CN101646548B - Fiber reinforced composite cores and panels - Google Patents
Fiber reinforced composite cores and panels Download PDFInfo
- Publication number
- CN101646548B CN101646548B CN2007800417817A CN200780041781A CN101646548B CN 101646548 B CN101646548 B CN 101646548B CN 2007800417817 A CN2007800417817 A CN 2007800417817A CN 200780041781 A CN200780041781 A CN 200780041781A CN 101646548 B CN101646548 B CN 101646548B
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- rove
- resin
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- fibroid
- band
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/22—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of both discrete and continuous layers
- B32B37/223—One or more of the layers being plastic
- B32B37/226—Laminating sheets, panels or inserts between two continuous plastic layers
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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
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/521—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement before the die
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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
- B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
- B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
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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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
- B29C53/68—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels with rotatable winding feed member
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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
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
- B29C53/8008—Component parts, details or accessories; Auxiliary operations specially adapted for winding and joining
- B29C53/805—Applying axial reinforcements
- B29C53/8058—Applying axial reinforcements continuously
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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
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/24—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using threads
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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
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
- B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
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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
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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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
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/545—Perforating, cutting or machining during or after moulding
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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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/022—Foam
Abstract
A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips, and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins. Continuously wound strips or strip sections may be continuously fed either longitudinally or laterally into molding apparatus which may receive skin materials to form reinforced composite panels.
Description
Related application
This application is the application sequence No.10/810 submitted on March 27th, 2004,298 part continuation application, application sequence No.10/810,298 application is the application sequence No.09/749 submitted on December 27th, 2000,064 part continuation application, and this application requires the provisional application sequence No.60/857 submitted on November 9th, 2006,593 interests.
United States government rights
The present invention is according to USAF contract No.F29601-02-C-0169 and based on contract F33615-99-C-3217, F33615-00-C-3018, F42650-03-C-0029, FA8201-06-C-0091, the contract N00167-99-C-0042 of USN and NASA contract NNC04CA18C and make under the support of U.S. government.Federal government has certain right in the present invention.
Technical field
The present invention relates to a kind of battenboard composite construction that comprises the low density porous material of fiber reinforcement, resin, fibroid and non-fiber covering reinforce, and relate to particularly improved Structural Tectonics, improved resin is inculcated method and production method.
Background technology
For many years, at the various products of structure, for example use when shell and refrigerated trailer and have by the low-density closed-cell materials core that for example the closed cell plastic foam material forms, with fibroid by cured resin matrix, strengthen the structure battenboard of the relative covering that liner or fabric form.This foam core for separating of and stablize this structural skin, bear and shear and compressive load, and provide heat insulation.
For example, as the U.S. Patent No. 5 the applicant, 834, disclosed ground in 082, by provide fibroid reinforcement structure with reinforced core in foam core and improve the link of core to the panel covering simultaneously, the structural behaviour with battenboard of foam core can be strengthened significantly.When the porous fibre reinforce is introduced in the closed-cell foam core and porous fibre covering when strengthening fabric or liner and being applied to each face of this core, can utilize differential pressure, for example, under vacuum bag, for example polyester, vinyl esters or epoxy resin flow through whole porous skins and core reinforce to make binding resin.When the impregnation of fibers reinforce, because its hole-closing structure, resin does not make the plastic foam core saturated.Resin is then common in whole enhancing structures solidifies to provide a kind of firm monolithic panel.
Expectation is by improving structure connection between the reinforcement in foam core and between core and panel covering and supporting the battenboard of producing the structural behaviour with reinforcement.This makes us expectation, thereby bears the buckling load in reinforcement, prevent under load reinforcement each other with from covering, separate prematurely, and be provided for distributing a plurality of load paths of the active force that is applied to panel.In this respect, with respect to non-reinforced foam, important improvement is provided existing fiber reinforcement core product but can not be fully each of core being strengthened to element be integrated into unified and in inside in supported structure.For example, first group of continuous plate strengthened by the fibroid of second group of interruption or discontinuous plate intersection in the lattice-shaped structure of sheet template sheet therein, and flexing is resisted in the really mutual support of plate.Yet, under serious loading environment, discontinuous plate is tending towards losing efficacy at the binding resin binding site place to continuous plate along their narrow cross spider.As disclosed ground in above-mentioned patent, by the banded groove of resin filling is set in foam along cross spider, can basically reduce this trend.And, because be interrupted the fortifying fibre of plate, at each place, crosspoint with continuous plate, stopping, the structural contribution of those fibers is less than the structural contribution of the fiber of continuous plate basically.
In the situation of the pillar of the rove that comprises other fiber extended between glass fibre or carbon fiber or the face at core or bar type of core reinforce, each pillar in given a line pillar can mutually intersect in the grid structure.This provides buckling support for each pillar, but this is only in the plane capable at pillar.In order to realize Bidirectional supporting, the first row pillar should extend through the filament of the pillar of intersection row.In machine processing, this requires difficulty and expensive accuracy and level of control, because should in three dimensions, accurately locate all pillars.
Summary of the invention
One embodiment of the present of invention have overcome the restriction of plate type and these two kinds of reinforced foam cores of pillar type, and this is by this enhancing elements combination of two types is become to mix to strengthen structure.In mixed system, foam core is provided with parallel, the fibroid of embarking on journey that be spaced of extending between the face of cystosepiment with acute angle or right angle and strengthens plate or thin slice.Comprise shaft-like fibroid rove or pillar, embarking on journey of second group of parallel spaced apart strengthen element and also extend between the face of cystosepiment with acute angle or right angle, and rove or pillar intersect with plate and extend through plate.Therefore plate and pillar form the interlocking three dimensional support structure, and wherein all fortifying fibres in core are all non-interruptions.The plate be connected to each other and pillar provide a plurality of load paths to distribute efficiently normal load with the enhancing interelement at core and between cored structure and panel covering.Impact failure trends towards being restricted to immediately shock zone, because this complexity strengthens structure, stops shear surface to develop in core.
In a kind of alternative mixed system, plate comprises the fabric that is formed the ripple with the fragment of extending between the face of core or the continuous slice of liner, and utilizes the foam strips with coupling cross section to be filled in the space between ripple.Ripple can form structurally efficient or rectangle, triangle, parallelogram or other geometry of manufacturing advantage be provided together with the panel covering intersected in cross section.
In the efficient type of a kind of abnormal cost of mixing core, produce core enhancing plate by a spiral manner the fibroid rove of lower cost being wound on the rectangle foam strips, rather than the surface that is attached to foam strips by the weaving by basically more expensive or serving textile.During winding operation, can axially apply other rove with the structural property of strengthening band or the low-cost parts that are used as final panel covering along band length.Can also be linked to together to form the structure core by the foam strips of Filament-wound Machine, and need not add the structural posts of embarking on journey.In this structure, adjacency or the adjacent side with wound strips of square-section forms the plate element with I-beam (I-beam) flange for being attached to the panel covering.Compare with disclosing of U.S. Patent No. 4411939, in the both sides of plate but not only on a side, the fibroid extension of each core plate is attached to the panel covering, thereby increased widely the shear strength of gained panel.For given requirement of strength, this allows to use lighter and not too expensive plate.Similarly, as U.S. Patent No. 5,462,623, the No.5 with the applicant, when the structure disclosed in 589,243 and No.5,834,082 is compared, the invention provides significantly improved core to covering link and shear strength.By test, the plate consisted of the rove along circumferential winding shows those shear strengths of high 75% that stop than the contiguous panel covering in its end.Each band be wound all can be provided with inner transverse and strengthen plate so that two-way strength and stiffness to be provided.Can also use the band with triangular-section to form the core be wound around by rove.
Utilize machine to be wound around rove and will to be merged into single core by the band of Filament-wound Machine and there is economy and this two aspect of maneuverability.According to U.S. Patent No. 5,701, the single compound floorings of 234,5904972 or 5958325 structures or yacht hull normally comprise thousands of or more core blocks separately.The amount of labour of producing these independent cores is very high.Strengthen fabric be cut into by around each independently core be wound around and the thin slice of gummed, or less piece of cloth is glued to the independent face of each core, or at first forms tubing and core is inserted wherein.Along with the size reduction of core, these processes become more and more difficult.Arrange that in mould these cores are also labor-intensive, expensive with consuming time, this has limited the panel number that can produce from mould within preset time.Along with the curvature increase of mould or along with die surface departs from horizontal direction, locate each core blocks and become more and more thorny.By utilizing the parts of big figure in the core single, as to be easy to manipulation, as the core of theme of the present invention, these defects have basically been eliminated.
Except their superior structural performance, Mixed Design allows to utilize fairly simple process to produce extremely complicated and efficient structure and do not require high accuracy of manufacture level structurally in economic mode under high production of machinery amount.As mentioned above, the Bidirectional strut type of core requires with certain accuracy, the rove reinforce to be inserted in cystosepiment, and when expectation intersects the rove of row when extending each other, described accuracy is difficult to realize.Be necessary that in addition, insert device to settle along two pillars to the four direction inclination through pillar in plate in multiple times.
On the contrary, can produce two-way mixing core few passing to single ground when pillar inserts device.Strengthen plate and mutually cooperate to bear the load in the pillar plane with the pillar intersected.Plate also provides transversely in the intensity of the direction of pillar, and this is because plate extends transverse to the pillar of embarking on journey.In addition, need more limited accuracy when producing, this is because pillar only needs to intersect with plate plane but not the filament of narrow beam.
By increasing, core is strengthened element and overlays on the two resin-dipping or the speed of inculcating and reliability of battenboard covering above core, mix the production that core has improved molded panel.In vacuum-assisted resin transfer molding (VARTM) technique, comprise that the panel of dry and porous skin reinforce is positioned in the closed mould or one-sided mould of the sealing bag cover plate that wherein utilizes air proof.Then panel is evacuated, and allows resin to flow into and inculcate reinforce under atmospheric pressure.Because interconnecting of the plate in core of the present invention and the complexity between pillar, the two all can flow air and resin in total with spreading all over rapidly and.Porous plate and pillar form the natural resin flow path and resin are transported to a plurality of positions at porous skin rapidly from its introducing source between covering.This has alleviated wherein the competing flow problem that the resin forward position due to non-homogeneous propelling makes dry covering fabric extent be isolated from vacuum source, thereby prevents that covering is fully moistening before resin starts retrogradation and solidifies.
In one embodiment of the invention, between panel covering and die surface or vacuum bag barrier film without the resin distribution medium of any kind.This has not only eliminated the cost of this distribution media but also has allowed to produce all has the panel of even surface on all sides.And, with for example in U.S. Patent No. 5,958, in 325, disclosed prior art is contrary, foam core does not need as for the device to the covering distribution of resin, being provided with the micro-recesses be positioned on the core periphery adjacent with the panel covering, or in that extend between covering, slit in foam or hole.In the present invention, all resins all strengthen structure by core and flow to covering, and patent No.5,958,325 have described particularly because the resin that starts from the core surface place is inculcated the dipping caused.The shortcoming of periphery micro-recesses is, thereby the size of micro-recesses and interval should be selected with the type of the fibroid fabric of matching panel and quantity, guarantees before resin solidification the abundant dipping to covering and core reinforce.In the present invention, the all resins of inculcating covering all strengthens structure to arrive covering through the porous of core, and because the panel covering usually strengthens element with two of panel surfaces or more porous per square inch, intersects, resin trends towards rapidly and process skin-surface expansion equably simultaneously.The thorough dipping for the panel covering that can see is that core strengthens structure and do not have the dry and therefore a kind of reliable signal in fragile zone.Be adjacent to introduce resin with covering therein other inculcate system and compare, this is an important advantage.
According to the present invention, by foam core inside and adjacent with core enhancing plate and network that be parallel to that plate extends and not adjacent with panel covering groove, resin being fed to core, strengthen structure.The end of these grooves with usually there is the more feeding passage of heavy in section area and intersect.The resin that is supplied to the feeding passage flow through rapidly the groove adjacent with plate and basically whole resin then flow through the fibroid core and strengthen element to arrive and dipping panel covering.If the resin groove is arranged in the plane near the plate thickness center,, before realizing that complete resin is saturated, resin only need flow through from central plane along each direction half of plate thickness.Thisly passed through single panel ground than common wherein resin and introduce and should flow through whole plate thickness to inculcate technology with the resin that arrives and inculcate opposite face significantly faster.Thereby can be provided with other one group or organize the resin groove and the feeding passage is inculcated more rapidly more with the panel of thick core or thick covering.Groove in groups and feeding passage are depicted a plurality of planes that are parallel to panel.
The method of inculcating of the present invention is suitable for producing the molded panel that two faces of panel wherein all require good surface smoothness particularly well.Strengthen structure because resin is introduced in the inside of core and flowing to rapidly covering in whole cores under differential pressure, so two faces of panel can be all the adjacent rigid die surfaces with desired shape and fineness, and with at flexible surface, for example carry out under vacuum bag inculcate not compare can seriously increase and inculcate required time.On the contrary, the common differential pressure molding process that wherein before introducing resin, utilizes pressure to merge the covering reinforce for example VARTM requires to utilize a for example side of vacuum bag cover plate of flexible partition, this vacuum bag potting resin distribution media when expectation keeps suitable pressure and introduces resin rapidly on skin-surface simultaneously.If do not use this layout, the pressure of rigid die surface on two panels makes long and inculcates slowly path and necessitate, in this path, resin passes through length and the width along them, but not by the mobile covering that floods of their thickness.
Of the present invention inculcate method by inner and outer (inside-out) core can be for resin being beaten into to fibroid core reinforce and inner covering layer, in properties, this resin is different from the resin of the outer skin layer of inculcating panel.It can be used to for example produce the battenboard that has outer skin layer and the inner covering layer that comprises fire-resistant phenolic resins and strengthen structure the core that comprises the structure vinyl ester resin.This is by between the inside and outside layer of porous, fibroid covering reinforce, providing for example epoxy adhesive barrier of form of film to realize.By as supplied the first resin from inculcating in core as described in front, and the second resin directly beaten in the outer skin reinforce, wherein this barrier film is independently for keeping resin when the generation structure bond between them.
In a kind of useful modification of mixing core of the present invention, strengthen plate and do not extend between the face of panel.But two or more cystosepiments and porous, fibroid plate are interweaved and are stacking with sandwich structure.Porous rove pillar or bar extend between the face of core and by one or more intermediate plate ground.These one or more plates are for the flexing steady brace under load and for resin distribution is arrived to pillar and covering.Can introduce resin by groove in foam parallel, that be spaced adjacent with plate.Alternately, resin can be by flowing in core perpendicular to panel and feeding passage that end in the radial groove adjacent with plate.Inculcating round panel for example during manhole cover, this layout is useful.In the third modification, this plate can be inculcated medium in conjunction with low-density fibre liner or unstructuredness, porous, by this liner or medium, the central plane that the resin by the supply of feeding passage passes through panel flow to pillar and flow to the panel covering by pillar.
Other being characterised in that between pillar or bar type of core enhancing element and battenboard covering of the present invention provides improved connection.This improvement can be applied to having the mixing panel of plate and this core reinforcement of two types of pillar, with and core strengthen the panel only comprise pillar.Can between core and covering, stop at the porous fibre pillar extended between the face of core, can extend through covering and end at their outer surface, or can overlay on one or more above panel covering layer.Under load, pillar stands sizable stretching or compression force at place, the crosspoint with covering, and these active forces can cause at the adhesion failure strengthened between element and covering.
Prior art, for example, as at European patent No.0672, disclosedly, disclosed with covering and be adjacent to provide the annular end that strengthens element in 805B1.Under pressure during molded, the ring formed in the end of pillar provides the binding agent contact area with the expansion of covering.Yet the critical defect of this design is, as the ring of the fibre bundle by reflexed, is formed under molding pressure and causes that the panel skin morph becomes nonplanar caking.This causes excessive resin to gather in covering, and covering is the trend of flexing increase under compressive load in face, and undesirable surface smoothness.
In the present invention, the cut filament with permission formation pillar of terminal that the pillar type strengthens element laterally opens under molding pressure, and this flattens end and provide the bond area of expansion between each strut ends and covering simultaneously in the zone of next-door neighbour's strut ends towards covering significantly.By before molded, sometimes with heating, side by side to the face of panel, apply sufficient pressure, to be provided for, during molding process, any reinforce caking or convex ridge are embedded to the recess in foam core, can further improve the flatness of skin-surface.Alternately, can insert line along pillar and form groove in the face of foam, during molded, strut ends or cover superincumbent sutured portion and pressed in this groove of people.
