CN114801258A - Preparation method of bidirectional grid structure reinforced foam sandwich composite material - Google Patents
Preparation method of bidirectional grid structure reinforced foam sandwich composite material Download PDFInfo
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- 238000000034 method Methods 0.000 claims abstract description 34
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- 239000004699 Ultra-high molecular weight polyethylene Substances 0.000 claims description 6
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/681—Component parts, details or accessories; Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/681—Component parts, details or accessories; Auxiliary operations
- B29C70/682—Preformed parts characterised by their structure, e.g. form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
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Abstract
The invention provides a preparation method of a bidirectional grid structure reinforced foam sandwich composite material, which realizes the preparation of unidirectional grid structure reinforced foam by compounding foam blocks and a grid structure in an X/Z direction; then, dry fiber cloth II is laid in the Y/Z direction of the unidirectional grid structure reinforced foam block, and a bidirectional grid structure can be built in the foam by the unidirectional grid structure in the X/Z direction and the unidirectional grid structure in the Y/Z direction after molding, so that the bidirectional reinforcing effect is integrally realized; the scheme provided by the invention comprises the steps of firstly preparing unidirectional grid structure reinforced foam and then integrally forming the bidirectional grid structure reinforced foam sandwich composite material, and constructs an integrated integral structure of a bidirectional grid structure, a foam core material and a panel, so that the problems of difficult accurate control of the size of an interlayer preformed body, integral stability, quality uniformity, apparent quality and the like of a product in the forming process of the bidirectional grid structure reinforced foam sandwich composite material are fundamentally solved.
Description
Technical Field
The invention relates to a preparation method of a sandwich structure composite material, in particular to a low-cost high-precision preparation method of a bidirectional grid structure reinforced foam sandwich composite material, which is mainly applied to low-cost high-precision molding of the bidirectional grid structure reinforced foam sandwich composite material, especially a large-size bidirectional grid structure reinforced foam sandwich composite material.
Background
The traditional foam sandwich composite material is compounded by upper and lower composite material panels with higher strength and modulus and a low-density foam sandwich material between the upper and lower panels, and has higher specific strength and specific rigidity and excellent shock resistance. In addition, through the selection of the foam type, the traditional foam sandwich composite material can realize the functions of wave absorption, fire prevention, heat insulation, sound insulation, energy absorption and the like. Therefore, the traditional foam sandwich composite material becomes a typical structure and function integrated material and is widely applied to the fields of rail transit, high-speed trains, aerospace, ships, ocean engineering and the like. However, with the ever-increasing requirements of engineering applications on structural properties, the traditional foam sandwich composite materials have been unable to meet the requirements. The composite material grid structure is introduced into the foam sandwich material of the traditional foam sandwich composite material to construct a novel sandwich structure composite material, namely grid structure reinforced foam sandwich composite material, wherein the main part of the novel sandwich structure composite material is the traditional foam sandwich composite material, and the reinforced part is the composite material grid structure. Therefore, grid structure reinforcing foam core composite material has integrateed traditional foam core composite material and the advantage of combined material grid structure separately, has both kept advantages such as the lower density of traditional foam core composite material, higher strength, higher modulus, has played the outstanding mechanical properties of composite material grid structure again, promptly: on the premise that the overall density is slightly increased, the mechanical properties of the grid structure reinforced foam sandwich composite material such as flat pressure, lateral pressure, bending, shearing, impact resistance and the like are remarkably improved.
The grid structure reinforced foam sandwich composite material is divided into a unidirectional grid structure reinforced foam sandwich composite material and a bidirectional grid structure reinforced foam sandwich composite material. The unidirectional grid structure reinforced foam sandwich composite material realizes the 2D reinforcing effect in the X/Z direction or the Y/Z direction. The bidirectional grid structure reinforced foam sandwich composite material is a typical grid structure reinforced foam sandwich composite material, and realizes the three-dimensional (3D) reinforcing effect in X/Y/Z directions. Compared with the unidirectional grid structure reinforced foam sandwich composite material, the bidirectional grid structure reinforced foam sandwich composite material has more excellent mechanical properties such as flat pressure, side pressure, bending, shearing, impact resistance, instability resistance and the like.
