衍生物、二氨基二苯砜、聚醚二胺型固化剂、间苯二甲酸酰肼、异氰酸酯改性咪唑、过氧化甲乙酮、过氧化环己酮或过氧化苯甲酰,所述稀释剂为烯丙基缩水甘油醚AGE501、正丁基缩水甘油醚、苯基缩水甘醚、甲基丙烯酸缩水甘油醚、烯丙烯缩水甘油醚、乙二醇二缩水甘油醚、十二烷基缩水甘油醚中的一种或多种。
本发明中所述“纤维增强树脂基复合材料”、“纤维增强树脂基预浸料”可按现有技术制备获得或通过市购获得。“纤维增强树脂基预浸料”是“纤维增强树脂基复合材料”的半成品。
有益效果:
本发明的复合板材中,骨架支撑层分布更密实,具有更强的抗冲击性,且力学性能分布均一,当板材受到撞击时,不易坍塌,整个板材的使用寿命得到延长;同时,本发明的复合板材骨架支撑层和树脂泡沫层经一体化固化即成型出整个板材,制备工艺简单,使用模压成型模具直接成型,因此,具有很高的实用性,扩大了该种结构在车厢体上的应用。
附图说明
图1:高强度复合板材实施方式一的结构示意图;
图2:高强度复合板材实施方式二的结构示意图;
其中,1-上面板层,2-下面板层,31-第一支撑骨架,3101-横向支撑架,3102-纵向支撑架,32-第二支撑骨架,4-环氧树脂泡沫层。
具体实施方式
为使本发明更加清楚、明确,以下对本发明进一步详细说明。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。
实施例1
如图1所示,高强度复合板材,包括上面板层1、下面板层2以及位于两者之间的骨架支撑层,所述骨架支撑层包括第一支撑骨架31和第二支撑骨架32两部分;第一支撑骨架31为网格状结构,所述网格状结构包括两层横向支撑架3101和若干个纵向支撑架3102,每层横向支撑架3101由若干个横向支撑架3101间隔平行排列组成,纵向支撑架3102自下面板层2上表面开始向上依次纵向贯穿每层横向支撑架3101直至上面板层1下表面,纵向支撑架3102之间呈前后、左右间隔均匀分布;所述第二支撑骨架32的纵截面为矩形,第二支撑骨架32设置在上面板层1与最上层的横向支撑架3101之间以及下面板层2与最下层的横向支撑架3101之间;骨架支撑层的空隙中填充有环氧树脂泡沫层4;所述上下面板层2和骨架支撑层为玻璃纤维增强环氧树脂基复合材料。
制备方法,制备步骤如下:
(1)、裁切出1#纤维毡、2#纤维毡、3#纤维毡,1#纤维毡、2#纤维毡、3#纤维毡的数量、形状和尺寸分别与横向支撑架3101、纵向支撑架3102、第二支撑骨架32相对应;然后按照第一支撑骨架31和第二支撑骨架32的组成形式拼接1#纤维毡、2#纤维毡、3#纤维毡,形成框架结构;1#纤维毡、2#纤维毡、3#纤维毡为玻璃纤维毡;
(2)、在模具底板上由下至上依次铺放一层离型膜、一层预浸料,然后将步骤(1)所得框架结构放置在预浸料上方,并在其顶部依次铺放一层预浸料、一层离型膜,放置完毕后,闭模;所述预浸料为玻璃纤维增强环氧树脂基预浸料;所述离型膜为PET膜;
(3)、配制树脂泡沫浆料,所述树脂泡沫浆料由环氧树脂、固化剂、空心玻璃微珠、可膨胀微球发泡剂(EM406,日本油脂制药株式会社生产)、稀释剂按照100∶60∶20∶2∶3的质量比例混合而成,所述固化剂为甲基四氢苯酐,所述稀释剂为烯丙基缩水甘油醚;采用真空灌注方式将树脂泡沫浆料并从模具侧面的进料口注入框架结构的空格中;
(4)、0.7 Mpa、120 ℃条件下加压固化5 h,即得高强度复合板材。
本实施例制备的复合板材的导热系数为0.026 W/m·K,压缩强度为6.7 Mpa。
实施例2