Even the present invention also provide a kind of alternative for the anchoring strut ends and be also effective method above strut ends does not overlay on the panel covering time.In this structure, parallel groove or slit are so located in the face of cystosepiment, make the end of pillar type reinforcement through groove.Before inserting pillar component, strengthen rove with the porous of bonding mode anchoring strut ends and be inserted in groove thereby there is the abundant degree of depth, and flow into resin in structure provide pillar to link to the structure of the rove in groove during molded.And cover the rove that superincumbent panel covering has suitable contact area and complete the transfer of structural loads between covering and core.One of this structure is important, other benefit is, groove rove and pillar component can be sized the truss structure of the formula that is integrally formed, and its further groove rove is as chord member of truss.Because it is enough than in the situation of thin skin that the cost of rove basically lower than textile fabric, is that truss exists between capable, this allows economic panel manufacture.
In the present invention, during process in reinforcement is inserted to foam and substitute the face that the covering will have more expensive weaving or knit goods reinforce is applied to core, low-cost rove directly can also be applied to the face of cystosepiment to form the panel covering.In this method, insert by pillar that machine is advanced forward and transversely in the parallel circuit of core length, supply a plurality of rove and in a longitudinal direction it extracted out continuously from the supply creel with enough numbers by foam core, to cover more or less the face of foam.Before inserting pillar, rove is in groups passed through the face of core and laterally extracts out and advance together with core with right angle or acute angle from creel, sew up the pillar rove by core simultaneously.The superincumbent part of covering of stitch keeps putting in place just form the structural panel covering once resin, being applied to panel by all surperficial rove.The lightweight veil that as required, can before sewing up, on surperficial rove, apply reinforcing material is to improve the manipulation feature of core before molded.Substitute continuous rove, can between core face and surperficial veil, apply random or directed chopped roving to form the structure liner.
Even if by core ground, sew up covering, comprise overlay on above the axial roving that is used to substitute covering fabric reinforce and retrain it, the battenboard of rove is arranged is being also effective aspect the layering of resistance covering to spiral winding.In the flexing due in covering or tensile load produce zone layering, that have non-homogeneous core thickness, for example in face plate edge, progressively reduce and reduce place, this is very useful.
The present invention includes several useful modification that strengthens central layer, this enhancing central layer has two-way core intensity and wherein utilizes the spiral winding process that all core reinforcements are provided.In most economical embodiment, the unidirectional central layer consisted of the foam strips of wound in parallel is cut into uniform the second band along the direction perpendicular to the bar zone axis, and then the second band is rotated by 90 degrees and is merged to form the second integral type central layer.That then initial spiral winding rove stops as its end adjacent core face, independently pillar-shaped rove fragment is extended between the face of central layer.This core system provides double direction shear intensity and high compression-strength, but the core reduced is to the strength of connection of panel covering.By being wound around spirally the second band before merging at them, can link by stiffened skin, to be provided between foam strips and to pass through the reinforce layer be wound that the central layer face ground adjacent with covering extends continuously.According to desired structural property, before merging, the second band be wound can be directed, with or be adjacent to provide the roving layer doubled between covering or with covering.Thereby two-way central layer can also be provided with in the slit in the face that is inserted into central layer and strengthen parallel, the continuous rove that embark on journey that forms supporting member between plate for thin panel covering at core.The Diaphragm-braced between the enhancing plate be wound was provided with between band and strengthens plate, paired foam strips before being wound around by being wound around, in can be located at unidirectional core.
An important advantage of all two-way core described here is, the enhancing plate intersected is stabilized in adjacent low-density and low-intensity foam strips mutually for the flexing under load.By in adjacent being wound between foam strips, providing spacer tape, for example the high-density foam plastics, to increase the effective width of plate, can improve the anti-flexibility of plate in unidirectional core.In a kind of unidirectional central layer form of economy, the foam strips be wound around by rove and simple foam strips alternately, therefore allow panel output to double for the winding machine output of giving sizing.In this embodiment, in order for flexing, to stablize plate, spacer tape is located on the opposite side of each wound strips, relative being wound between layer.By strip edge wherein not parallel and therefore along the direction except common strip direction, provide band structural property, tortuous or other structure is provided, unidirectional tape can be modified to provide two-way intensity.Comprise band with all structures and in conjunction with the central layer of thermoplastic resin by applying fortifying fibre and low-cost thermoplastic as the independently parts that merge subsequently to band under heat and pressure, can producing economically.
Provide axially extended rove by the bight along band and under the rove be wound around, can improve the structural behaviour of spiral winding band.This interpolation causes that the reinforcement plate piece collection on each side of each foam strips has the general type of the bar joist of the top of being separated by shaft-like shear component and bottom cord.This structure is withstand shock more, and axial roving can allow to use less fortifying fibre in the panel covering.Each band be so constructed can be used as discrete structural elements, for example pillar or box beam, by providing with the band of horizontal reinforcement and, by other axial roving is provided between the bight of band, its performance can be strengthened further.
Thereby change angle and the density of the reinforce be wound along the length of foam strips by the feed rate of rove Wiring apparatus by changing band, can strengthen comprising the structure efficiency of the particular panel of the band be wound.This can provide improved compressive strength for panel at load supporting-point place, or is customized to mate the core shearing resistance along the prediction shear-type load of panel length.
By separating the foam strips that is wound around continuously during winding process and merging they with before forming central layer by folding before and after band, can be transferred to the end of band and be transferred to thus the panel reinforce intersected comprising by the shear-type load in the central layer of the foam strips of unidirectional winding.That pass through like this winding rove of the fragment that the opposed end location of foam strips is spaced and be provided to the face plate edge reinforce or connect to structure adjacent central layer, strong.Also may expect to produce and have basic cylindricality or other closed construction and to there is the battenboard that does not end in the core joint and avoid thus the continuous central layer reinforce that structure interrupts.This embodiment can for example be used to form the jet engine casing, and the jet engine casing is designed to bear the general integrity that very high energy impact keeps casing simultaneously.Be wound around spirally the enhancing rove by the foam strips around continuous, then around cylindrical mandrel, coat band spirally and produce central layer.Can below being wound around rove, provide continuous axial roving to realize extra hoop intensity and impact resistance.
In a useful embodiment of the present invention, light-wall pipe is used to substitute and is wound around the foam strips that strengthens rove thereon.Described pipe can comprise the material of low structural matter, the paper (stiffened paper) of for example putting more energy into, the material that perhaps there is high structural property, for example preferably processed take be implemented to as the fibroid reinforce as the strong adhesion of the resin of matrix, roll extrusion or extrude aluminium.When expectation provides hollow structure, or eliminate the weight of low-density solid core, or in panel during in conjunction with the structural property of tubular material, this embodiment is useful.
The another kind of scheme that strengthens the impact resistance of the battenboard comprise the core that is wound around spirally and thermosetting resin is to there is no so fragile thermoplastic resin in conjunction with usually comparing with thermosetting resin in the exterior section of panel covering.This can realize by several schemes.A kind of thermoplastic film can be heated to flow in the exterior section of fibroid enhancing liner or fabric, and making inside is porous, thereby utilizes subsequently for flooding the thermosetting resin dipping of core reinforce.As required, the tissue layer consisted of combined fiberglass and thermoplastic fibre can be used to substitute thermoplastic film.Mixed goods is heated to form the thermoplasticity outer surface be enhanced and makes thermoplastic resin flow through partly the inner thickness that strengthens liner.In yet another embodiment, the mixed goods covering can not apply heat with strengthening core be adjacent to place and be inculcated, thus the glass fibre of this covering and thermoplastic fibre the two all be used to inculcate the thermosetting resin dipping of core.
The accompanying drawing explanation
Fig. 1 is the fragment perspective view of reinforced foam core composite panel constructed according to the invention;
Fig. 2 is the fragment cross section according to the reinforced foam core composite panel of another embodiment of the present invention structure;
Fig. 3 is the fragment cross section of another embodiment of reinforced foam core composite panel constructed according to the invention;
Fig. 4 is the fragment cross section of another embodiment of reinforced foam core composite panel constructed according to the invention;
Fig. 5 is the fragment cross section of another embodiment of reinforced foam core composite panel constructed according to the invention;
Fig. 6 is the fragment cross section of another embodiment of reinforced foam core composite panel constructed according to the invention, and wherein core is broken away;
Fig. 7 be basic on the line 7-7 of Fig. 6 intercept and fragment cross section that core is broken away;
Fig. 8 is the fragment cross section of another embodiment of reinforced foam core composite panel constructed according to the invention;
Fig. 9 is the fragment perspective view according to the reinforced foam core composite panel of another embodiment of the present invention structure;
Figure 10 is the fragment perspective view according to the reinforced foam core composite panel of another embodiment of the present invention structure;
Figure 11 is the fragment perspective view according to the reinforced foam core composite panel of modification structure of the present invention;
Figure 12 be for the production of according to of the present invention by the diagrammatic view of the equipment of the foam strips of Filament-wound Machine;
Figure 13 is the perspective view of the fragment by the foam strips of Filament-wound Machine constructed according to the invention;
Figure 14 is the fragment perspective view of reinforced foam core composite panel constructed according to the invention;
Figure 15 is the diagrammatic view for the production of the equipment of fiber enhanced foam central layer according to the present invention.
Figure 16 is the fragment perspective view of reinforced foam parts constructed according to the invention;
Figure 17 is the fragment perspective view of reinforced foam parts that uses the parts of Figure 16;
Figure 18 is constructed according to the invention and the fragment perspective view of the reinforced foam core of the parts of use Figure 17;
Figure 19 is the fragment perspective view of another embodiment of reinforced foam core constructed according to the invention;
Figure 20 is the fragment perspective view according to the central layer of modification structure of the present invention;
Figure 21 is the amplification fragment part of Figure 20;
Figure 22 is the fragment perspective view from a cross section of the cutting of panel shown in Figure 20;
Figure 23 is formed with the band shown in Figure 22 and the fragment perspective view of the central layer that decomposed partly;
Figure 24 is with the perspective view of band shown in spiral winding rove, Figure 22;
Figure 25 is the enlarged perspective of the part that is wound band shown in Figure 24;
Figure 26 is the fragment perspective view that utilizes the central layer of banded structure as shown in Figure 24;
Figure 27 is the fragment perspective view that modification according to the present invention utilizes the central layer of the banded structure shown in Figure 24;
Figure 28 is according to the another kind of fragment perspective view of revising the core band formed of the present invention;
Figure 29 is the enlarged perspective of a part of the band of core shown in Figure 28;
Figure 30 is the fragment perspective view that uses the central layer of core banded structure as shown in Figure 28;
Figure 31 is according to the another kind of fragment perspective view of revising the central layer formed of the present invention;
Figure 32 is according to the another kind of fragment perspective view of revising the central layer of structure of the present invention;
Figure 33 is the fragment perspective view according to the core band of modification formation of the present invention;
Figure 34 is the fragment perspective view according to the another kind of central layer of modification formation of the present invention;
Figure 35 is that assembly is wound around core band constructed according to the invention and the fragment perspective view of the annular core that forms spirally;
Figure 36 is all had the fragment perspective view of the central layer that tubular core band that spiral winding rove and modification according to the present invention form forms by each;
Figure 37 further revises the fragment plan view of the core band of structure according to another kind of the present invention;
Figure 38 is the fragment plan view that utilizes the central layer formed according to the core band shown in Figure 37 of the present invention;
Figure 39 is according to the another kind of fragment perspective view of revising the central layer formed of the present invention;
Figure 40 is according to the another kind of fragment perspective view of revising the panel formed of the present invention;
Figure 41 is according to the another kind of fragment perspective view of revising the composite panel formed of the present invention;
Figure 42 is the fragment perspective view of modification central layer formed according to the present invention;
Figure 43 is the fragment perspective view of another kind of composite panel formed according to the present invention;
Figure 44-47th, the fragment perspective view of central layer formed according to the present invention;
Figure 48 illustrates the diagram perspective drawing of manufacture according to the equipment of the method for composite panel of the present invention;
Figure 49 illustrates another diagram perspective drawing another kind of method, another kind of equipment of manufacturing according to composite panel of the present invention;
Figure 50 is the further diagram perspective drawing for the production of the equipment of the composite panel according to another kind of form of the present invention; And
Figure 51 is the fragment exploded end view of composite panel formed according to the present invention.
The specific embodiment
Fig. 1 signal can for example be used as the highway truck driver's cabin base plate, hull or transom, shop building roof or be used as vehicle or the structure composite battenboard 30 of foot bridge panel.Panel 30 comprises fiber reinforcement closed cell plastic foam core 31 and relative fiber reinforcement covering 32.Foam core 31 comprises a plurality of foam strips 33, and the structural property of foam strips 33 is not enough to bear the load in core, the load that described load will be used for corresponding to design covering 32.
The core fortifying fibre that is selected as giving the required structural property of core is glass fibre or carbon fiber or other fortifying fibre.Along a direction, fortifying fibre forms a plurality of parallel thin slice or the plate 34 of porous, fibroid fabric or liner, and thin slice or plate 34 extend and be attached to bonding mode a face while sizable porosity of maintenance in plate material sheet of each foam strips 33 between the face of core 31.As required, plate 34 can in conjunction with comprise from its cut out band 33, be applied to the reinforce of a plurality of independent rove of cystosepiment (not shown) with bonding mode.Along being basically perpendicular to the crisscross of plate 34, the core fortifying fibre forms that multirow is parallel, bar that be spaced or pillar 35, and bar or pillar 35 extend and consist of porous enhancing filaments bundles or rove between the face of core.
Every a line pillar include with the panel covering with contrary acute angle for example+58 degree and-58 degree or+a plurality of pillars 35 that 45 degree and-45 degree tilt.Two groups of relative pillars in every a line are arranged in same level and mutually intersect to form triangularization or structure lattice types.The diameter of the pillar 35 in a line pillar and interval are considered to be determined according to structure, but usually 0.01 inch to 0.12 inch diameter and 0.25 inch in the scope at 2.0 inches intervals.In some cases, pillar can surpass 0.50 inch diameter and 7.0 inches intervals.Working of pillar 35 often is spaced 0.5 inch to 1.0 inches.Closed-cell foam band or silver 33 can be polyurethane, polyvinyl chloride, polystyrene, phenolic aldehyde, polyethylene, Polymethacrylimide or have other foamed material for the desired character of application-specific.Usually, foam density is low, in the scope of 2 to 5 pounds every cubic feet, but can use much higher density in due course.
As shown in FIG. 1, pillar 35 intersects with plate 34, and the fiber of formation pillar extends through the fiber that forms plate.Because in sew application, the fibroid rove that forms pillar is inserted in foam core and passes plate, do not disconnect arbitrary group of filament so form the filament of pillar through the filament of plate, remain unaffected thereby core strengthens the continuity of all elements of structure.In a preferred embodiment, panel covering 32 comprises inner covering 36 and outer skin 37.The end 38 that strengthens pillar 35 also extends through inner covering 36 and laterally opens to overlay on above inner covering 36.Before utilizing resin molded panel 30, inner covering 36 is covered by outer skin 37.Therefore pillar mechanically is attached to covering, thereby provides high resistance for covering 32 under load from core 31 layerings.As required, the end of pillar rove can be close to the face termination that strengthens core 31.
Utilize binding resin dipping or inculcate core and the two porous fibre reinforce of covering, binding resin preferably in the differential pressure current downflow by whole reinforcing materials and solidify the load supporting structure with the formation rigidity.Before panel 30 is molded and solidifies, the friction that utilization causes the pressure of the rove fiber that forms pillar 35 due to plastic foam and covering fiber, and utilization overlays on rove fragment or the end above the panel covering, inner covering 36 and with the foam strips 33 of the plate 34 be bonded, be held together as the structure of integral type.Although, for specific application, core 30 can be varying sized on a large scale, practical core dimensions for example comprises 0.25 inch foot long to 40 feet to 5.0 inchs and 2 feet to 8 feet wide * 2.Core is usually by the produced in lengths with continuous and be cut into desired length.For the molded Area Ratio larger battenboard of single enhancing core constructed according to the invention, can before introducing resin, mutually be adjacent to arrange two or more core in mould.