The unidirectional grid structure reinforced foam sandwich composite material and the bidirectional grid structure reinforced foam sandwich composite material have great difference in spatial structure form, so that the preparation methods of the unidirectional grid structure reinforced foam sandwich composite material and the bidirectional grid structure reinforced foam sandwich composite material are completely different. From the characteristic of the spatial structure of the bidirectional grid structure reinforced foam sandwich composite material, the grid structure of the composite material is distributed in the longitudinal and transverse directions in the plane and extends to the upper panel and the lower panel in the thickness direction, so that a 3D mesh structure which is staggered longitudinally and transversely is formed. The foam core sheet, originally in the conventional foam sandwich composite as a whole, is divided into discrete foam pieces by this network structure. The preparation method has two difficulties in preparing the bidirectional grid structure reinforced foam sandwich composite material interlayer preform, namely, foam blocks with huge quantity are difficult to accurately arrange and fix, and dry fiber fabrics for the grid structure are difficult to finish paving in the longitudinal and transverse directions, and the paving quality consistency is difficult to control. In the general invention patent of 'a bidirectional corrugated lattice reinforced composite sandwich structure' (grant publication No. CN 109318541B), a bidirectional reinforced core material is formed by a unidirectional corrugated plate and a plurality of lattices in corrugations in the unidirectional corrugated plate, and then the bidirectional corrugated lattice reinforced composite sandwich structure is bonded with an upper panel and a lower panel. The bidirectional reinforced sandwich structure is a hollow structure, and the hollow part can be added with fillings such as foam, glass beads and the like. The manufacturing method comprises the steps of prefabricating the unidirectional corrugated plate in advance, processing the dot matrix by the unidirectional corrugated plate to obtain discrete single bodies, and bonding the dot matrix with the unidirectional corrugated plate, the upper panel and the lower panel and the bidirectional reinforcing core material by resin, so that the following problems are caused: (1) one-way buckled plate is thin-walled structure, if the size increase leads to warpage, deformation scheduling problem certainly, therefore the unable (2) dot matrix of enlargiing of technology is discrete monomer one by one, realizes accurate even the arranging on one-way buckled plate that it is fixed that a great difficult problem (3) dot matrix adopts the resin bonding mode with one-way buckled plate, and the dot matrix quantity is great, leads to preparation inefficiency, quality uniformity uncontrollable scheduling problem certainly. In addition, in the molding processes described in other published documents, either the manufacturing cost is low but the quality consistency is poor, or the quality consistency is good but the manufacturing cost is high.
Disclosure of Invention
In view of the above, the present invention aims to provide a low-cost high-precision preparation method for a bidirectional grid structure reinforced foam sandwich composite material, which mainly solves the problem that no low-cost high-precision molding scheme for the bidirectional grid structure reinforced foam sandwich composite material exists so far, and realizes the low-cost high-precision preparation of the bidirectional grid structure reinforced foam sandwich composite material.
In order to achieve the purpose, the invention adopts the technical scheme that: a preparation method of a bidirectional grid structure reinforced foam sandwich composite material comprises the following steps:
3, reversely laying foam blocks, namely reversely laying the foam blocks on the dry fiber cloth and between the adjacent foam blocks laid in the forward direction, and extruding the foam blocks into gaps between the adjacent foam blocks laid in the forward direction from top to bottom to prepare the reinforced foam plate preformed body with the unidirectional grid structure;
7, laying a lower panel, determining the number of layers of the fiber fabric to be laid according to the target thickness of the lower panel and the type of the selected reinforced fiber fabric, wherein the size of the cut fiber fabric is 5-100 mm larger than the planar size of the designed bidirectional grid structure reinforced foam sandwich composite material preformed body, and then laying the fiber fabric on a mold according to the laying design;
step 8, the unidirectional grid structure reinforced foam blocks are placed and fixed in the forward direction, the unidirectional grid structure reinforced foam blocks are sequentially placed on the lower panel in the forward direction along the Y-axis direction at intervals and fixed by the positioning blocks, and the adjacent unidirectional grid structure reinforced foam blocks are identical in interval and parallel to each other;
step 10, reversely laying the unidirectional grid structure reinforced foam blocks on the dry fiber cloth and between the unidirectional grid structure reinforced foam blocks which are adjacently and forwardly laid, and extruding the unidirectional grid structure reinforced foam blocks into gaps of the unidirectional grid structure reinforced foam blocks which are forwardly laid from top to bottom;
step 11, laying an upper panel, determining the number of layers of fiber fabrics to be laid according to the target thickness of the upper panel and the type of the selected reinforced fiber fabrics, wherein the size of the cut fiber fabrics is 5-100 mm larger than the planar size of the designed bidirectional grid structure reinforced foam sandwich composite material preformed body, and then laying the fiber fabrics on a flat unidirectional grid structure reinforced foam block inserted with dry fiber cloth according to the laying design to prepare the bidirectional grid structure reinforced foam sandwich composite material preformed body;
and step 12, integrally forming, namely forming the preformed body of the bidirectional grid structure reinforced foam sandwich composite material prepared in the step 11 by adopting a forming process, and obtaining the bidirectional grid structure reinforced foam sandwich composite material after dry fiber cloth is formed.