与实施例1的区别在于:如图2所示,所述第二支撑骨架32的纵截面为拱形;其它均同实施例1。
本实施例制备的复合板材的导热系数为0.028 W/m·K,压缩强度为6.8 Mpa。
Claims (7)
1.高强度复合板材,其特征在于:包括上下面板层以及位于两者之间的骨架支撑层,所述骨架支撑层包括第一支撑骨架和第二支撑骨架两部分;第一支撑骨架为网格状结构,所述网格状结构包括至少两层横向支撑架和若干个纵向支撑架,每层横向支撑架由若干个横向支撑架间隔平行排列组成,纵向支撑架自下面板层上表面开始向上依次纵向贯穿每层横向支撑架直至上面板层下表面,纵向支撑架之间呈前后、左右间隔均匀分布;第二支撑骨架设置在上面板层与最上层的横向支撑架之间以及下面板层与最下层的横向支撑架之间;骨架支撑层的空隙中填充有树脂泡沫层;所述上下面板层和骨架支撑层为纤维增强树脂基复合材料,所述树脂泡沫层中的树脂和纤维增强树脂基复合材料中的树脂相同。
2.如权利要求1所述的高强度复合板材,其特征在于:所述第二支撑骨架的纵截面为矩形或拱形。
3.如权利要求1所述的高强度复合板材,其特征在于:纤维增强树脂基复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶,树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
4.如权利要求1-3至任一所述的高强度复合板材的制备方法,其特征在于,制备步骤如下:
(1)、裁切出1#纤维毡、2#纤维毡、3#纤维毡,1#纤维毡、2#纤维毡、3#纤维毡的数量、形状和尺寸分别与横向支撑架、纵向支撑架、第二支撑骨架相对应;然后按照第一支撑骨架和第二支撑骨架的组成形式拼接1#纤维毡、2#纤维毡、3#纤维毡,形成框架结构;1#纤维毡、2#纤维毡、3#纤维毡中的纤维与纤维增强树脂基复合材料中的纤维相同;
(2)、在模具底板上由下至上依次铺放一层离型膜、一层预浸料,然后将步骤(1)所得框架结构放置在预浸料上方,并在其顶部依次铺放一层预浸料、一层离型膜,放置完毕后,闭模;所述预浸料为与纤维增强树脂基复合材料对应的纤维增强树脂基预浸料;
(3)、配制树脂泡沫浆料,采用真空灌注方式将树脂泡沫浆料并从模具侧面的进料口注入框架结构的空格中;树脂泡沫浆料中的树脂与纤维增强树脂基复合材料中的树脂相同;
(4)、加压固化,即得高强度复合板材。
5.如权利要求4所述的高强度复合板材的制备方法,其特征在于:步骤(2)中,所述离型膜为PET膜、PE膜、PI膜或OPP膜。
6.如权利要求4所述的高强度复合板材的制备方法,其特征在于:步骤(4)中,0.5-5Mpa、50-150 ℃条件下加压固化1-10 h。
7.如权利要求4所述的高强度复合板材的制备方法,其特征在于:步骤(3)中,所述树脂泡沫浆料由树脂、固化剂、空心微珠、可膨胀微球发泡剂、稀释剂按照100∶(2-70)∶(5-30)∶(1-5)∶(1-5)的质量比例混合均匀;所述固化剂为甲基四氢苯酐、甲基六氢苯酐、十二烯基琥珀酸酐、双氰胺及其衍生物、二氨基二苯砜、聚醚二胺型固化剂、间苯二甲酸酰肼、异氰酸酯改性咪唑、过氧化甲乙酮、过氧化环己酮或过氧化苯甲酰,所述稀释剂为烯丙基缩水甘油醚AGE501、正丁基缩水甘油醚、苯基缩水甘醚、甲基丙烯酸缩水甘油醚、烯丙烯缩水甘油醚、乙二醇二缩水甘油醚、十二烷基缩水甘油醚中的一种或多种。
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