Mainly by pillar 35 along a direction and mainly by plate 34 transversely direction bear the shear-type load in core 31.In addition, the rigid resin by place, each crosspoint at pillar and plate in conjunction with and by fortifying fibre, the continuity by all this crosspoints has realized that the complexity of plate and pillar is integrated.Plate and pillar mutually support and resist buckling load, and this allows, and flexibility at the core reinforcement makes that they tend to occur that flexing was that lost efficacy, the lighter reinforcement of operating weight in thick panel.Structure shown in Fig. 1 can bear perpendicular to covering, large compressive load, and this is ground orientation and pillar 35 its flexings of prevention because plate 34 and covering 32 meet at right angles.The structure assembly of plate and pillar also provides a plurality of load paths to increase sharing and providing sizable resistance for generation and the development of shear fails separating plane in core local compressive load to strengthen interelement at core.The core reinforcement to the bonding of covering and mechanical link for pulling fastener by high resistance is provided in the panel covering.
Usually by technique for example in vacuum bag molding, resin transfer moulding or vacuum assisted resin transfer moulding (VARTM), under differential pressure, make resin flows by whole porous fortifying fibres in, and utilize resin-dipping or inculcate foam core and the fabric reinforcement of covering.In VARTM is molded, usually seal core and covering in thering is the airtight mould of a flexible die face, and air is found time from this mould, this mould applies atmospheric pressure by flexible face so that panel 30 is complied with the fiber of mould and compression covering 32.Catalyzed resin is usually by being located at resin distribution medium on panel surface or network of channels and by vacuum suction mould, and is allowed to solidify.As required, the present invention can inculcate method in conjunction with a kind of improved VARTM.
Enhancing core 31 can be provided with to be machined in foam strips 33 and with the plate 34 in foam core 31 inside and be adjacent to the resin groove 39 of locating.Groove 39 ends at common area of section and locates than the larger resin feeding passage 40 (Fig. 1) that still can have same size of each groove 39.Passage 40 for arriving groove 39 by resin distribution under differential pressure.Can be along strengthening one of edge core 31, that enhancing plate 34 stops or two edges location feeding passages 40.Alternately, passage 40 can fully be located in the inside of core.For the purpose of illustrating, Fig. 1 is illustrated in the passage 40 at core edge place, and Fig. 7 is illustrated in the feeding passage of core inside.If passage 40 is located on only edge of core 31, according to resin flows dynamics in reinforced foam core and panel covering reinforce, groove 39 can extend to the opposite edges of core 31 or alternately can be in the interior termination of foam strips 33.
Catalyzed resin by being connected to resin source, the pipe (not shown) that is generally resin roll flow to passage 40.Tube opening can be positioned at any position along passage 40.Using during vacuum bag inculcates a kind of method for optimizing of enhancing core of the present invention, before any resin tube equipment is attached to mould, mould is sealed and find time.Rigid resin connects or Inserting Tube is provided with sharp keen pointed end and then pass vacuum bag barrier film and panel covering 36 and 37, or passes vacuum bag in the edge of panel 30, and enters in the enhancing core 31 intersected with feeding passage 40.Inserting Tube has been provided with the opening allowed in resin flow channel 40 in its periphery.In insertion point, place applies sealing joint strip to prevent vacuum leak, and Inserting Tube is connected to the resin source of supply, and resin is passed through in Inserting Tube and admission passage 40 by vacuum draw.
Except speed, terseness and the low material cost of resin being introduced to this method in panel, carry out when middle inculcating, other resin tube connector can be so that other resin enters the specific region of panel in other position is inserted into panel.By one or more hole that can insert the resin tube connector by it is provided in die surface, this pipe insertion method can also be used to inculcate the panel 30 fully be enclosed in rigid die.When resin filling groove 39, its flows into and by whole porous fibre plates 34, flows into and by the porous fibre pillar 35 all intersected, and inflow and by the panel covering 32 all intersected, after this, resin solidification is to form the rigidity reinforced Sandwich structure.The enhancing core 31 that has been provided with passage 40 can be placed in adjacent one another are and form in the mould of passage 40 single, more major path.Flow in resin solidification in this larger passage is keyed to plate 34 marginal portion with formation and bear the structure spline of the shear force between adjacent core 31.
Compare with existing VARTM technique, be attached to the resin distribution system strengthened in core 31 and there is significant advantage.By utilizing plate and pillar with a plurality of, the connecting portion of uniform distribution relatively of covering, resin is filling groove 39 and flowing to panel covering 32 in strengthening structure at all plates and pillar rapidly, makes thus to exist the minimizing possibility in not impregnated zone in covering.On the periphery of core 31 without any resin micro-recesses or distribution media material.Resin is introduced into a plurality of grooves 39 of the midplane that is arranged in panel and marches to two coverings 32 by shorter distance.Externally one or more any desired position on covering 37 or face plate edge fabric applies vacuum.The little zone that other that as required, multirow perforation vacuum pipe, fibroid earial drainage medium can be provided towards the surface of outer skin 37 or introduce vacuum installs to guarantee drying, porous skin reinforce not by around resin flows from vacuum insulation.Having abnormal thick core or the panel of covering can be provided with the other groove of resin in groups 39 and be arranged in the feeding passage 40 plane, relevant that is parallel to panel covering 32.The resin be introduced in face plate center advances to two coverings 32 by shorter distance.In not having intersect the fibroid pillar, core that be included in the plate extended between covering, it is also effective that the inside core of just having described is inculcated system.For uniform resin distribution, may need plate interval more closely.
With strengthen die surface that central layer contact can or rigidity or flexible, and do not weaken the rapid flow of resin in all cores enhancing structures or covering.For example, with the enhancing core of relevant porous fibre covering, can be placed between rigid die platform and rigid wall, the vacuum bag that makes dividing plate be sealed to mould table covers.Apply atmospheric pressure from a described sack of edge-evacuation of panel to panel, and the resin of introducing at the opposite edges place of panel flows in strengthening structure rapidly at all cores and covering, and needn't be all whole length or the width that longitudinally flows through the panel covering in VARTM technique rigidity, traditional as two die face therein.
Enhancing panel 30 can be configured to allow utilization to have two kinds of resins of different nature and side by side inculcate core.For example, can utilize the outer skin of fire-resistant resin impregnating panel, and can utilize the structurally good still lower vinyl ester resin of fire resistance to flood inner covering and core enhancing structure.If expect this structure, before resin is inculcated, for panel 30 provides the binding agent barrier film 41 between inner covering 36 and outer skin 37.Barrier film 41 by binder material for example epoxy resin form, this material prevents that liquid resin from entering opposite side from film one skidding, and solidifies to form the structure combination when applying heat and modest pressure between inner covering 36 and outer skin 37.
In order to inculcate panel together with the inside covering 36 with being bonded, to strengthen core 31, binding agent barrier film 41 and outer skin 37 are placed in closed mould, then utilize vavuum pump this mould of finding time.The first resin is introduced into by passage 40 and 39 in the inside of core 31 and as is allowed to as described in front flow in strengthening structures and inner covering at whole cores.Side by side, the second resin that has a different component is by die surface or outer skin edge and directly introduced in outer skin.Binding agent barrier film 41 is for preventing this two kinds of different mixed with resin, and also promoted solidifying of adhesive film by the heat produced that solidifies of these two kinds of resins, and therefore the structure combination is provided between inside and outside covering.If adhesive film is applied to the both sides of panel 30, three kinds of independent resins can be beaten in panel.If adhesive film 41 only is applied to a side of panel 30, the resin of inculcating core 31 also will inculcate inside and outside covering on the opposite side of panel the two.
In Fig. 1,2,6,7,13,14 and 18, the embodiment of the present invention of signal has been depicted as to be provided with to core and has strengthened the internal resin distribution groove that plate is adjacent and be provided with relevant resin feeding passage.Should be appreciated that, as required, this feature can be omitted from Fig. 1,2,6,7,13,14 and 18 embodiment and can be among the embodiment shown in Fig. 3,4,5,9 and 19 or have in foam core in any other embodiment of porous fibre plate and add described feature.
Battenboard 50 (Fig. 2) utilizes and the reinforced foam core 52 that can produce with the output speed improved of comparing embodiment illustrated in fig. 1, and this is only need be with single angle but not be inserted in foam core with two contrary angles because strengthen pillar.The face of parallel fibers enhancing plate 51 and core acutangulates for example 58 degree or 45 and extends between the face of foam core 52 with spending.The plate 51 of embarking on journey intersects with parallel with the one group squarely fiber reinforcement pillar 53 of embarking on journey substantially, and the fiber of pillar 53 extends through plate 51 and covering 54 in the mode of describing about Fig. 1.
In the embodiment shown in Figure 2, all pillars all tilt with certain angle with respect to the panel covering, and this angle is still along contrary direction with the angle automatching of plate 51.Plate 51 and pillar 53 support and opposing flexing and mutual the cooperation to bear along the shear-type load of a direction mutually, and plate also bears the transversely shear-type load of direction.Although can select the plate of any number to strengthen fabric or liner, make the plate enhancing fabric of the angle orientation that its a part of fiber is contrary with the angle with pillar 53 by use, can strengthen the dual direction structure function of plate.Its cofibre by the directed plate 51 of angle with become with the panel covering+45 degree and-45 degree can be realized lateral shear intensity efficiently, and this is because the shear force in core resolves into self these angles basically.The core enhancing plate 51 that the core of Fig. 1 strengthens plate 34 and Fig. 2 ends at adjacent panel covering 32 and 54 respectively.Therefore, the resinous substrates by surrounding all fortifying fibres in panel bonding, provide the direct organization between plate and covering to connect.As at United States Patent (USP) 5,834, ground is described in 082, protrusion and fiber that open by the marginal portion that is positioned at them is provided for plate 34 and 51 or provide by the marginal portion with plate and be adjacent to the plate edge resin strip that foam strips 55 flutings are formed, can improve the intensity of this plate to the covering connection.
Plate 34 and 51 also have respectively by pillar 35 with 53 and with covering 32 and 54 between connecting structure be connected, described pillar be linked to plate and covering the two and therefore bear a part of load between plate and covering.Also utilize the structure of the rove pillar shown in Fig. 2 that the panel covering is combined, described rove pillar comprises the continuous tilt independence short fiber of embarking on journey, and each short fiber all has the strut ends of opening.The support construction of inclination short fiber form can also be located in the panel with relative pillar and in conjunction with Fig. 8 and be described more fully.
Intersect the strength and stiffness of composite panel of plate and pillar if expectation further increases to have, core strengthens plate and can comprise single, continuous fiber reinforcement liner or fabric but not a plurality of discrete plate band.Illustrate this embodiment in Fig. 3,4 and 5.With reference to figure 3, composite laminboard 60 comprises fiber reinforcement covering 61 and fiber enhanced foam core 62.The fibroid rove pillar 64 of the one-tenth between-line spacing that foam core 62 comprises foam silver or band 63, separate and be formed between the panel covering and the fibroid plate 65 of a plurality of rectangle ripples that extend transverse to the pillar of embarking on journey.As in Fig. 1, pillar 64 and covering become equal opposite angles to tilt and intersect with relative pillar and covering 61 and extend through relative pillar and covering 61.Pillar also intersects and extends through corrugated cardboard sheet fragment 66 with the corrugated cardboard sheet fragment 66 of extending between covering, and pillar extends through the plate fragment 67 adjacent with covering.System shown in Fig. 3 provides several structural strengthening things for the system shown in Fig. 1.Corrugated cardboard sheet fragment 67 is provided to the binding agent connecting area of the expansion of covering 61, and pillar 64 provides the stitching mechanical link between plate fragment 67 and covering 61.And the ripple of sheet structure transversely provides sizable, other strength and stiffness in the direction of the pillar of embarking on journey.
Enhancing battenboard 70 shown in Fig. 4 also provides plate to link and the advantage of the ripple strength and stiffness described in conjunction with Fig. 3 to covering.In Fig. 4, foam strips 71 has parallelogram section, and the plate fragment 72 of continuous wave pattern plate 73 and covering 74 extend with acutangulating between the face of core 76.The fibroid rove pillar 75 that parallel multirow is spaced also extends strengthening between the face of core 76, and pillar 75 with the angle that equals plate fragment 72 but angle in contrast tilts.Pillar intersects with corrugated cardboard sheet fragment 72 and extends through corrugated cardboard sheet fragment 72, extends through the plate fragment 76 adjacent with covering 74, and preferably extends through one deck or multi-layer covering.As described more fully ground in conjunction with Fig. 2, for overall cored structure character, the fiber alignment in plate can be optimised.Same as in the situation of Fig. 2, pillar allows fast and produces efficiently to strengthen core with the orientation of single angle, and this is because only need an only pillar inserting step.
Another shown in Fig. 5 strengthens battenboard 80 and also adopts a part of reinforce of continuous wave pattern plate 81 as foam core 82.Foam silver or band 83 have triangular-section, and the plate fragment 84 of extending between covering 87 becomes contrary angle to tilt with covering with 85.But the fibroid rove pillar 86 that multirow is spaced is each other to equate that contrary angle tilts, and intersects with plate fragment 84 and 85 and extend through plate fragment 84 and 85.Pillar also intersects with one deck or multi-layer covering 87 and preferably extends through one deck or multi-layer covering 87.
With Fig. 3, with the structure shown in 4, compare, even when not having enhancing pillar 86, the triangularization plate system of Fig. 5 also provides sizable strength and stiffness with horizontal this both direction to panel 80 along the longitudinal.Pillar is by stablizing plate fragment 84 and 85 and by covering 87 is combined and strengthened these character.Also along pillar, capable direction provides extra strength and stiffness to pillar 86.The angle of pillar is based on that general structure is considered and selecteed and need to be corresponding to the angle of plate fragment 84 and 85.For example, as required, pillar 86 can be perpendicular to covering.This not only provides to panel 80 compressive strength increased, but also only requires single pillar to insert angle, has therefore simplified panel production.
Fig. 6 and a kind of battenboard 90 of 7 signal, the enhancing rove pillar 93 that the parallel multirow that this battenboard 90 has enhancing rove pillar 92 that parallel multirow is spaced in reinforced foam core 91, intersect is spaced, and be parallel to the single continuous enhancing plate 94 of covering 95.Foam core 91 comprises the cystosepiment that separate, stacking by plate 94 96.If structural design needs,, aspect interval, diameter, fibre fractionation and angle, pillar 92 can be different from pillar 93.If the structural requirement of panel is mainly unidirectional, can be set as one group of single parallel pillar capable for pillar.Compression and the shear property of panel 90 mainly are provided by pillar 92 and 93.Along with the thickness increase of core 91, or the reduction of the diameter of pillar, pillar more and more is easy to occur flexing under the structural loads condition and lost efficacy.Pillar 92 in every a line or 93 intersects mutually with lattice-shaped structure, at pillar in capable plane for buckling support is provided each other.Yet low density foam 96 only provides weak and often insufficient lateral buckling support.The continuous fiber that all pillars 92 and 93 extend through strengthens plate 94 provides required, extra buckling support.If necessary, can provide one or more other support plate 94, described support plate 94 all is spaced from each other and is parallel to panel covering 95.
Fig. 6 also illustrates strut ends 97 and plate marginal portion 98, and they protrude to provide from cystosepiment 96 and guarantee at the reinforcement of core 91 with as the parts of single battenboard between the reinforcement of molded adjacent foam core or to the scheme of the reinforcement structural continuity of other adjacent composite construction (not shown).If be desirably in structure in given battenboard, adjacent core, link, the marginal portion of the cystosepiment of the marginal portion of cystosepiment 96 and adjacent enhancing core (not shown) was worn away or is otherwise removed before in resin being introduced to core and covering reinforce and exposes fibroid strut ends 97 and plate marginal portion 98.Strengthen core then for example be extruded to together in mould, and the end exposed from adjacent core and edge part phase-splitting mix and subsequently embedded resin, described resin flows in the panel reinforce and is curing to form strong bonding with strut ends and plate marginal portion under differential pressure.Preferably, the band that strengthens liner or fabric in the fibroid of extending between covering 95 be disposed in mould between adjacent core in to strengthen the load support properties of the joint between core.