Further, the molding process in step 4 and step 12 is an LCM molding process.
Further, in step 6, sanding with 200-400 meshes of sand paper is adopted during sanding.
Furthermore, the foam block is made of one or more of polyvinyl chloride, polymethacrylimide, polyethylene terephthalate or polyurethane, and the density is less than or equal to 400 kg/m 3 The length is 200mm-4000 mm.
Further, the shape of the foam block is rectangular, trapezoidal or triangular.
Further, the dry fiber cloth laid in the step 2 and the dry fiber cloth laid in the step 9 are both dry fiber fabrics made of glass fibers, carbon/glass hybrid fibers, quartz fibers, Kevlar fibers, ultra-high molecular weight polyethylene fibers or PBO fibers, and the surface density is more than or equal to 100 g/m 2 And the fiber fabric types of the two fabrics can be the same or different, and the thicknesses of the two fabrics are mutually independent and range from 0.1mm to 10 mm.
Further, the length of the unidirectional grid structure reinforced foam block is 200mm-4000mm, and the thickness of the unidirectional grid structure reinforced foam block is 0-10mm larger than the thickness of the foam block.
Further, the lengths and the cross-sectional areas of the unidirectional grid structure reinforced foam blocks and the foam blocks are independent of each other.
Furthermore, the lower panel and the upper panel are both dry fiber fabrics made of glass fibers, carbon/glass hybrid fibers, quartz fibers, Kevlar fibers, ultra-high molecular weight polyethylene fibers or PBO fibers, and the surface density is more than or equal to 100 g/m 2 。
Furthermore, the thickness, the layering mode and the type of the fiber fabrics used by the lower panel and the upper panel are independent from each other.
Compared with the prior art, the invention has the beneficial effects that: firstly, the foam block is compounded with a grid structure in an X/Z (or Y/Z) direction to realize the preparation of unidirectional grid structure reinforced foam; then, dry fiber cloth is laid in the Y/Z (or X/Z) direction of the unidirectional grid structure reinforced foam block, and a bidirectional grid structure can be built in the foam by the unidirectional grid structure in the X/Z (or Y/Z) direction and the unidirectional grid structure in the Y/Z (or X/Z) direction after molding, so that the bidirectional reinforcing effect is realized on the whole; secondly, the scheme of preparing the unidirectional grid structure reinforced foam and then integrally forming the bidirectional grid structure reinforced foam sandwich composite material effectively solves two technical difficulties in preparing the bidirectional grid structure reinforced foam sandwich composite material interlayer preform and constructs an integrated integral structure of the bidirectional grid structure, the foam core material and the panel; thirdly, the problems that the size of the interlayer preformed body is difficult to accurately control in the molding process of the bidirectional grid structure reinforced foam sandwich composite material, and the overall stability, quality uniformity, apparent quality and the like of a product are solved fundamentally through the accurate laying and fixing of the foam block and the unidirectional grid structure reinforced foam block, the accurate control of the size and thickness of the grid structure, the accurate control of the thickness of the panel and the like; fourthly, the longitudinal and transverse grid structures are mutually independent, namely the shapes and the sizes of the cross sections of the longitudinal and transverse grid structures, the types and the layers of the used reinforced fiber fabrics and the like are not interfered with each other, and the reinforced fiber fabrics can be respectively designed according to the loaded working conditions, so that the advantage of good designability of the bidirectional grid structure reinforced foam sandwich composite material is exerted to the maximum extent.
Drawings
FIG. 1 is a schematic view of one of the structures of a foam block/unidirectional grid structure reinforced foam block;
FIG. 2 is a schematic view of a process for preparing a unidirectional grid structure reinforced foam board;
FIG. 3 is a schematic view in partial transverse cross-section of a unidirectional grid construction reinforced foam block;
FIG. 4 is a schematic longitudinal cross-sectional view of a unidirectional grid construction reinforced foam block;
FIG. 5 is a schematic view of a transverse cross-section of a foam block in a preform of a bi-directional lattice structure reinforced foam sandwich composite;
FIG. 6 is a schematic view of a partial longitudinal cross-section of a foam block in a preform of a bi-directional lattice structure reinforced foam sandwich composite;
FIG. 7 is a schematic cross-sectional view of a bi-directional lattice structure reinforced foam sandwich composite preform;
FIG. 8 is a schematic cross-sectional view of a bi-directional grid structure reinforced foam sandwich composite;
the labels in the figure are: 1. the foam block comprises a foam block 2, dry fiber cloth I and 3, a unidirectional grid structure reinforced foam block, a grid structure in the X/Z direction 4, a lower panel 5, a dry fiber cloth II and 7, an upper panel 8, a grid structure in the Y/Z direction 9 and a mold.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments, and all other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the protection scope of the present invention.