The fibroid plate 34 in crosspoint that can also be by that extend beyond them and edge core 31 are provided for core 31 realize between adjacent enhancing core 31 or the strong structure between core 31 and battenboard edge covering be connected.The extension of plate 31 folds with respect to foam strips 33 with the form of fin with being met at right angles.Thereby these plate end fins provide the contact area of expansion with bonding mode, the plate reinforcement to be attached to adjacent reinforce when utilizing resin-dipping panel 31.If be desirably in and realized strong structure combination between resin-dipping and curing panel 90 and adjacent composite construction, cystosepiment 91 is abraded to expose strut ends 97 hard, that hardened and plate marginal portion 98, and the zone of contiguous this end and marginal portion is utilized binding resin, olibanum resin or potting compound and fills and be extruded to panel 90 when resin solidification and will be incorporated on this panel.
Enhancing core 91 shown in Fig. 6 and 7 be provided with as in conjunction with Fig. 1 in the above describe, in general terms, the all-in-one-piece resin inculcates system.Battenboard 90 comprises porous fibre covering and core reinforce and is placed in the closed mould of air being found time from it.Then resin is introduced in the feeding passage 99 at channel end place or by the hole (not shown) got out from panel.Then resin is filled and is positioned at the resin feeding passage 99 that strengthens core 91 inside, and is filled in the resin groove 100 that be connected, that be spaced of inside or the interior and contiguous porous fibre plate of core 91 94 location.Then resin flows through whole porous plate 94 from groove 100, from plate 94, flows through whole porous pillars 92 and 93, and flows through whole porous skins 95 from pillar, and after this, resin solidification is to form structural panel.If core 91 will be used to produce round panel, can be from the center of panel along radial arrangement resin groove 100, and resin is fed to center from panel.
Fig. 1,3,5,6 strengthens with the core shown in 7 form that pillar system is taked relative pillar smooth, that embark on journey, and described pillar mutually intersects in foam core.The number in this crosspoint and the density of formed lattice-shaped structure depend on core thickness, the interval between pillar, and the pillar angle is with respect to the steepness of panel covering.A kind of alternative pillar system is shown in Figure 8 and can be for the system shown in alternate figures 1,3,5,6 and 7, but is optimal in the situation of thinner panel or thicker pillar.The core enhancing system of Fig. 8 comprises that unidirectional pillar as illustrated is capable, or pillar in groups, that intersect is capable and can use or not use core to strengthen plate according to structural requirement.
With reference to figure 8, battenboard 110 comprises relative covering 111 and has the reinforced foam core 112 of multirow fibroid rove pillar 113, but fibroid rove pillar 113 extends between panel covering 111 and with respect to covering to equate contrary angle inclination.Relatively pillar 113 mutually intersects with the contiguous panel covering 111 of simple triangularization structure and extends through covering.When producing enhancing core 110, from the opposite face of foam core, continuous fiber rove 114 is sewn by covering 111 and foam core 112.As required, can two groups of rove pillars be sewed up by covering and foam core from the identical faces of core.In sewing process, rove 114 leaves covering 111 and protrudes with the form of encircling 115 (illustrating with phantom) continuously.Rove is then by the pillar 113 consisted of dual rove fragment with formation along insertion line reflexed.
When panel 110 is advanced by robotic suturing device, rove fragment 116 overlays on above covering 111.The rove ring 115 of the protrusion formed during sewing process the desired distance in the surface of distance covering for example 0.2 inch be cut off to form the strut ends 117 (illustrating with phantom) of protrusion.When during resin molded process, pressure is applied to the panel covering, the strut ends 117 of protruding is opened and is formed against covering 111 end 118 be flattened, thus be formed into covering, strong bonding and for pull the mechanical resistance of the strut ends 118 be flattened by covering 111.
As in conjunction with as shown in Figure 1, can improve mechanical link by adding outer skin.With the covering feature of utilizing complete ring to realize, compare, cut and strut ends 118 that open also provides improved covering feature basically, described complete ring trends towards contiguous covering and forms caking or stop the close die surface that is fitted on of panel, thereby allows excess resin to gather at the skin-surface place.So that foam core 112 is complied with any rove fragment of protruding the surface that surpasses covering 111 or can be pressed into groove or recess wherein by be provided at the rove fragment of protruding under appropriate molding pressure for foam core, can further improve surface flatness by panel 110, applying sufficient pressure.
As shown in FIG. 8, comprise pillar 113, cut and strut ends 118 that open and overlay on short fiber structure rove fragment 116, that tilt above covering providing that a kind of structure between pillar and panel covering is that link, efficient and resultful scheme for guaranteeing to strengthen at core, and a kind of method for optimizing for the production of all enhancing cores as theme of the present invention.Should be appreciated that, can also use other sewing method and, to other processing of the rove fragment of the face outside that is positioned at foam core, for example, purl traditional pattern, continuous fiber is sewed up or chain is sewed up.
The width that the battenboard of signal and core have the degree of depth that is greater than them usually in Fig. 1-8.The core reinforcement that comprises porous fibre plate and pillar can also be merged in the battenboard of width that the degree of depth is greater than it.Fig. 9 illustrates a kind of beam profile plate or crossbeam 120 that the pillar type of core strengthens system and be designed to be used as roof supported in corrosion-resistant building that be combined with.Crossbeam 120 comprises relative glass fibre or carbon fibre reinforced plastic covering 121 and reinforced foam core 122, and reinforced foam core 122 comprises that cystosepiment or silver 123 extend through cellular glass fiber foam core 122, relative or carbon fiber reinforcement pillar 124 with the general type with bar joist with respect to covering 121 with acutangulating.If structural design needs, other pillar can be added to cross-braces 124 to form as to construct at the lattice-shaped of meaning as shown in Fig. 6 and 7, or other a line or the parallel enhancing pillar of multirow can be merged in panel or crossbeam 120.Covering 121 is as structure chord member flange, and its fiber is mainly directed along the longitudinal.Covering 121 comprises inner covering 125 and has the outer skin 126 of fibroid reinforce, and wherein as in conjunction with as described in Fig. 8, the end 127 of reinforcement 124 is opened and is sandwiched between the covering layer.As required, extend through the fiber of end 127 and the flexible fiber of contiguous covering 125 and 126 or thin rigid rod by use covering is sewn onto to end, covering 125 and 126 can be attached firmly to more to the end 127 of opening.
If necessary, one or more porous fibre support plate 128 can be merged in the flexing of resisting under load with steady brace 124 in crossbeam 120.Face at the cystosepiment 123 relatively extended between covering 121 is provided with porous fibre enhancing fabric, and for example second of glass fibre group of covering 129, resist the lateral deflection under load to stablize crossbeam 120.As described in front, the curable resin dipping of introducing under differential pressure forms whole porous fibre reinforcing material of crossbeam 120 and solidifies to form the load bearing cross beam of rigidity.If at structural considerations if required, crossbeam can have cross section heterogeneous, that is, the degree of depth changes from beam-end to the crossbeam center, and can have form that be bent or arch.As required, the thickness of covering 120 can be lowered quite a lot of, and, as more fully described in conjunction with Figure 10 below, the rove bundle that can utilize contiguous covering to inject in cystosepiment in groove provides the chord member of truss structure function.
The core that wherein panel width is greater than the battenboard of the degree of depth strengthens the form that structure can be taked a plurality of parallel real truss type structures, and its king-rod or pillar type reinforcement are anchored between top wherein and bottom cord member and extend with contrary angle in the triangularization structure in the end of pillar.This layout provides good strut ends to link.It is also as the fibroid reinforcing material of chord member of truss member, for example carbon fiber or glass fibre, substitutes sizable part of more expensive fabric covering reinforce with their the rove form of lower cost.As shown in Figure 10, battenboard 140 comprises that strengthening closed-cell foam core 141 strengthens covering 142 with relative fibroid.Strengthen core 141 and be provided with parallel multirow truss 143, truss 143 extends between covering 142.Each truss 143 includes parallel multiple fibre enhancing rove 144, for example glass fibre or carbon fiber, described multiple fibre enhancing rove is located in the groove formed in foam core 141 and with the top that acts on each truss 143 and bottom cord member.Fibroid strengthen bar or pillar 145 through the chord member member and in chord member member 143 by anchoring, and extends between panel covering 142 with contrary acute angle, preferably pass and overlay on one deck or above multi-layer covering 142.As described in front, cured resin floods whole reinforcing materials.As for example as shown in Fig. 1 and 7, the truss structure that comprises pillar 145 and chord member member 143 also can be merged in to have between the panel covering or is parallel in the core of the enhancing plate that the panel covering extends.
With reference to Figure 11, use the alternative weaving of both economical fibroid rove or knitted fibers enhancing fabric can be expanded to forming whole panel stressed-skin constructions.Battenboard 150 comprises enhancing closed-cell foam core 151 and relative fibroid covering 152.Fibroid reinforcement or pillar 154 that core 151 comprises cystosepiment 153 and extends between covering.Each covering 152 includes contiguous foam core 153 and substantially covers the parallel enhancing rove 155 of ground floor of foam face.The parallel enhancing rove 156 of the second layer overlays on above the first roving layer 155 and passes through the first roving layer 155 and basically cover the surface of ground floor 155.As required, the layer of fibroid liner or veil 157 can overlay on above the second roving layer 156.
When producing panel 150, comprise that the end of the rove of the first covering layer 155 is fixed in the line of the leading edge that passes through cystosepiment 153.This plate is advanced by for example robotic suturing device shown in Figure 15, thereby and travelling forward of plate pull rove from the supply creel and cover the opposite face of this plate to form covering layer 155.Before utilizing robotic suturing device insertion pillar 154, utilize the reciprocator with guiding piece to pass through the first roving layer 155 ground and apply a plurality of parallel covering rove 156, described guiding piece keeps desired interval and the tension force of rove 156.Then utilize the fibroid veil 157 of extracting out from the supply volume to cover the second covering layer 156.Core strengthens pillar 154 and is sewn layer by veil 157, covering rove 156 and 155 and cystosepiment 153 to produce battenboard 150.
If need at structural considerations, can before sewing up, with various angles, other covering roving layer be applied to panel.Alternately, directed or nondirectional rove fiber can be by chopped for desired length and be applied to the core face with substituting continuous rove.Sew up pillar rove 154, cover superincumbent fragment 158 will whole covering rove 155 and 156 maintenances put in place until panel 150 is placed in mould, at the mould place, but curable or hardening resin flows through whole fibroid reinforces to produce structural panel.This method that directly forms the panel covering from rove can be incorporated into any embodiment shown in Fig. 1-10.
In a preferred embodiment of the invention, by directly produce plate type of core reinforcement from the fibroid rove, but not by will than rove, more expensive weaving or serving textile, as plate, have been realized sizable cost savings significantly.In this method, around the continuous foam band, along circumferentially being wound around rove, around band, to form structural tube, strengthen structure.The effective scheme of a kind of abnormal cost that forms winding arrangement is by spirality or spiral winding.In the mode of describing in conjunction with Figure 15, the band be wound is cut into desired length and is fed in the rove quilting machine.
With reference to Figure 12, there is the plastic foam band 170 that facilitates length and passed through the schematically spiral winding equipment 171 of signal by feeding end to end.With existing process, compare, the core reinforce is carried out to spiral winding provides great economical advantage.The cost of the fiber of rove form be merged in dual bias voltage 45 degree fabrics those roughly percent 50 to 60, and be wound around five to ten times of speed that the machine throughput rate is seam loop.As required, foam strips can be provided with one or more groove 39 as described in conjunction with Fig. 1 so that resin is mobile in molded operation subsequently.Foam strips 170 has the thickness of the thickness that equals the battenboard core produced from this band and equal to strengthen the width at the desired interval of plate in core.
When band 170 is advanced by Wiring apparatus 171, it is through along the rotational line arbor wheel 172 of a direction rotation with the axle of the bobbin wheels 173 of rotating in the opposite direction.Each wheel all is mounted with and utilizes fibroid to strengthen a plurality of bobbins 174 that rove 175 is wound around.Rotational line arbor wheel 172 is wound into roving layer 176 on foam strips with single angle, and this angle is determined by the travel rate of equipment 171 and the speed of rotation of bobbin wheels 172 by band 170.Then single wound strips advances by the bobbin wheels 173 of reverse rotation, and bobbin wheels 173 is wound around the second roving layer 177 on the roving layer 176 be wound around.
Thereby Wiring apparatus 171 can have certain ratio processes large-scale foam strips size efficiently, for example, thickness is from 1/4th inches to one foot or larger.To be incorporated into the structural requirement of composite panel wherein according to final wound strips and it, rove can have different thickness and can closely be separated, thereby covers the surface of foam strips or separated by wider.The rove that is applied to the surface of foam strips can have and is low to moderate 0.1 ounce every square feet or lower and high to 5.0 ounces every square feet or higher gross weight.Rove shown in Figure 12-14 is thicker than normally, thereby is appreciated that structure detail.Thereby rove can be wound around and realize maximum resistance for the shear stress in the application that stands bending load at band by the angle with+45 degree and-45 degree, or other angle that can stipulate with the structural requirement that will be incorporated into special-purpose terminal product wherein according to them applies rove.
Have the continuous foam band 170 that covers superincumbent winding layer 176 and 177 by the travelling cutting equipment for example the annular saw (not shown) cut into certain-length to form final wound strips 178.Be used as example foam and the plate element of hybrid battenboard as shown in Figure 14 because be wound around foam strips 178, so their length equals the desired width of battenboard.Before cut, for example, by utilizing on the either side of otch by spun yarn 179 coatings of hot-melt adhesive dipping or by applying adhesive tape around cutting position or, by rove, applying binding agent, guaranteeing to be wound around rove 174 and can not scatter.As required, can utilize the barrier film applied before roving layer to be wound around foam strips 170 and avoid moisture, resin invasion and attack etc. with the protection foam.
Figure 13 provides the detailed view that is wound around foam strips 178, is illustrated in level and the orientation of four groups of porous fibre rove that apply during the winding process of illustrating in Figure 12.In Figure 13, all rove are shown to have smooth cross section and are closely separated to cover the surface of closed cell plastic foam band 170.Vertically roving layer 180 covers end face and the bottom surface of foam strips 170.Be wound around with the ground floor shown in the angle of+45 degree the side that rove 176 covers vertical roving layer 180 and foam strips 170.Become the second layer of the angle of-45 degree to be wound around rove 177 covering the first winding layers 176.When utilizing curable thermosetting resin subsequently or can hardening when thermoplastic resin impregnated, all fibroid rove go out to have the structural detail with the general aspects of the crossbeam of rectangular tubular section together with that solidify or production of resins sclerosis.
Having of describing in conjunction with Fig. 1 above Figure 14 is shown in intersected the reinforced foam core battenboard of plate and pillar combination construction, but wherein the band be wound around by rove 178 shown in Figure 13 for shown in alternate figures 1 with the foam strips 33 of the plate 34 be bonded.Additionally, in the production method shown in Figure 15, Figure 14 is combined with and substitutes weaving or knit goods to form the rove of battenboard covering.The foam core band be wound around by rove provides important structure and cost advantage with this combination that applies the panel covering of rove.Refer again to Figure 14, structure composite panel 190 comprises fiber reinforcement closed cell plastic foam core 191 and relative fiber reinforcement covering 192.Reinforced foam core 191 comprises a plurality of parallel band 178 shown in Figure 13.As required, foam strips 178 can be by replace the right hand and left hand wound strips when forming the battenboard core be provided with along the rove that angular direction is wound around along a direction only, thereby adjacent winding edge is in positive and negative angle orientation, but not the two is all in identical orientation and therefore structurally uneven.
Being wound around foam strips 178 meets at right angles and intersects with that extend between the face of core and that form by porous fibre enhancing rove, the bar multirow parallel spaced apart or pillar 193.Pillar 193 in every a line all with respect to panel covering 192 and with respect to the plane surface of wound strips 178 with reciprocal inclined at acute angles.Along 194 layers of the plane that is parallel to pillar 193 row and the parallel porous fibre covering rove that extend perpendicular to the direction that coats band 178 and their vertical roving layer 180 overlay on wound strips 178 above.Can using a plurality of discrete rove or as the form of the one-way fabric with the rove that is pre-attached to the lightweight veil and the light fibre veil, liner or the tulle 195 that are applied to panel 190 overlay on above covering roving layer 194.The end of pillar 193 is through all layers of vertical rove 180, winding rove 176 and 177, covering rove 194 and veil 195, and these ends overlay on above veil 195.
Thereby the panel of illustrating in Figure 14 is illustrated by the reversing of the position from wherein it produces the equipment of Figure 15 the continuous rove that forms pillar 193.As shown in Figure 14, a plurality of continuous rove are sewed up by battenboard 190 by the angle with contrary and from the same side of panel, and wherein each continuous coarse yarn sheet section 196 is all with chain stylolitic structure and self interlocking.Should be appreciated that and can use alternative sewing method, for example locking stitching or cut ring as shown in FIG. 1.
The key character that fibroid shown in Figure 14 strengthens structure is that the vertical roving layer 180 on wound strips 178 forms the horizontal reinforce of battenboard coverings 192, and overlay on above longitudinal layer 180+45 degree and-45 degree roving layers 176 and 177 also form the element of battenboard covering.That is, the plate element of core reinforce consists of the continuous winding rove identical with-45 degree covering elements with+45 degree.This causes for separation resistance between core and stressed-skin construction higher, and this is to stop not as like that contiguous panel covering in Fig. 1 because the core of plate type strengthens plate.Roving layer 180,176 and 177 covers foam strips 178, also by the end anchorage of pillar 193.
When the enhancing core 190 of producing shown in Figure 14, can also save the roving layer 180 and 194 and veil 195 of covering element continuous on the length that is formed in panel and/or width.Be used to produce the large-scale battenboard that usually consists of a plurality of cores adjacent one another are and between the panel covering for example during shell when strengthening core, this may make us expectation.In this panel, usually preferably, the covering that use has abundant length and width provides structural continuity to pass through a plurality of cores, but not use the core with pre-link covering, no matter as in conjunction with Figure 14, described, whether this pre-link covering comprise enhancing fabric or the rove be integrated in core.When continuous covering element 180,194 and 195 is removed, utilize the friction of the pillar rove 193 intersected with adjacent core and utilize by the continuous pillar rove fragment of the end face along band 178 and bottom surface stitching, wound strips 178 continues closely to be kept together as the integral type core.In this structure, the end 196 of pillar 193 does not extend through the covering of battenboard, but in fact be absorbed in, be wound around outside roving layer 177 and be applied between the panel covering of core surface.
The foam strips be wound around by rove 178 of Figure 12-14 is shown to have square-section.As required, these bands can have as other cross section as shown in Fig. 4,5 and 19, for example, and parallelogram or triangle.
U.S. Patent No. 5,904,972 have disclosed the battenboard core component consisted of the discrete plastic foam piece that utilizes the enhancing fabric to coat or band.With ojosa stacking a plurality of coating pieces between the battenboard covering, make the end of foam block and the contiguous panel covering in marginal portion of coating fabric in mould.Foam strips 178 the application, that be wound around spirally shown in Figure 13 can coat pieces with at fabric cost with manufacture aspect the labour and providing comparable structural property with sizable saving for substituting these.
As at patent No.5, described in 904,972, may expect to make the marginal portion that strengthens fabric to extend beyond the end of foam block, thereby they can be folded to form the flange linked for improvement of the structure to the battenboard covering.By the band of alternately sacrificing end to end the foam block (not shown), being wound around foam as described above, being wrapped by via the middle part cutting of sacrificing foam block with core foam strips 170, and remove sacrificial block, can realize Figure 13 be wrapped by and roving layer 180,176 and 177 similar extension longitudinally.Foam strips 170 can also be provided with surperficial micro-recesses before inserting Wiring apparatus 171.Other suitable core material can substitute for being wound the plastic foam of band or piece, for example Ba Er China fir or hollow, sealed plastic bottle with similar geometric.
Because usually mainly utilize the fibroid core to strengthen the structural property that structure provides battenboard core shown in Fig. 1-19, panel character that can be desired based on other, for example waterproof or fire line, heat insulation or light transmission and select to form the closed cell plastic foam of core.For example, can utilize semi-transparent resin to flood translucent polyethylene and fiber glass reinforcement to produce printing opacity and the bearing panel as on-highway tractor roof or building roof.For example carbon foam or Ba Er China fir substituted for plastic foam be also within the scope of the invention to use other porous material.
Fig. 1-8,10,11 and 14 signals are partly by inserting or sew up porous fibre enhancing element fiber reinforcement core and battenboard that for example fibre glass roving is produced by the thickness of foamed plastics core material.This can utilize the equipment 200 of illustrating in Figure 15 to realize.A plurality of foam strips 201 are inserted in robotic suturing device 200 adjacent to each other.Band 201 can have rectangle or other cross section and can be as described in front, be provided with the porous fibre plate of the enhancing fabric be bonded or be provided with the porous fibre enhancing rove be wound.Should be appreciated that, as required, the much larger cystosepiment of the width of Length Ratio band 201 can comprise plastic foam material.
For example utilize back and forth press rods (not shown) or removable endless belt 202, with substantially equal stride, band 201 is advanced to sewing- end 203 and 204, a plurality of end of tubular needle 205, sleeve pipe or the compound hook that are applicable to pierce through and insert the fibroid rove are attached to described sewing-end by rigidity.Sewing-end 203 becomes contrary inclined at acute angles with 204 surfaces with respect to band 201.When band 201, when each stops advancing when step finishes forward, back and forth sewing- end 203 and 204 inserts and passes band 201 by pin 205.Utilize pin guiding piece 207 by pin be positioned at exactly they to the inlet point place in band 201.From the porous fibre rove 208 of the Rove Package (not shown) supply that is wound, by pin 205, through band 201 and with the general type of ring 115 as shown in FIG. 8, at the inlet point with them, relative surface occurs.
Refer again to Figure 15, the equipment (not shown) that ring 115 is held outside the surface that these rings are formed on band (these rings occur from this surface) grasps, and, as required, this equipment is sewed up with other engagement of loops these rings to form chain stitching as shown in Figure 14 or these rings are engaged to form purl with the rove of being supplied dividually.Then sewing- end 203 and 204 contracts and moves back, they by rove 208 be enough to form the next predetermined length of sewing up and be advanced in pin 205.After indentation, the row of band 201 advances predetermined stride or distance and stops, and sewing-end 203 with 204 back and forth to insert lower a pair of relative pillar.The device that integrated component is sawed or other is suitable of the band 201 together with the stitching rove 208 intersected with band remains to cuts into the core 209 with desired length.
Equipment 200 shown in Figure 15 also can for the production of wherein as shown in Figure 14, the two all structural reinforcing parts of core and covering include the battenboard of low-cost fibroid rove.Produce panel 206 in the robotic suturing device 200 shown in Figure 15 during, apply the layer (Figure 14) of vertical covering rove 194 as the surface of panel 206.Being enough to panel 206 that a plurality of porous fibre rove 211 of the face of cover plate are being advanced pulls and the face be exposed out of adjacent tapes 201 is advanced to sewing-end from rove supply package (not shown).The panel 206 that thin porous veil, liner or tulle 210 are being advanced pulls to overlay on above covering rove 211 and they is kept putting in place after rove 208 has been sewn by panel 206 from volume.Band 201 has been provided with vertical roving layer 180, and as shown in Figure 14, thereby the layer 180 and 194 of Figure 14 is formed in the horizontal and vertical covering reinforce of the panel 206 of producing in Figure 15.Be to provide to have to the face of panel 206 and apply the panel production equipment 200 of reciprocator's (not shown) of horizontal and dual bias voltage angle rove also in scope of the present invention.This allows to produce the panel 150 shown in Figure 11, and wherein foam core does not comprise the wound strips 178 that contains roving layer 180.
In another preferred embodiment of the present invention, by for being wound around foam strips 177, providing the inner transverse reinforcement, but not, by structure rove 193 is passed to band 177, realized two-way slab strength.With reference to Figure 16, reinforced foam band 220 comprises by en plaque fibroid reinforcing material, a plurality of or silver 221 of the foamed plastics that for example thin slice 222 of glass fibre or carbon fibre fabric or liner separates.As described ground in United States Patent (USP) 5834082, foam silver 221 and enhancing plate 222 are interconnected with bonding mode in order to process and handle, and keep sizable plate material sheet porosity simultaneously.Strengthen band 220 and can be provided with the groove 223 for resin flows.Should be appreciated that, other material can be for substituting foam silver 221, for example Ba Er China fir or plastics blow molding cube, and do not affect form or the structural intergrity of core.
With reference to Figure 17, strengthen band 230 and be provided with fibroid roving layer 176 and 177, as shown in Figure 12 and 13, to form to be wound around, strengthen band 233.If needing increases bending or axial strength, can also provide the roving layer 180 shown in Figure 13.With reference to Figure 18, strengthen core 240 and utilized veil 241 to be held winding together as integral structure to strengthen bands 233 and form by a plurality of, veil 241 utilizes heat-activated binder and is attached to the opposite face of core 240.If need higher sag, veil 241 can be applied to an only surface of core.Utilize other scheme of cored structure to comprise to pass through parallel band that wound strips adheres to hot melt spun yarn or tulle or apply pressure sensitive adhesives to the face be in contact with one another of band.Substitute veil 241, structural skin fabric or liner may be attached to core surface to form the preformed battenboard of preparing dipping.In one or more core 240 is placed in mould between fabric covering reinforce and resin flows by whole cores and stressed-skin construction and solidify when forming the structure composite panel, be wound around by four fabric plate 222 and the rove plate 242 that roving layers 176 and 177 form and form lattice-shaped enhancing structure, thereby and the part of the contiguous panel covering of winding layer 176 and 177 provide abnormal close-burning link to bear shear force.The articulated construction of core 240 also allows the height compliance for crooked die surface.
Figure 19 signal is by an embodiment of the core 250 of Filament-wound Machine, wherein realized two-way strength and stiffness and do not add inner plate or rove pillar.Fiber reinforcement core 250 comprises a plurality of triangle foam strips 251, and band 251 is provided with spirality fiber roving layer 252 and 253 to form wound strips 254.Being wound around triangle strip 254 is utilized the veil 255 that outside that heat-activated binder is attached to wound strips 254 is wound around roving layer 253 and remains to together as the integral type cored structure.Thereby can be selected and realize desired shearing and compressive strength balance for the angle of cutting triangle strip 251.
Within the scope of the invention, but can use the hardening resin of two kinds of general types to inculcate or flood any in the porous fibre reinforce of core and covering.Thermosetting resin for example polyester, vinyl esters, epoxy and phenolic aldehyde is the liquid resin of chemosetting by occurring during molding process or cross-linking process sclerosis.By previous crosslinked thermoplastic resin for example polyethylene, polypropylene, PET and PEEK by applying that heat is liquefied and underhardening again when they are cooling in panel inculcating before reinforce.
As a kind of of the porous reinforcing material that utilizes liquid resin to inculcate to assemble panel construction, substitute, reinforcing material can comprise fabric and the rove that has utilized partly solidified thermosetting resin pre-preg, and described resin is cured by applying heat subsequently.Similarly, strengthening rove and textile material can pre-preg have thermoplastic resin or mix with thermoplastic fibre, by applying heat and pressure, described thermoplastic fibre is fused together subsequently.
Further in scope of the present invention, by rigidity covering sheeting, for example steel, aluminium, glued board or fiberglass reinforced plastics are attached to the face of reinforced foam core.But this can be by utilizing curable or hardening resin dipping core reinforce and exerting pressure to the rigidity covering when the resin solidification, or by utilize binding agent the rigidity covering is attached to core before dipping and curing core strengthen structure and be implemented.
Figure 20-23 are illustrated in structure and comprise wound strips spirally and have improved two-way intensity and the step during fiber enhanced foam central layer of useful manufacture advantage.In Figure 20, the foam strips 178 be wound around spirally is joined together to form unidirectional enhancing central layer 260.As required, the band 178 that comprises the winding layer (Fig. 2) of rove 176 and 177 can, in conjunction with the plate 94 of the face that is basically parallel to central layer 260, as shown in Fig. 6 and 7, be resisted the flexing under load to stablize rove 176 and 177.Shown in Figure 23ly will comprise low density foam and be wound around strengthen spirally a kind of method for optimizing that a plurality of bands of rove connect together, wherein by applying heat and pressure, the glass fibre tulle 271 that is coated with hot-melt adhesive will be attached to the opposite face of central layer.The row of each fiber of tulle 271 or bonded dose of coating can be used to connect and be in all central layer embodiment of shown here and adjacent ribbons that form a plurality of bands or piece.
With reference to Figure 20 and 22, utilize rip or other device central layer 260 to be cut into to a plurality of first narrow fiber reinforced core panel 261 with desired thickness along the direction C of the length perpendicular to band 178.During cutting process, rove 176 and 177 cut end 262 are worn and owing to utilizing cutting process to remove froth bed, its surface from foam strips 170 are protruded.With reference to Figure 23, a plurality of first narrow central layer 261 is used bonding tulles 271 and is joined together, and with formation, has along the longitudinal and the two-way central layer 270 of the enhancing plate that laterally this both direction extends.But, when utilizing hardening resin to inculcate panel, strengthen the bonding connection that rove 176 and 177 protrusion end 262 contribute to be formed into relative panel covering (not shown).As required, can utilize single roving layer 176 to be wound around spirally each band 170 and adjacent roving layer 176 will still comprise the cross-level with balanced structural property.Similarly, described here and comprise that the simple layer of the rove that all central layers of adjacent ribbons all can be extended spirally is wound around.
As shown in Figure 13, by before being wound around on a side of foam strips 170 or many sides for wound strips 178 provides axial roving 180, can produce and there is the more core of high compression-strength.In final central layer 270, these axial rovings that can be applied to similarly central layer 290 and 300 vertically extend between the face of panel.An important advantage of two-way enhancing central layer 270 is, by simply panel 260 being sliced into to its width corresponding to the first narrow central layer 261 of desired plate thickness and foregoingly like that band being connected together, can produce rapidly two-way enhancing central layer 270 with any desired thickness from the unidirectional central layer 260 had in the past.
Can for central layer 270 provide as shown in Figure 24-26, to the structure basically be reinforced of panel covering, connect.This be a kind of winding layer that comprises foam strips 170 and rove 176 and 177, narrow central layer 261 (Figure 24), be provided with the roving layer 281 and 282 that overlays on spiral winding above layer 176 and 177, other, to form the second narrow central layer 280.Use bonding tulle 271 or other device that a plurality of panels 280 are connected together, to form the enhancing central layer 290 shown in Figure 26.The layer that is wound around rove 281 and 282 is formed on the continuous plate extended between the face of central layer 290, and roving layer 176 and 177 forms the discontinuous plate intersected with this continuous plate., when but hardening resin is introduced in battenboard, four all roving layers all are connected to battenboard covering 291.Figure 25 at length illustrates the fibroid core and strengthens the link area that widely increased of rove to the panel covering.Refer again to Figure 24, if the layer of rove 282 is omitted, 281 layers of rove on adjacent wound strips 280 will form the enhancing plate that wherein rove 281 passes through with opposite angles.
Figure 27 illustrates a kind of modification of two-way enhancing central layer 290, and wherein, before being joined together, the second narrow central layer 280 is by directional-rotation 90 degree from shown in Figure 26.In the structure of Figure 27, the densest roving layer be wound around on central layer 280 at each is arranged in core rather than contiguous covering.Definitely, the orientation that is wound around panel 280 is selected to produce central layer 290 or central layer 300 as the balance according to strengthening the strength and stiffness of expecting between plate and panel covering.
By being wound around spirally reinforcement, for example in Figure 23 and 26 signal those and the two-way central layer produced is to consist of a plurality of foam blocks that are linked to together.If utilization has the tissue fibres of lower tensile strength and makes the convex of panel integrated, perhaps by applying heat, to soften the binding agent that tulle is connected to panel, realize curvature, this hinged structures allows panel to conform to curved surface.With reference to Figure 23, after towards forming tool, panel-shaped being become to simple or composite curvature, have high-tensile bonding tulle 271 for example glass fibre can be applied to the opposite face of central layer 270.After the tulle binding agent has cured, can release pressure and central layer 270 its curvature of maintenance.This method is useful for production can be loaded into the preformed member in bending mould efficiently.Also can use in this way the bonding tulle to comprise the crooked preformed member of nonreinforcement foamed plastics with production.