The principle of the invention is as follows: the invention provides a low-cost high-precision preparation method of a bidirectional grid structure reinforced foam sandwich composite material, which comprises two key processes: firstly, one-way grid structure reinforcing foam accurate molding: the foam blocks 1 are precisely laid and fixed in the X (or Y) direction, the dry fiber cloth i 2 is precisely laid in the X/Z (or Y/Z) direction and squeezed between the adjacent foam blocks 1 with the foam blocks 1, and the grid structure reinforced foam is formed by a typical LCM (Liquid composite Molding) process such as VARI, RTM, VARTM, and the like. And secondly, accurately preparing a bidirectional grid structure reinforced preformed body, processing grid structure reinforced foam into a plurality of completely same unidirectional grid structure reinforced foam blocks 3 along the Y/Z (or X/Z) direction, paving a lower panel 5, accurately paving and fixing the unidirectional grid structure reinforced foam blocks 3 on the lower panel along the Y (or X) direction, accurately paving dry fiber cloth II 6 along the Y/Z (or X/Z) direction, extruding the dry fiber cloth II between the adjacent unidirectional grid structure reinforced foam blocks 3 by using the unidirectional grid structure reinforced foam blocks 3, and paving an upper panel 7 to finish the preparation of the bidirectional grid structure reinforced preformed body. The preformed body is formed by adopting typical LCM processes such as VARI, RTM, VARTM and the like, so that the low-cost high-precision preparation of the bidirectional grid structure reinforced foam sandwich composite material is realized.
The technical scheme mainly comprises the following steps:
3, reversely laying the foam blocks 1 on the dry fiber cloth I2 and between the adjacent foam blocks 1 laid in the forward direction, and extruding the foam blocks 1 into gaps between the adjacent foam blocks 1 laid in the forward direction from top to bottom to prepare a preformed body of the reinforced foam plate with the unidirectional grid structure;
7, paving a lower panel 5, determining the number of layers of the fiber fabric to be paved according to the target thickness of the lower panel 5 and the type of the selected reinforced fiber fabric, wherein the size of the cut fiber fabric is 5-100 mm larger than the planar size of the designed bidirectional grid structure reinforced foam sandwich composite material preformed body, and then paving the fiber fabric on a mold 9 according to the paving design;
step 8, the unidirectional grid structure reinforced foam blocks 3 are placed and fixed in the forward direction, the unidirectional grid structure reinforced foam blocks 3 are sequentially placed on the lower panel 5 in the forward direction along the Y-axis direction at intervals, the unidirectional grid structure reinforced foam blocks are fixed by the positioning block II, and the adjacent unidirectional grid structure reinforced foam blocks 3 are identical in interval and are parallel to each other; the cross section of the positioning block II is the same as that of the unidirectional grid structure reinforced foam block 3;
step 10, reversely laying the unidirectional grid structure reinforced foam blocks 3 on the dry fiber cloth II 6 and between the unidirectional grid structure reinforced foam blocks 3 which are adjacently and forwardly laid, and extruding the unidirectional grid structure reinforced foam blocks 3 into gaps of the unidirectional grid structure reinforced foam blocks 3 which are forwardly laid from top to bottom;
step 11, laying the upper panel 7, determining the number of layers of the fiber fabrics to be laid according to the target thickness of the upper panel 7 and the type of the selected reinforced fiber fabrics, wherein the size of the cut fiber fabrics is 5-100 mm larger than the planar size of the designed preformed body of the bidirectional grid structure reinforced foam sandwich composite material, and then laying the fiber fabrics on the smooth unidirectional grid structure reinforced foam block 3 inserted with dry fiber cloth II 6 according to the laying design to prepare the preformed body of the bidirectional grid structure reinforced foam sandwich composite material; the schematic cross-sectional view of the bidirectional grid structure reinforced foam sandwich composite material pre-forming body is shown in FIG. 7, and further, the schematic cross-sectional view and the schematic partial longitudinal cross-sectional view of the foam blocks in the pre-forming body are respectively shown in FIG. 5 and FIG. 6;
and step 12, integrally forming, namely integrally forming the bidirectional grid structure reinforced foam sandwich composite material preformed body prepared in the step 11 by adopting typical LCM (liquid crystal module) forming processes such as VARI (resin transfer molding), RTM (resin transfer molding), VARTM (resin transfer molding) and the like, and obtaining the grid structure material in the Y/Z (or X/Z) direction after dry fiber cloth II 6 is formed. The schematic cross-sectional view of the bidirectional grid structure reinforced foam sandwich composite material prepared by the invention is shown in figure 8.