The central layer that thin covering is for example used for the roof of trailer can core enough shear strength and rigidity are provided but impacting or the compressive load condition under for the underbraced of covering.Bad Diaphragm-braced can be due to as do not have a core reinforce overlayed on above the central layer face in Figure 23, or, owing to using the wider band that is wound around spirally foam that forms central layer, this causes the plate that supports covering to have wide interval.A kind of device that other Diaphragm-braced is provided shown in Figure 27, wherein, comprise that the two-way central layer 300 of a plurality of narrow central layers 280 has been provided with rigidity diaphragm braced member 301.In a preferred embodiment, supporting member 301 is included in and utilizes enhancing rove 281 and 282 to be wound around spirally the fibroid rove that panel 261 is inserted in the slit formed in the narrow central layer 261 shown in Figure 22 to form the narrow central layer 280 shown in Figure 24 before, for example glass fibre.Supporting member 301 has been described the square-section of basic crossbeam shape and has strengthened at them and core each some place that plate 302 intersects in turn supported, and described core enhancing plate 302 comprises the rove 176 shown in Figure 22 and 177 winding layer.Refer again to Figure 27, the compression or the shock loading that are applied to panel covering 291 are transferred to and are strengthened plate 302 by diaphragm braced member 301, prevent from thus damaging covering 291.
Figure 28-30 illustrates an alternative embodiment of the invention, and wherein fiber reinforcement band 310 is provided with along a side or both sides and the axially extended enhancing rove 311 below one or more spiral winding layer of rove 176 and 177 in the bight of foam strips 170.This structure is shown enlargedly in Figure 29.When a plurality of enhancing bands 310 are joined together to form enhancing central layer 320 as shown in Figure 30 as described in the preceding like that, by pass through adjacent paired enhancing plate that the spiral winding rove forms and bight axial roving 311 mutually cooperation there are the top of being separated by shaft-like shear component and a plurality of structure bar joists of bottom cord in fact to form.This structure provides the strength of connection of good impact strength and reinforcement between plate reinforce and panel covering, and allows to use covering reinforce still less.As required, for example in the structure of the two-way central layer shown in Figure 24-26, also can add axial corner rovings 311.
Other axial roving has the reinforcement of spiral winding any one or all surfaces of foam strips 170 of any form of the present invention with covering can be set below being wound around rove., after but the utilization hardening resin is molded, single enhancing band 310 (Figure 28) can be used as discrete structural elements, for example pillar or box beam.By providing as the horizontal reinforcement as shown in Figure 17 and 24 and by providing other axial roving to cover all foam surfaces be exposed, can further strengthen the performance of this structural elements.By before being wound on band by roving layer, end at band, perhaps in other desired zone of band, around foam strips 170 coat spirally reinforcing material for example the layer of glass fibre or carbon fibre fabric so that the intensity of reinforcement to be provided in the structure connecting area, can further strengthen pillar.
Can utilize a kind of continuous processing to produce economically molded column structure member, in this continuous process, the output of the fiber enhanced foam of spiral winding equipment directly and continuously is fed into molding equipment, for example, for applying and the resin injection extruding equipment (not shown) of cured thermoset resin.Similarly, by being advanced past continuously a kind of equipment (not shown) that the fiber enhanced foam structure is one after the other carried out to heating and cooling, with the thermoplastic filaments of being manufactured by Saint-Gobain Vetrotex, the fibre glass roving of the spiral winding that for example " Twintex " rove mixes can mixed and sclerosis.Within the scope of the invention, also provide a kind of continuous processing, in this technique, the fibre-reinforced products of spiral winding equipment is cut to have the parts of predetermined length and described parts with formation and is sent to for applying subsequently and the mould of hardening resin.
Figure 31 signal comprises that the unidirectional fibre of a plurality of spiral winding bands 331 of integral type strengthens central layer 330, in band 331, between the core enhancing plate of spiral winding, for the panel covering, provides support.At least two foam strips 170 are provided with facing 332 on a side or both sides, facing 332 can comprise the rigidity stripping or can comprise the porous fibre material, fiberglass blankets for example, during molded central layer, resin flows is in facing 332 and sclerosis.In a kind of economic especially embodiment, from the low-cost plastic foam insulation board cutting foam strips 170 of producing a kind of continuous processing, in this technique, foam is introduced between the continuous slice of fiberglass blankets 332.Paired adjacent pad 332 strengthens between plate and provides sizable support for the panel covering at the core that comprises the spiral winding rove.Contiguous those fragments that are wound around rove of fiberglass blankets cooperate with each other to form the enhancing plate 333 structurally be reinforced, and strengthen plate 333 and consist of layer glass fibre gasket 332 and four layers of winding rove 176 and 177.This structure provides and only by the plate of spiral winding, is compared the fortifying fibre that quantity increases, simultaneously because higher total sheet has improved for the resistance in load lower sheet space flexing.The instead of glass fibre gasket, thus band 332 can be used to protect various other materials of foam strips 170 to comprise for example aluminium foil during can being included in the radiations heat energy that applies the thermoplastic component that is applied to band 331 fusing rove 176 and 177.
The enhancing central layer of a kind of form that Figure 32 signal can be produced with the quantity greatly increased from given rove Wiring apparatus.Strengthen the alternately band that central layer 340 comprises rove winding plastic foam 178 and simple plastic foam band 170.By being increased on band 178 weight of the enhancing rove be wound around, can realize roughly being equal to those structural property of the even band central layer 260 shown in Figure 20 in the alternately band central layer shown in Figure 32.
The method of spiral winding foam strips allows to produce has the battenboard of its structural property along the core of core length change.By when them, be wound onto subsequently will by integrated with the foam strips that becomes central layer on the time change in a controlled manner interval and the angle of rove, this structure is achieved.Figure 33 illustrates the spiral winding rove 176 that comprises foam strips 170 and interval and 177 wound strips 350.With reference to Figure 12, under the given speed of rotation of winding head 172 and 173, by changing in order to advance band to pass through the speed of winding head 172 and 173, on foam strips 170, the angle of rove and interval are controlled.The bar belt conveyer CD-ROM drive motor be programmed by use, can control this relation nearly.For example, when the band feed speed reduces, be wound around the angle reduction that interval reduces and rove passes through the axis of band of rove.Winding head 172 and 173 mutual intervals preferably can be conditioned with band 350 length corresponding to desired.The band 350 that is wound shown in Figure 33 illustrates a kind of foam strips, and wherein, with respect to the face of band 350, the density of rove and angle steepness are the highest in the end of band, thereby the compressive strength that reinforcement is provided is to bear the concentrfated load on the panel support part.In order to improve two-way intensity, the enhancing band 310 shown in the enhancing band 261 shown in Figure 22 or Figure 28 can be used to substitute the non-reinforced foam band 170 shown in Figure 33.
Figure 33 also is shown in the composite panel with non-homogeneous core thickness a kind of device that improved covering intensity is provided.In the structure battenboard, usually make end, edge (closeout) the part convergent of panel or progressively be reduced to less thickness, and sometimes needing varied in thickness in panel inside.When the fiber that forms the panel covering departs from plane surface, the stretching in covering or compression stress can cause the inefficacy of covering reinforce and covering from the layering of panel core.On the opposite face of the band 350 that will form the face that strengthens central layer, the spiral winding band 350 shown in Figure 33 has been provided with the layer of axial roving 180, as in conjunction with Figure 12 and 13 described.As described ground in conjunction with Figure 14, the axial layer of rove 180 provides the function of the covering fiber extended along the direction of band, and utilizes roving layer 176 and 177 to be wound around spirally on axial roving.Under the bending stress condition, axial roving 180 or the trend that lost efficacy near core thickness transitional region 351 places reduce, this is because the outside movement of spiral winding roving layer constraint axial roving.By as described in front for band 350 provides horizontal reinforce, to prevent the inside flexing of roving layer 180, can further strengthen the stability of axial roving.
In comprising unidirectional central layer low density foam, spiral winding, by reducing the flexibility of plate, can basically improve thinner enhancing plate in the thicker panel resistance for the flexing under compression or shear-type load.Figure 34 illustrates the central layer 360 that comprises fiber enhanced foam band 178 and plate spacer tape 361, and the function of spacer tape 361 is to cooperate with each other to form composite strengthening plate 362 with roving layer 176 and 177.Spacer tape 361 can comprise that foamed plastics, the porous mat with compressive strength higher than foam strips 170 or other material with abundant intensity are so that composite strengthening plate 362 is used as the structure plate of the thickness with increase.The distance piece of composite board sheet 362 and the utilization of rove parts are for the resin of inculcating battenboard together with structurally being incorporated into.Spacer tape 361 is present in the quality of the resin between foam strips 170 for separation and reduces thus usually during solidification process the contraction that the resin in the part quality causes.Increased the flatness of molded panel covering along this contraction be reduced that strengthens plate, this has improved outward appearance and can allow to use lighter covering reinforce.
For for example for the casing of jet engine or for the use of the application of the structural support of the plate armour that is designed to prevent that projectile from penetrating, verified, it is effective that the battenboard that comprises the spiral winding band keeps aspect suitable structural intergrity after high-energy trajectory impacts.Figure 35 signal can be used as the jet engine casing, cylindricality of the present invention or annular embodiment, wherein by the joint of eliminating between the end of spiral winding foam strips, optimized the structural continuity in core character, thereby each the spiral winding rove in whole panel all is not interrupted.By with helical pattern, around cylindricality or non-cylindrical mandrel, coating continuously band 371 and from single spiral winding foam strips 371 production cylindricalitys or annular core plate 370.
The wound strips 371 that comprises plastic foam band 170 and spiral winding roving layer 176 and 177 can have the cross sectional shape except rectangle, thus triangle for example as shown in Figure 19 or trapezoidal and wherein the enhancing plate in core provided lateral shear intensity to core by the angle with contrary is directed.Can also provide lateral shear intensity by inner transverse reinforce as shown in Figure 24 for example is provided for wound strips 371.As required, can preferably with intersecting angle, on central layer 370, be wound around spirally the second continuous strip 371 to realize higher intensity.Can also be as shown in Figure 13 by the hoop intensity and the impact resistance that provide axial roving 180 to strengthen central layer 370 below being wound around rove 176 and 177.As before in conjunction with as described in Figure 14 and 15, can be by with intersecting angle or sew up the fibroid reinforce perpendicular to panel covering ground and increase the trajectory impact resistance of the battenboard with spiral winding core reinforce and structural skin reinforce by panel covering and core.By forming bands 371 and the covering that utilizes the filament winding process to apply is provided around all of container, the continuous enhancing band 371 of one deck or multilayer also can be used to form cylindricality or box columnar structure and be intended to the closed container of prevent exploding.
Can operating weight the lower or fortifying fibre of fragility relatively, for example carbon crude fibre (carbon tow) is wound around continuous strip 371, thereby allow ballistic body for example the jet engine fan blade can seriously not damage shape or the structural intergrity of panel through cylindrical outer cover, and for example by the non-resin dipping aramid fibre fabric that coats around Kevlar and catch and penetrate object in the outside of shell for example.Alternately, panel can be designed to contain impacted object and still keeps the panel integrality simultaneously.In this structure, may expect to adopt for example aramid fibre or will become elongated under impacting and stop the steel penetrated of fiber as core, covering and the reinforce sewed up by panel.By the resin film barrier 41 that adopts as describe in conjunction with Fig. 1, can during molded, keep the special layer of the reinforce of these withstand shock to be substantially free of resin, to optimize ballistic impact properties.
Figure 36 illustrates one embodiment of the present of invention, wherein hollow tube be used to substitute foam strips with produce can for air distribution or water or especially when be provided with there is high thermal conductivity fortifying fibre for example during carbon as the uninsulated structure battenboard of efficient heat exchanger.Strengthen central layer 380 comprise can there is rectangle, triangle or other cross sectional shape, and utilize and strengthen roving layer 176 and 177 and by a plurality of light-wall pipes 381 of spiral winding.Pipe 381 can be mainly as the axle of winding arrangement rove thereon and therefore can comprise the structurally weak material paper of for example putting more energy into.Alternately, manage 381 and can comprise the material with important structure character, for example roll extrusion or extrusion plastic or aluminium, described material preferably is wound around enhancement layer and to the structure combination with after-applied panel covering by surface treatment to be implemented to.
During molding process, manage wall 381, that comprise thin flexible material and can be provided with convex curvature to bear pressure.Can also bear molding pressure by the end of sealed tube 381 during producing the process of central layer 380 or during molding process.Contain air or other gas and comprise plastic film or thoroughly the flexible pipe other material, sealed spiral winding that have circular cross-section of resin can be by integrated not form central layer 380 and can exert pressure and make it comply with the cross section of basic rectangle to the central layer face by using Rigid Plates Under Compression during molding process.Sealed to prevent that the central layer 380 that resin is invaded can be combined with the covering reinforce and use liquid resin molded.When rove 176 and 177 comprises partly solidified pre-preg thermosetting resin or thermal softening thermoplastic resin, can be by applying the molded central layer 380 of heat, and without the end of sealed tube 381.
Figure 37 and 38 illustrates an embodiment who strengthens central layer, wherein between the face of central layer and above extend, spiral winding core reinforce also extends on the edge at central layer.This structure provide structural loads in central layer to adjacent central layer and to the good transfer at the edge of battenboard and illustrate in Figure 37.The foam strips axial corner rovings 311, that be spaced 170 be provided preferably with as described in conjunction with Figure 28-30 is passed as the spiral winding equipment in front description to form continuous enhancing band 390.Band 390 comprises a plurality of along axially spaced, spiral winding foam strips 178, band 178 can be provided with as at front description, horizontal reinforcement that be spaced, and interconnected by roving layer 176 and 177, and utilization extends axially rove 311 and support roving layer between band 178, to form hollow, be wound around fragment 391.Be wound around roving layer and keep complete on the space between foam strips.
In the second step shown in Figure 38, wound strips 178 by front and back fold, thereby band in succession is adjacent one another are form to strengthen central layer 400.Comprise that hollow is wound around the end folding that the enhancing rove of fragment 391 is folded and pass through band 178, thereby link transfer organization load between inner central layer reinforce and external core panel edges with the good bonding that provides strap ends to arrive the adjacent panels parts.By at them, be moved or folded with apply continuous bonding tulle to the band fragment 178 be connected after adjacent ribbons contacts, can strengthen central layer 400 with continuous produced in lengths.In its conitnuous forms, central layer 400 is applicable to for example pultrusion of continuous molding process be associated with the rove spiral winding equipment well.
In another embodiment of the present invention, by strengthening rove, be wound into spirally on the foam strips with meander-shaped, can provide two-way intensity for the fiber enhanced foam central layer.Figure 39 signal comprises the enhancing central layer 410 of spiral winding foam strips 411, and each band 411 all has tortuous structure and is shown to have battenboard covering reinforce 291.Comprise that tortuous plate 412 that spiral winding strengthens the cross-level of rove 176 and 177 provides along the longitudinal for central layer 410 and the horizontal shear strength of this both direction, and utilize plate 412 and the angular deviation of straight line to determine along the ratio of the intensity of each direction.Foam strips 170 can have parallel edge with complications structures to substitute shown in Figure 39, symmetrical non-parallel edge, and can use a plurality of rip water jets or heat or abrasion wire and cut from cystosepiment or can apply heat by the linear foam strips to thermoformable and be formed.Can be by changing the winding angle that is controlled at the winding rove on the band with non-parallel edge by the band feeding of the Wiring apparatus as in front description.
Can be by basically increase the impact resistance of the battenboard comprise the fiber reinforcement core that utilizes the thermosetting resin dipping in the exterior section at the battenboard covering in conjunction with the thermoplastic resin with good shock feature, rather than allow the thermosetting resin of fragility more to extend to the outer surface of panel.Figure 40 signal comprises that a height of the composite laminboard 420 of the fiber reinforcement core 260 of spiral winding and panel covering 421 and 422 amplifies cross section.Foam strips 170 has been provided with the resin distribution groove 223 that is described in front groove 39 in conjunction with Figure 13 and 14.Panel covering 421 comprises that following fibroid strengthens liner or fabric, that is, its exterior section 423 is impregnated with for example polyacrylic thermoplastic resin, and its outer surface from covering 421 extends and pass through partly covering thickness.