Further, the foam block 1 is made of one or more of polyvinyl chloride, polymethacrylimide, polyethylene terephthalate or polyurethane, and the density is less than or equal to 400 kg/m 3 The length is 200mm-4000 mm. In order to achieve the best use effect, the cross section geometry of the foam block 1 can be determined according to requirements and structural design, simple geometries such as rectangle, trapezoid and triangle can be selected, and other shapes can also be selected; compared with the design value, the tolerance of the cross section size of the foam block 1 is-0.5 mm-0.5mm, and the tolerance of the distance between the adjacent foam blocks 1 is-0.5 mm-0.5 mm; the number of the foam blocks 1 is more than or equal to 2N +1 (N is more than or equal to 1 and less than or equal to 100, and N is an integer). One structural schematic diagram of the foam block 1/unidirectional grid structure reinforced foam block 3 is shown in fig. 1, and the cross section geometry of the foam block is an isosceles trapezoid.
Further, the dry fiber cloth I2 paved in the step 2 and the dry fiber cloth II 6 paved in the step 9 are both dry fiber fabrics made of glass fibers, carbon/glass hybrid fibers, quartz fibers, Kevlar fibers, ultra-high molecular weight polyethylene fibers or PBO fibers, and the surface density is more than or equal to 100 g/m 2 And the fiber fabric types of the two fabrics can be the same or different, and the thicknesses of the two fabrics are mutually independent and range from 0.1mm to 10 mm.
Further, the length of the unidirectional grid structure reinforced foam block 3 is 200mm-4000mm, and the unidirectional grid structure reinforced foam block is independent of the foam block 1 and is simultaneously constrained by the size and the number of the foam blocks 1; the thickness is 0-10mm greater than the thickness of the foam block 1. The cross section geometry can be determined according to the requirement and the structural design, simple geometries such as rectangle, trapezoid and triangle can be selected, other shapes can be selected, and the cross section geometry and the foam block 1 are mutually independent; compared with the design value, the tolerance of the cross section size of the unidirectional grid structure reinforced foam blocks 3 is-0.5 mm-0.5mm, and the tolerance of the distance between the unidirectional grid structure reinforced foam blocks 3 is-0.5 mm-0.5 mm; the number of the unidirectional grid structure reinforced foam blocks 3 is more than or equal to 2N +1 (N is more than or equal to 1 and less than or equal to 100, and N is an integer), and the unidirectional grid structure reinforced foam blocks and the foam blocks 1 are independent from each other, but are constrained by the size and the number of the foam blocks 1.
Furthermore, the lower panel 5 and the upper panel 7 are both dry fiber fabrics made of glass fiber, carbon/glass hybrid fiber, quartz fiber, Kevlar fiber, ultra-high molecular weight polyethylene fiber or PBO fiber, and the surface density is more than or equal to 100 g/m 2 . The thickness, the layering mode and the type of the fiber fabrics used of the lower panel 5 and the upper panel 7 are independent from each other.
Example one
The first embodiment is a bidirectional grid structure reinforced foam sandwich composite material with the same longitudinal and transverse grid structures.
In this example, the foam core material was 60 kg/m 3 The PVC foam of (1); the foam blocks 1 are 950mm long, 40mm wide and 20mm high, the number is 31, and the distance between adjacent foam blocks 1 is 40.4 mm; the fiber cloth for the X/Z direction grid structure 4 and the fiber cloth for the Y/Z direction grid structure 8 have the surface density of 198 g/m 2 The number of the twill carbon fiber fabrics is 1 layer; the upper panel 7 and the lower panel 5 are made of fiber cloth with the surface density of 400 g/m 2 The number of the E glass fiber plaid is 8 layers. Therefore, the length of the unidirectional grid structure reinforced foam board is 1246mm, the width thereof is 950mm, and the height thereof is 20mm, and the processed unidirectional grid structure reinforced foam block 3 has the length of 1200mm, the width thereof is 40.4mm, the height thereof is 20mm, and the number thereof is about 20. Therefore, the preformed body of the bidirectional grid structure reinforced foam sandwich composite material is 1200mm in length and 771mm in width.
The preparation process of the reinforced foam sandwich composite material with the bidirectional grid structure and the reinforced bidirectional grid structure comprises the following steps:
(1) the PVC foam block is laid and fixed in the forward direction: PVC foam blocks are sequentially paved on the die 9 at positive intervals according to the structural design and fixed by the positioning blocks I, the intervals between the adjacent PVC foam blocks are the same and are parallel to each other, and the cross section of the positioning block I is the same as that of the PVC foam block.
(2) Laying dry twill carbon fiber cloth: and flatly paving the cut dry twill carbon fiber cloth on neat PVC foam blocks which are paved at intervals.
(3) Reversely laying the PVC foam block: and reversely laying the foam blocks between the PVC foam blocks which are laid on the dry twill carbon fiber cloth and adjacent to the PVC foam blocks in the forward direction, and extruding the foam blocks into gaps between the adjacent PVC foam blocks which are laid in the forward direction from top to bottom.
(4) Preparing a unidirectional grid structure reinforced PVC foam board: after the preparation of the one-way grid structure reinforced PVC foam board preformed body is completed, the one-way grid structure reinforced PVC foam board is prepared by adopting a VARI (vacuum amorphous alloy) forming process, and the X/Z direction grid structure 4 is formed after the dry twill carbon fiber cloth is formed.
(5) Processing the one-way grid structure reinforced PVC foam block: and processing the prepared unidirectional grid structure reinforced PVC foam board according to the structural design, wherein the processing direction is vertical to the grid structure direction, so that the unidirectional grid structure reinforced PVC foam block is obtained.
(6) Surface treatment of the unidirectional grid structure reinforced PVC foam block: the surface of the reinforced PVC foam block with the unidirectional grid structure is polished by 220-mesh sand paper, and then is wiped clean by alcohol or acetone and dried.
(7) Laying the lower panel 5: the 8-ply density of 400 kg/m is cut to 1250mm long and 820mm wide according to the target thickness of the lower panel 5 and the type of reinforcing fiber fabric selected 3 The E glass fiber scrim of (a) is orthogonally laid on the mold 9.
(8) The unidirectional grid structure reinforced PVC foam block is laid in the forward direction: sequentially and positively laying unidirectional grid structure reinforced PVC foam blocks at intervals on the lower panel 5 according to the structural design, fixing the unidirectional grid structure reinforced PVC foam blocks by using the positioning block II, and enabling the adjacent unidirectional grid structure reinforced PVC foam blocks to be identical in spacing and parallel to each other; the cross section of the positioning block II is the same as that of the unidirectional grid structure reinforced foam block 3.
(9) Laying dry twill carbon fiber cloth: and flatly paving the cut dry twill carbon fiber cloth on regular unidirectional grid structure reinforced PVC foam blocks which are paved at intervals.
(10) Reversely laying the reinforced PVC foam blocks with the unidirectional grid structure: and paving unidirectional grid structure reinforced PVC foam blocks between adjacent positively laid unidirectional grid structure reinforced PVC foam blocks on the dry twill carbon fiber cloth, and extruding the unidirectional grid structure reinforced PVC foam blocks into gaps of the positively laid unidirectional grid structure reinforced PVC foam blocks from top to bottom.
(11) Laying of the upper panel 7: the type, the number, the size and the laying mode of the fiber cloth used by the upper panel 7 are the same as those of the lower panel 5, and the fiber cloth is laid on the flat unidirectional grid structure reinforced foam block 3 which is penetrated by dry fiber cloth II 6.
(12) Integral molding: after the bidirectional grid structure reinforced PVC foam sandwich composite material preformed body is prepared, the preformed body is integrally formed by adopting a VARI forming process, and a grid structure 8 in the Y/Z direction is formed after dry twill carbon fiber cloth is formed.
Example two
The type and density of the foam core material, the structural parameters and number of the foam blocks, the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3, the type and number of layers of the fiber cloth for the X/Z direction grid structure 4, the number of layers of the fiber cloth for the Y/Z direction grid structure 8, the type and number of layers of the fiber cloth for the upper panel 7 and the lower panel 5, the forming process, the preparation process and the like of the second embodiment are the same as those of the first embodiment, except that the type of the fiber cloth for the Y/Z direction grid structure 8 is 220 g/m in surface density 2 The satin high-strength glass fiber fabric.
EXAMPLE III
The third embodiment relates to the same as the first embodiment in terms of the type and density of the foam core material, the structural parameters and number of the foam blocks, the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3, the type and number of layers of fiber cloth for the X/Z direction grid structure 4, the type and number of layers of fiber cloth for the Y/Z direction grid structure 8, the type and number of layers of fiber cloth for the upper panel 7 and the lower panel 5, the forming process, the preparation process and the like, and the difference is that the number of the fiber cloth for the Y/Z direction grid structure is 2.
Example four
The fourth embodiment relates to the type and density of the foam core material, the structural parameters and number of the foam blocks, the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3, the type and number of layers of the fiber cloth for the X/Z direction grid structure 4 and the Y/Z direction grid structure 8, the type and number of layers of the fiber cloth for the upper panel 7, the number of layers of the fiber cloth for the lower panel 5, the forming process, the preparation process and the like, which are the same as those of the first embodiment, except that the fiber cloth for the lower panel 5Type 400 g/m of areal density 2 The T700 carbon fiber biaxial fabric of (a).