Can be by providing this thermoplastic resin utilizing thermosetting resin to apply thermoplastic film to a side of fibroid covering 421 before inculcating panel 420 under heat and pressure.As required, the tissue layer for example consisted of from " Twintex " fabric of Saint-Gobain Vetrotex combined fiberglass and thermoplastic fibre can be for substituting thermoplastic film.Mixed goods is heated to form the thermoplasticity outer surface of enhancing and makes thermoplastic resin partly flow through the thickness of enhancing fabric below.Also can be by applying not by heating merged " Twintex " covering fabric 422 to strengthen central layer 260, and utilize thermosetting resin to inculcate all cores and covering reinforce and realize the impact resistance of strengthening.The thermoplastic filaments that forms covering 422 is given the impact resistance of the covering reinforcement of having been inculcated, and this covering can be heated with the melting heat Plasitc fibers after inculcating.
There is low density porous core for example in foamed plastics, a kind of method for optimizing spiral winding fiber-reinforced composite panel in production, central layer is provided with the fibroid reinforce that separately applied and hardening heat plastic material, but not mixed filament roving " Twintex " fabric for example.With reference to Figure 20, by in Continuous Extrusion Process, to band, applying the resin that is heated and liquefies, before the enhancing rove 176 and 177 coated spirally on band, resin is cooled and solidifies after this, and foam strips 170 can be by for example polyacrylic layer of the thermoplastic resin around being provided with.The band 178 be wrapped by can be joined together, and thermoplastic resin is by applying heat and pressure floods fortifying fibre, and comprises that the covering of fibroid reinforce and thermoplastic resin can be attached to central layer similarly.Substitute and to extrude, can be close to roving layer 176 and 177 and the band of thermoplastic is set between foam strips 170.
In another method, utilize each by a plurality of enhancing rove roving layer 176 and 177 that for example glass fibre and thermoplasticity rove form, to be wound around spirally foam strips 170.In all these methods that apply dividually fibroid enhancing and thermoplastic component to foam strips, with comparing that the rove by use mixing filament is realized, usually so incomplete to the dipping of fortifying fibre by applying heat and pressure subsequently.The advantage of this method is, the low-down material of use cost, comprise the recovery thermoplastic in process of production.Should be appreciated that, in all fiber reinforced panel that are to describe in the present invention, various flexible materials, comprise and the monfil of metal and high-tensile plastics can be used as reinforce, to substitute the fibroid rove that comprises a plurality of filaments.
As described in front, resin strengthens element in the differential pressure current downflow by all inside cores and floods inner core and strengthens embodiments of the invention in the process of element and be applicable to use liquid heat solidity moulded resin therein.These embodiment illustrate and comprise that in central layer porous strengthens element in Fig. 1-40.Battenboard industry mainly adopts differential pressure wherein not to be utilized or to be not enough to cause the process of the moistening core reinforce of resin.Along with the thickness increase of battenboard core, the shortage differential pressure has seriously limited moulded resin can permeate and flow through for example degree of fibre glass roving of the interior whole core reinforcements of core.Resin infiltration and sclerosis are necessary for the structural property of realizing fiber reinforcement core and battenboard.
Several embodiment described here makes the present invention be suitable for not adopting in the battenboard manufacture process of differential pressure.This process comprises the open type molding, open flume type pultrusion and the rigidity covering that for example the utilize liquid resin bonding lamination to the panel core.In being applicable to the embodiment of these processes, during producing central layer, the impregnated and sclerosis of those parts that are positioned at the battenboard core of reinforcement, and those parts maintenances of the face of the contiguous central layer of reinforcement are porous.Desired cored structure character has been guaranteed in the sclerosis of inner reinforcement, and the strong especially structure that the porosity of those parts of the contiguous central layer face of reinforcement makes core be suitable for the battenboard covering links, and uses subsequently binding resin that the battenboard covering is attached to core.
Also can the molding process that adopts differential pressure for example resin advantageously use the central layer of sclerosis plate in inculcating, inject pultrusion and resin transfer moulding.In these heat release resin curing process, by reducing or eliminate the quantity of the uncured resin in plate, the resin temperature in core is considerably reduced, and has therefore reduced the possibility of foam damage or generation escaping gas.Come in handy, bore a hole to allow the covering moulded resin to flow to another face from a face of central layer the central layer of sclerosis plate.Alternately, the plate of central layer can only partly be flooded and be hardened, thereby in the plate reinforce, keeps certain residual porosity to flow during molding process with the permission resin.
Figure 41 signal comprises the structure composite battenboard 430 that strengthens central layer 431 and wall panel covering 432, that can be used as refrigerated trailer or recreational vehicle.Central layer 431 comprises a plurality of spiral winding bands 178 that construct as described in conjunction with Figure 12-14 substantially, plastic foam or other low density porous material.But not shownly in Figure 41 can provide axial roving layer 180 as required.As required, be wound around foam strips 178 and can save the second roving layer 177, and as required, can also be provided with enhancing liner 332 as shown in Figure 31, that linked in advance or be provided with the horizontal reinforcement 222 as described in conjunction with Figure 16.
Refer again to Figure 41, merging a plurality of bands 178 with before forming central layer 431, sclerosis binding resin 433 for example polyester or polyurethane is applied to porous and is wound around those parts roving layer 176 and 177, that form the enhancing plate of central layer 431.Resin 433 is coated to two relative plate faces of each foam strips with the quantity that is enough to the porous fibre that moistening adjacent panels is unilateral when band 178 is joined together, or it is coated to an only face.As required, by restriction, the quantity of coated resin, can keep certain porosity.Can before coated with resins, when applying heat with its contact of box lunch heated reinforce, roving layer pass through to reduce resin viscosity and moistening fortifying fibre.The temperature raise has also been accelerated the resin solidification speed after coated with resins.When resin 433 hardens to form composite strengthening plate 434, by stacking, pushing toward each other adjacent band, plate band 178 is connected together.Alternately, the plate of each band 178 part can be hardened, and can be as described in front, used bonding tulle or other jockey to form central layer 431 to merge the stacking of band 178.
In the embodiment shown in Figure 41, keep for example distance of 1/8th inches, the face in the distance central layer of plate hardening resins 433 from those parts of the face of central layer plate next-door neighbour central layer or opposite flank, thereby allow covering to link the resin wicking or flow in the exterior section of plate reinforce to improve plate 434 to link to the structure of covering 432.Should be appreciated that, as required, hardening resin 433 can extend to opposite flank or the face of central layer fully, or resin can partially or fully pass through the further extension of face ground of central layer.
Figure 51 illustrates central layer 500, and wherein plate hardening resin 433 passes through the surface be exposed of adjacent fiber wound strips 178 or the part of face laterally extends to form a series of structure I-beam 501.This embodiment is useful for increasing that the binding agent wherein have lower structural property is used to covering is attached to for the strength and stiffness of battenboard of central layer.The part of the winding fiber 502 that the face that the winding fiber between resin 433 dipping adjacent ribbons 178 and dipping pass through central layer 500 extends, and resin 433 hardens to form structure I-beam 501.Use the infiltration porous to be wound around pars fibrosa 502 and to the binding agent 435 of core combination, covering 432 is attached to central layer 500 to form strong covering, the I-beam 501 that hardened of while provides slab strength and the rigidity of reinforcement.
If the opposite flank of central layer 431 or face are fully flooded and harden by resin 433, central layer 431 becomes the rigidity battenboard.Can be by as described in conjunction with Figure 13 and 14, for wound strips 178 provides longitudinal fiber rove 180, strengthened the structural property of this gained battenboard and the structural property of the I-beam as shown in Figure 51 501.Can be by applicator roll, extrude, injection or mobile units, resin film or otherwise apply plate hardening resin 433.Resin can be that heat cured for example polyester, epoxy or polyurethane or it can be thermoplastic for example polypropylene, PET or nylon.Can, by applying high catalyst level, heat, ultraviolet radiation or otherwise accelerating the hardening rate of thermosetting resin, thereby increase wound strips 178, mutually link to form the speed of central layer 431.
Can be by the rove of " Twintex " that comprise that mixed structure and thermoplastic filaments are for example manufactured by Saint-GobainVetrotex be provided, the thermoplastic resin that perhaps utilizes as manufactured by Hexcel Corporation carries out the structure rove that surface applies, and during winding process, thermoplastic resin is attached in roving layer 176 and 177.Divide and apply sufficient heat with after the melting heat plastic substrate, that band is pinched together and will comprise that the band 178 of thermoplastic resin interconnects by the sheet part to band.Alternately, can be close to winding layer 176 and 177 provides for example carbon fiber of conductive fiber, and electric current can flow through conductive fiber with the melting heat plastic substrate.As required, layer 176 and 177 can comprise that sclerotic fiber strengthens the thermoplasticity adhesive tape, and " Zenicon " for example manufactured by Crane Composites, to substitute the Twintex rove.Can by with provide sufficient heat to soften adhesive tape, the thermoplasticity adhesive tape to be wound on foam strips 170 before band 170 contacts.As described in about Twintex, the band be wound around by adhesive tape is joined together.Within the scope of the invention, also can make layer 176 and 177 comprise the high-tensile polymer fiber, for example the Curv of the MFT of Milliken and Propex.
Final central layer 431 (Figure 41) is moved to molded or lamination process, wherein uses binding resin 435 as described in front, battenboard covering 432 is attached to central layer.For the resin 435 that links covering can but and nonessentially there is the type identical with resin 433 for the plate 434 that hardens.Resin 433 can for example comprise catalyzed mylar, and resin 435 can comprise the moisture-curing Polyurethane resins, or a kind of resin can be thermoplastic and another kind of be heat cured.Covering links the moistening opposite flank that comprises central layer 431 of resin 435 or face and can comprise marginal portion, the porous part that be wound around roving layer 176 and 177 of the plate adjacent with the central layer face, thereby provides strong covering to link to cored structure.
If all parts of dipping and sclerosis roving layer 176 and 177, apply for the binding resin in conjunction with covering similarly as described in front.Battenboard covering 432 can be the porous fibre before linking resin 435, glass fabric for example, or they can be rigidity, for example aluminium or fiberglass reinforced plastics thin slice.Covering link resin can utilize any coating procedure easily to apply and and do not require for flowing into the differential pressure of plate 434, this be because as described in front, plate is hardened.When central layer 431 comprises the roving layer in conjunction with thermoplastic matrix, the thermoplastic matrix that can expose roving layer with liquefaction by heating core face links covering.
Be included in for example covering 432 of ornamental glued board or thin painting non-ferrous metal of sheeting commonly used in building industry by combination, battenboard 430 can be used as constructing panel or building wall.Binding resin 435 also can be used to adhere to the independent clad material of multi-disc, for example goes up vitreous brick or stone.In a kind of useful modification of the panel shown in Figure 41, resin bed 435 can comprise for example fiber reinforced polymeric plaster of Boswellia carterii smectic material, or other sclerosis wall finishing material.In this embodiment, the material of constituting layer 435 before sclerosis permeable fiber roving layer 176 and 177 permanent structures with the face that is formed into central layer 431 in conjunction with and mutually cooperate to bear with sclerosis plate 434 structural loads that are applied to building panels.As required, as front in conjunction with as described in Figure 36, hollow tube can be used to substitute foam strips 170, and can utilize dense material, for example sand or concrete filled tube, can be used as battenboard 430 soil conservation wall or road noise barrier, shown in Figure 41 to provide.
Sclerosis plate with porous part of contiguous panel covering also can be located at core reinforcement wherein and comprise that smooth fibroid reinforcing material plate is for example in the central layer of glass fabric or liner.Figure 42 illustrates as at the front enhancing central layer 440 in conjunction with comprising a plurality of foam strips 33 with the porous fibre plate 34 be bonded as described in Fig. 1.The step of the fibroid pillar 35 provided shown in Fig. 1 has been provided.Refer again to Figure 42, hardening resin 433 is applied to porous plate 34, and as in conjunction with as described in Figure 41, with a plurality of foam strips 33 of the plate 34 be bonded, be joined together.Can be from plate 34 and opposite flank central layer 440 or the adjacent marginal portion of face do not apply the plate hardening resin 433 shown in Figure 42, thereby as in conjunction with Figure 41, describe, will be penetrated into plate so that improved structure combination to be provided for the binding resin that covering is attached to central layer.As required, plate 434 can comprise Twintex combined fiberglass and thermoplastic fabric, and can be by applying heat and the pressure plate that hardens, thereby remains on for using liquid resin to be attached to the porosity of the plate marginal portion of covering.
Embodiment signal shown in Figure 43 has the battenboard 450 of the enhancing core band be spaced.Have sclerosis plate part 451 and porous area part 452, a plurality of foam strips that are wound around by rove 178 are by the array to separate or relation assembling and use binding resin 435 to adopt the lamination processes to be linked to relative stiffness panel covering 453.This embodiment basically reduced required plastic foam volume and and do not require heat-insulating structure battenboard in be useful.If need for the heat insulation of panel covering or support continuously, can as in conjunction with Figure 32 describe, in general terms, the alternately band of simple foam and the winding foam with sclerosis plate 451 be connected together.As required, the embodiment of the present invention shown in Figure 41 and 43 can be in conjunction with hollow tube 381 as shown in Figure 36, to substitute foam strips 33.In alternate embodiments, more highdensity material for example dimension stock can be used to substitute foam strips 170 to realize improved structural property.
Figure 44-47 are illustrated in structure and comprise wound strips and hardening structure plate spirally and have the step in the enhancing central layer of improved two-way intensity.Shown in Figure 44 and central layer 431 that have the sclerosis plate 434 as described in conjunction with Figure 41 is cut into a plurality of first narrow fiber reinforced core panel 462 with desired thickness by the direction of the length along perpendicular to band 178.With reference to Figure 46, utilize intersection roving layer 281 and 282 to be wound around spirally the first central layer 462 to form the second enhancing band 464.With reference to Figure 47, hardening resin 433 is applied to the adjacent surface of a plurality of the second enhancing bands 464.The moistening roving layer at length illustrated in Figure 46 177,178,281 of resin 433 and 282 is to form the sclerosis plate 465 shown in Figure 47, and band 464 is extruded to together and be connected when resin 433 sclerosis, with formation have the sclerosis plate 465 that longitudinally extends and laterally extension, with the enhancing central layer 460 of the sclerosis plate 434 shown in phantom.As described in conjunction with Figure 41, the battenboard covering can be applied to central layer 460.With reference to Figure 45, also can apply hardening resin 433 and will be wound around edge when the resin solidification by the winding rove to narrow central layer 462 pinched together, there is the central layer with similar system shown in Figure 23 with formation, thereby produce two-way central layer.
The favourable scheme of the continuous battenboard that comprises the foam strips with spiral winding reinforce layer is roughly illustrated to produce in Figure 48-50.In the panel molding equipment 470 shown in Figure 48, utilize normally used pulling equipment (not shown) in pultrusion technique to move a plurality of foam strips 471 with continuous length of porous enhancing roving layer to comprise resin pool or resin injection module 474 and heated mould 475 extruding equipment 473 from rolling up 472.During the process of wound strips 177 as shown in Figure 12, continuous winding band 471 is brought on volume 472, saves the step that band 177 is cut into to certain-length.As required, can provide single continuous strip 471 to substitute a plurality of bands shown in Figure 48, and as required, can side by side from a plurality of volumes 472, band 471 be drawn in extruding equipment 473.
Band 471 can be provided with horizontal reinforcement, axially reinforce or previous other improvement described here.When band 471 is advanced by equipment 470, skin material 476 for example glass fabric is applied to the surface of band 471, covering and core reinforce in resin module 474 by moistening, resin hardens and has with formation the enhancing battenboard 477 that strengthens core 478 in heated mould 475, and battenboard is cut into desired length (not shown).Continuous strip 471 provides the enhancement layer 176,177 and 180 of non-interruption in battenboard core 478, and, with to cut wherein battenboard 477 irrelevant, therefore produces the panel that has uniform strength on its whole length.