EXAMPLE five
The fifth embodiment relates to the same type and density of the foam core material, the structural parameters and number of the foam blocks, the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3, the type and number of layers of the fiber cloth for the X/Z direction grid structure 4 and the Y/Z direction grid structure 8, the type and number of layers of the fiber cloth for the upper panel 7, the type of the fiber cloth for the lower panel 5, the forming process, the preparation process and the like as those of the first embodiment, except that the type and number of the fiber cloth for the lower panel 5 are 5 layers.
EXAMPLE six
The sixth embodiment relates to the structural parameters and number of the foam blocks, the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3, the types and the number of layers of the fiber cloth for the grid structure 4 in the X/Z direction and the fiber cloth for the grid structure 8 in the Y/Z direction, the types and the number of layers of the fiber cloth for the upper panel 7 and the lower panel 5, the forming process, the preparation process and the like which are the same as those of the first embodiment, and the difference is that the type of the foam core material is 110 kg/m 3 PMI foam of (1).
EXAMPLE seven
The seventh embodiment relates to the type and density of the foam core material, the structural parameters and number of the foam blocks, the type and number of layers of the fiber cloth used for the grid structure 4 in the X/Z direction and the fiber cloth used for the grid structure 8 in the Y/Z direction, the type and number of layers of the fiber cloth used for the upper panel 7 and the lower panel 5, the forming process, the preparation process and the like, which are the same as those of the first embodiment, except for the structural parameters and number of the unidirectional grid structure reinforced foam blocks 3.
In this embodiment, the unidirectional grid structure reinforced foam board is 1246mm long, 950mm wide and 20mm high, and the processed unidirectional grid structure reinforced foam block is 3 mm long and 1200mm long. According to the structural design, the cross section of the unidirectional grid structure reinforced foam block 3 is in an isosceles trapezoid shape, the upper bottom is 20mm, the lower bottom is 43.5mm, the height is 20mm, and the number is about 25. Thus, the preform of the bidirectional grid structure reinforced foam sandwich composite material with the length of 1200mm and the width of 810mm can be obtained.
In summary, the foam block is compounded with the grid structure in the X/Z (or Y/Z) direction, so that the preparation of the unidirectional grid structure reinforced foam is realized; then, dry fiber cloth I2 is laid in the 3Y/Z (or X/Z) direction of the unidirectional grid structure reinforced foam block, and a bidirectional grid structure can be built inside foam by the unidirectional grid structure in the X/Z (or Y/Z) direction and the unidirectional grid structure in the Y/Z (or X/Z) direction after molding, so that the bidirectional reinforcing effect is integrally realized; the scheme of firstly preparing the unidirectional grid structure reinforced foam and then integrally forming the bidirectional grid structure reinforced foam sandwich composite material effectively solves two technical difficulties faced when preparing the bidirectional grid structure reinforced foam sandwich composite material interlayer preform and also constructs an integrated integral structure of the bidirectional grid structure, the foam core material and the panel; the problems that the size of an interlayer preformed body is difficult to accurately control in the molding process of the bidirectional grid structure reinforced foam sandwich composite material, and the overall stability, quality uniformity, apparent quality and the like of a product are solved fundamentally through the accurate laying and fixing of the foam block and the unidirectional grid structure reinforced foam block 3, the accurate control of the size and thickness of the grid structure, the accurate control of the thickness of a panel and the like; the longitudinal and transverse grid structures are mutually independent, namely the shapes and sizes of the cross sections of the longitudinal and transverse grid structures, the types and the layers of the used reinforced fiber fabrics and the like are not interfered with each other, and the reinforced fiber fabrics can be respectively designed according to the loaded working conditions, so that the advantage of good designability of the reinforced foam sandwich composite material of the bidirectional grid structure is exerted to the greatest extent.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. A preparation method of a bidirectional grid structure reinforced foam sandwich composite material is characterized by comprising the following steps:
step 1, foam blocks are laid and fixed in a forward direction, a plurality of foam blocks are sequentially laid on a die at intervals in the X-axis direction in the forward direction and fixed by positioning blocks, and adjacent foam blocks are the same in interval and parallel to each other;
step 2, paving dry fiber cloth, namely flatly paving the cut dry fiber cloth on regular foam blocks which are paved at intervals in the forward direction;
3, reversely laying foam blocks, namely reversely laying the foam blocks on the dry fiber cloth and between the adjacent foam blocks laid in the forward direction, and extruding the foam blocks into gaps between the adjacent foam blocks laid in the forward direction from top to bottom to prepare the reinforced foam plate preformed body with the unidirectional grid structure;
step 4, preparing the unidirectional grid structure reinforced foam board, molding the unidirectional grid structure reinforced foam board pre-molded body prepared in the step 3 by adopting a molding process, and preparing the unidirectional grid structure reinforced foam board after the dry fiber cloth is molded;
step 5, processing the unidirectional grid structure reinforced foam blocks, namely processing the unidirectional grid structure reinforced foam board prepared in the step 4 along the Y-axis direction to obtain a plurality of unidirectional grid structure reinforced foam blocks;
step 6, surface treatment of the unidirectional grid structure reinforced foam block, namely polishing the surface of the unidirectional grid structure reinforced foam block, cleaning the surface with alcohol or acetone, and airing;
7, laying a lower panel, determining the number of layers of the fiber fabric to be laid according to the target thickness of the lower panel and the type of the selected reinforced fiber fabric, wherein the size of the cut fiber fabric is 5-100 mm larger than the planar size of the designed bidirectional grid structure reinforced foam sandwich composite material preformed body, and then laying the fiber fabric on a mold according to the laying design;
step 8, the unidirectional grid structure reinforced foam blocks are placed and fixed in the forward direction, the unidirectional grid structure reinforced foam blocks are sequentially placed on the lower panel in the forward direction along the Y-axis direction at intervals and fixed by the positioning blocks, and the adjacent unidirectional grid structure reinforced foam blocks are identical in interval and parallel to each other;
step 9, paving dry fiber cloth for the second time, namely flatly paving the cut dry fiber cloth on regular unidirectional grid structure reinforced foam blocks which are paved at intervals in the forward direction;
step 10, reversely laying the unidirectional grid structure reinforced foam blocks on the dry fiber cloth and between the unidirectional grid structure reinforced foam blocks which are adjacently and forwardly laid, and extruding the unidirectional grid structure reinforced foam blocks into gaps of the unidirectional grid structure reinforced foam blocks which are forwardly laid from top to bottom;
step 11, laying an upper panel, determining the number of layers of fiber fabrics to be laid according to the target thickness of the upper panel and the type of the selected reinforced fiber fabrics, wherein the size of the cut fiber fabrics is 5-100 mm larger than the planar size of the designed bidirectional grid structure reinforced foam sandwich composite material preformed body, and then laying the fiber fabrics on a flat unidirectional grid structure reinforced foam block inserted with dry fiber cloth according to the laying design to prepare the bidirectional grid structure reinforced foam sandwich composite material preformed body;
and step 12, integrally forming, namely forming the preformed body of the bidirectional grid structure reinforced foam sandwich composite material prepared in the step 11 by adopting a forming process, and obtaining the bidirectional grid structure reinforced foam sandwich composite material after dry fiber cloth is formed.
2. The method for preparing the bidirectional grille structure reinforced foam sandwich composite material as claimed in claim 1, wherein the molding processes in step 4 and step 12 are both LCM molding processes.
3. The method for preparing the bidirectional grille structure reinforced foam sandwich composite material as claimed in claim 1, wherein in step 6, sand paper of 200-400 meshes is used for grinding.
4. The method for preparing the foam sandwich composite material with the reinforced bidirectional grid structure according to claim 1, wherein the foam blocks are made of one or more of polyvinyl chloride, polymethacrylimide, polyethylene terephthalate or polyurethane, and the density is less than or equal to 400 kg/m 3 The length is 200mm-4000 mm.
5. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 4, wherein the shape of the foam block is rectangular, trapezoidal or triangular.
6. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 1, wherein the dry fiber cloth laid in step 2 and the dry fiber cloth laid in step 9 are both dry fiber fabrics made of glass fiber, carbon/glass hybrid fiber, quartz fiber, Kevlar fiber, ultra-high molecular weight polyethylene fiber or PBO fiber, and the surface density is not less than 100 g/m 2 And the fiber fabric types of the two fabrics can be the same or different, and the thicknesses of the two fabrics are mutually independent and range from 0.1mm to 10 mm.
7. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 1, wherein the unidirectional grid structure reinforced foam block has a length of 200mm to 4000mm and a thickness 0 to 10mm greater than that of the foam block.
8. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 7, wherein the lengths and the cross-sectional areas of the unidirectional grid structure reinforced foam blocks and the foam blocks are independent of each other.
9. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 1, wherein the lower panel and the upper panel are both dry fiber fabrics made of glass fiber, carbon/glass hybrid fiber, quartz fiber, Kevlar fiber, ultra-high molecular weight polyethylene fiber or PBO fiber, and the surface density is not less than 100 g/m 2 。
10. The method for preparing the bidirectional grid structure reinforced foam sandwich composite material as claimed in claim 1, wherein the thickness, the layering mode and the type of the fiber fabric used for the lower panel and the upper panel are independent from each other.
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