As here as described in front, spiral winding form of the present invention is applicable to the continuous process production of molded composite panel well.Figure 49 illustrates a kind of method of producing the economy of continuous battenboard, described battenboard can be used as trailer walls or building wall and have the core comprised transverse to the fiber enhanced foam band 178 of panel length.At traditional continuous surface plate producing process for example in pultrusion, in conjunction with horizontal reinforcement, be difficulty especially efficiently.Panel production equipment 480 comprises that Wiring apparatus 171 (Figure 12), wound strips advance device 482 and molded module 483.Wiring apparatus 171 producd fibers of describing in conjunction with Figure 12 are wound around foam strips 178, and as shown in Figure 49, Filament-wound Machine foam strips 178 is pushed into device 482 and one after the other is advanced in resin module 483 and passes through resin module 483.Can or advance band 178 with respect to the band direction of propulsion perpendicular to the length (Figure 49) of band with acutangulating.
Wound strips can be in conjunction with previous feature described here, for example, and the horizontal reinforcement in band.As required, be wound around foam strips 178 can as described in conjunction with Figure 48 by from rolling up 472 feedings, and be cut into desired length before in being advanced to resin module 483.Before entering molded module, it is the stacking porous skin material 484 that provides of band 178.Porous rove in the moistening porous skin 484 of resin and foam strips 178, and solidify to form continuous battenboard 485 in molded module 483.In an economic especially embodiment of the present invention, wound strips 178 is provided with axial roving layer 180, and is used for substituting covering 484 from a plurality of enhancing rove of volume supply, thereby eliminates the cost that braiding strengthens fabric.
Molded module 483 can be a kind of extruding equipment as described in conjunction with Figure 48, as a kind of extrusion equipment of describing in connection with Figure 50, or in industry known other molded device.An important advantage of this method is, can be directly from the output that is wound around machine or the panel that alternately from the production of monovolume continuous fiber reinforced foam band, has any desired width.As shown in Figure 31, as required, the foam strips 178 that is wound with rove can comprise the plate 332 of putting more energy in advance of of contiguous foam strips or relative face.In this structure, plate 332 provides sizable compression and shear strength to core, and can omit as required and utilize for linking the moulded resin infiltration roving layer 176 and 177 of covering 484.
Figure 50 illustrates to produce the method for a kind of economy of continuous battenboard, and this continuous battenboard can be used as having high strength, low material usage and low weight, and in conjunction with structure solid wood, plate or the pillar of plastic resin extrusion.Panel production equipment 490 comprises Wiring apparatus 171 ' and 173 ' and extrude module 491.The Wiring apparatus 171 of describing in conjunction with Figure 12 ' and 173 ' produce the continuous fiber be pushed into as shown in Figure 50 by extruding module 491 to be wound around foam strips 178.In module 491, for example PVC or polyethylene are with moistening fibroid enhancement layer 180,176 and 177 to apply heated liquid thermoplastic resin, and resin is cooled and hardens to form continuous battenboard 492.The plastic foam component that band 178 comprises the temperature that can bear heated extrusion resin is polyisocyanurate or phenolic aldehyde for example.
As required, as described ground in conjunction with Figure 31, Filament-wound Machine foam strips 178 can comprise that fibroid liner reinforce 332 is so that the compressive strength of reinforcement to be provided to battenboard 492, and, as in conjunction with Figure 48 and 49, described ground, other skin material can be provided for battenboard 492.As required, as described ground in conjunction with Figure 48, can be from volume supply reinforced foam core.And, as required, extrusion resin can comprise that for example the cellulose wood chip is for example to produce surface nature useful in deck for filler material, and in this case, extrusion can comprise fully moistening with the fibroid reinforce that guarantees battenboard 492 of the first non-potting resin stage.And, as usually putting into practice in extruding technology, panel 492 can be provided with embossed surface or be provided with other extrusion resin superficial layer to bear ultraviolet radiation.According to the concrete material and the character that need, as can being used to substitute, the pultrusion module 473 of describing in conjunction with Figure 48 extrudes module 491 as shown in Figure 50 in battenboard 492.As can being used to substitute, the Filament-wound Machine hollow tube of describing in conjunction with Figure 36 is wound around foam strips 178, as long as hollow tube is enough firm in to bear the pressure of extrusion.
Here disclosed any fiber reinforced core panel all can be used to produce the molded composite panel of structure with the thickness that surpasses independent central layer.Can be in mould stacking two or multicore plate more, the fabric reinforcement that makes adjacent central layer face mutually or with separate central layer, for example layer contact of glass fabric of reinforcing material.As required, for example, by along intersecting the two-layer central layer shown in oriented stack Figure 18, can be to intersect the fibroid reinforce of the adjacent central layer of purposive prearrangement to realize special structural property.Wound strips 178 shown in Figure 32, can be provided with as the horizontal reinforcement in front description, and there are two of described horizontal reinforcement or more multicore plate 340 can be with arranged crosswise and stacking the second central layer that has the two-way intensity of reinforcement with formation of band 178.As required, can utilize enhancing liner or fabric to separate the central layer 340 be stacked.
For clear and purpose relatively, here central layer has been shown to have rectangular shape and has had the fibroid reinforce that is basically parallel to the central layer edge in groups.If need at structural considerations, can become with central layer direction or edge the directed described reinforce in groups in any desired angle ground.For example, with reference to Figure 18, laterally reinforced foam band 233 can be with the angle of 45 degree and the intersect edge of rectangle central layer 240.
Although the form of reinforced foam core described here and central layer and their building method step form the preferred embodiments of the present invention, should be appreciated that and the invention is not restricted to these accurate forms and method step and can make therein and change and do not depart from scope and spirit of the present invention.
Claims (27)
1. a method of producing composite panel comprises the following steps:
Form the continuous elongated band of low density porous material, described band has along this band length continuously and spirally around at least one deck fibroid rove of described continuous elongated band,
Described continuous elongated band is cut into to the some bands with predetermined length,
Advance described some bands one after the other by molding equipment, adjacent ribbons is separated by the layer of described fibroid rove, thereby forms continuous central layer, and described central layer has the layer of the described fibroid rove extended between the opposite flank of described central layer,
But provide hardening resin in the layer of the described fibroid rove between described some bands,
The described resin of sclerosis and connect described some bands to form continuous composite panel with bonding mode in described molding equipment, and
Described continuous composite panel is cut into to predetermined length,
Wherein said resin passes through the part on the surface be exposed of adjacent ribbons and laterally extends to form a series of structure I-beam, the part of the fibroid rove that the face that the fibroid rove between described resin-dipping adjacent ribbons and dipping pass through central layer extends, and described hardening of resin is to form described structure I-beam.
2. method according to claim 1, be included in the step of the horizontal reinforcement that in described elongated band, formation separates along the longitudinal.
3. method according to claim 1, be included in the step that described hardening of resin keeps the porosity in described fibroid rove afterwards.
4. method according to claim 1, comprise with described continuous central layer and be adjacent to advance skin material by described molding equipment and utilize described resin described skin material to be attached to the step of described central layer with bonding mode.
5. method according to claim 1, but comprise the step of the described hardening resin of thermal activation.
6. method according to claim 1, but comprise the step that applies described hardening resin to the described rove between described some bands.
7. method according to claim 1, but comprise described hardening resin is applied to the step on the opposite flank of described some bands.
8. method according to claim 1, comprise with spiral around roving layer be adjacent to roving layer extending longitudinally is added to the step of described elongated band.
9. method according to claim 1, the layer of wherein said fibroid rove is formed by one group of braiding rove.
10. method according to claim 1, wherein said some bands are formed with the width of the length that is greater than them.
11. method according to claim 1, wherein the direction along the length perpendicular to described some bands is advanced to described some bands in described molding equipment.
12. method according to claim 1 wherein is advanced to described some bands in described molding equipment with respect to the direction that advances described some bands with acutangulating.
13. method according to claim 1, wherein advance described some bands by described molding equipment by exerting pressure to described some bands.
14. method according to claim 1, wherein advance described some bands by described molding equipment by pulling on described continuous composite panel.
15. method according to claim 1, comprise the step that applies the continuous fiber rove by described some bands of described molding equipment to just being pushed into.
16. a method of producing composite panel comprises the following steps:
Form a plurality of parallel continuous elongated band of low density porous material, described band has along this band length continuously and spirally around at least one deck fibroid rove of described band,
Direction along the length that is parallel to described band advances described continuous elongated band to pass through molding equipment, adjacent ribbons by the layer of described fibroid rove separately, thereby form continuous central layer, described central layer has the layer of the described fibroid rove extended between the opposite flank of described central layer
But apply hardening resin in described fibroid rove, and
Harden described resin to form continuous composite panel,
Wherein said resin passes through the part on the surface be exposed of adjacent ribbons and laterally extends to form a series of structure I-beam, the part of the fibroid rove that the face that the fibroid rove between described resin-dipping adjacent ribbons and dipping pass through described central layer extends, and described hardening of resin is to form described structure I-beam.
17. method according to claim 16, be included in the step of the horizontal reinforcement that formation separates along the longitudinal in described elongated band.
18. method according to claim 16 comprises from the second former described continuous elongated band is directed to the step described molding equipment that described the second former applies roving layer to described band.
19. method according to claim 16, comprise described continuous elongated band be directed to the step described molding equipment from least one supply volume.
20. method according to claim 16, comprise with described continuous elongated band and be adjacent to advance skin material by described molding equipment and utilize described resin described skin material to be attached to the step of described central layer with bonding mode.
21. method according to claim 16, but comprise the step of utilizing the described hardening resin of heat activation.
22. method according to claim 16, comprise with spiral around the roving layer step that is adjacent to add roving layer extending longitudinally.
23. method according to claim 16, the layer of wherein said fibroid rove is formed by one group of braiding rove.
24. a reinforced composite panels comprises:
Form and have the central layer of opposite flank by low density porous material,
The fibroid reinforcement extended between described opposite flank,
The fibroid covering adjacent with the described side surface of described central layer, and
Extend through described fibroid reinforcement and only by least one the hardening heat thermosetting resin of inside in described covering, and
Only extend through described at least one the thermoplastic resin of outside in described covering,
The part on the surface be exposed that wherein hardening resin passes through the adjacent ribbons of described central layer laterally extends to form a series of structure I-beam, the part of the fibroid reinforcement that the face that the fibroid reinforcement between described resin-dipping adjacent ribbons and dipping pass through central layer extends, and described hardening of resin is to form described structure I-beam.
25. a composite panel comprises:
A plurality of elongated parallel band of low density porous material,
Along the length of described band continuously and spirally around at least one deck fibroid rove of each described band,
Adjacent described a plurality of elongated parallel band, described a plurality of elongated parallel bands are separated by the layer of described fibroid rove and form continuous central layer, and the layer of described fibroid rove extends between the opposite flank of described central layer, and
In the layer of the described fibroid rove between described a plurality of elongated parallel bands and connect the hardening resin of described a plurality of elongated parallel bands,
Wherein said resin passes through the part on the surface be exposed of adjacent ribbons and laterally extends to form a series of structure I-beam, the part of the fibroid rove that the face that the fibroid rove between described resin-dipping adjacent ribbons and dipping pass through central layer extends, and described hardening of resin is to form described structure I-beam.
26. composite panel according to claim 25, comprise the skin material that utilizes binding resin to be attached to the described opposite flank of described central layer.
27. a composite panel comprises:
A plurality of elongated parallel band of low density porous material,
Adjacent described a plurality of elongated parallel band, described a plurality of elongated parallel bands are separated by the fibroid rove and form continuous central layer, and described fibroid rove extends between the opposite flank of described central layer,
In described fibroid rove between described a plurality of elongated parallel bands and connect the hardening resin of described a plurality of elongated parallel bands, and
The part adjacent with described opposite flank of described fibroid rove do not contain described hardening resin,
Wherein said resin passes through the part on the surface be exposed of adjacent ribbons and laterally extends to form a series of structure I-beam, the part of the fibroid rove that the face that the fibroid rove between described resin-dipping adjacent ribbons and dipping pass through central layer extends, and described hardening of resin is to form described structure I-beam.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US85759306P | 2006-11-09 | 2006-11-09 | |
| US60/857,593 | 2006-11-09 | ||
| PCT/US2007/023537 WO2008147393A1 (en) | 2006-11-09 | 2007-11-08 | Fiber reinforced composite cores and panels |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101646548A CN101646548A (en) | 2010-02-10 |
| CN101646548B true CN101646548B (en) | 2013-12-04 |
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|---|---|---|---|
| CN2007800417817A Expired - Fee Related CN101646548B (en) | 2006-11-09 | 2007-11-08 | Fiber reinforced composite cores and panels |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP2086746A4 (en) |
| JP (2) | JP2010509101A (en) |
| CN (1) | CN101646548B (en) |
| AU (1) | AU2007354365B2 (en) |
| BR (1) | BRPI0716707A2 (en) |
| CA (1) | CA2673013C (en) |
| WO (1) | WO2008147393A1 (en) |
Cited By (1)
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| CN109209671A (en) * | 2017-06-29 | 2019-01-15 | 通用汽车环球科技运作有限责任公司 | For reinforcing the continuous fiber grid of polymer composites |
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| DK2483076T3 (en) * | 2009-10-01 | 2016-10-24 | Milliken & Co | Composite cores and panels |
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| US8663791B2 (en) * | 2011-04-04 | 2014-03-04 | Milliken & Company | Composite reinforced cores and panels |
| US20130334366A1 (en) * | 2012-06-14 | 2013-12-19 | The Boeing Company | Formation of a shaped fiber with simultaneous matrix application |
| CN103404626B (en) * | 2013-07-11 | 2015-04-22 | 中国农业科学院茶叶研究所 | Processing method of bud-shaped black tea |
| BR112016009755A2 (en) * | 2013-10-30 | 2018-05-02 | Evonik Röhm Gmbh | continuous profile production in a foam core sandwich construction and rigid foam filled profile. |
| CA2928929C (en) * | 2013-10-31 | 2017-09-12 | Blh Technologies Inc. | Fire resistant article, and associated production method |
| CN103707610B (en) * | 2013-12-24 | 2016-04-20 | 唐地源 | The preparation method of fiber reinforced compound board and the composite plate of acquisition |
| RU2705089C2 (en) * | 2014-12-22 | 2019-11-01 | Басф Се | Fibre-reinforcement of foam materials, consisting of interconnected segments |
| NL2015927B1 (en) * | 2015-12-08 | 2017-06-28 | Atg Europe B V | Composite grid structure. |
| US10519965B2 (en) | 2016-01-15 | 2019-12-31 | General Electric Company | Method and system for fiber reinforced composite panels |
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| JP6797365B2 (en) * | 2017-01-31 | 2020-12-09 | 住友ゴム工業株式会社 | Cord ply joining device and joining method for tires |
| CN107605122B (en) * | 2017-10-24 | 2023-06-02 | 福建金竹竹业有限公司 | Recombined bamboo floor and production process thereof |
| US11498748B2 (en) * | 2017-11-29 | 2022-11-15 | Owens Corning Intellectual Capital, Llc | Pallet with rolls of reinforcement material |
| WO2019161926A1 (en) * | 2018-02-26 | 2019-08-29 | Ahlstrom-Munksjö Oyj | A stitched multi-axial reinforcement and a method of producing the same |
| CN110435701B (en) * | 2019-08-15 | 2020-08-14 | 航天材料及工艺研究所 | Composite material connection sleeper beam for rail transit vehicle and forming method thereof |
| US11840849B2 (en) * | 2020-04-27 | 2023-12-12 | Sp Advanced Engineering Materials Pvt. Ltd. | Light weight composite deck panelling |
| CN116046255B (en) * | 2022-12-30 | 2023-10-10 | 马鞍山合力仪表有限责任公司 | Dustproof temperature control alarm type protective pressure gauge |
| CN117141012A (en) * | 2023-10-31 | 2023-12-01 | 廊坊市飞泽复合材料科技有限公司 | Foam material reinforcing method |
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- 2007-11-08 JP JP2009536295A patent/JP2010509101A/en active Pending
- 2007-11-08 CN CN2007800417817A patent/CN101646548B/en not_active Expired - Fee Related
- 2007-11-08 WO PCT/US2007/023537 patent/WO2008147393A1/en active Application Filing
- 2007-11-08 AU AU2007354365A patent/AU2007354365B2/en not_active Ceased
- 2007-11-08 BR BRPI0716707-5A2A patent/BRPI0716707A2/en not_active Application Discontinuation
- 2007-11-08 EP EP07875053A patent/EP2086746A4/en not_active Withdrawn
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2012
- 2012-12-26 JP JP2012283411A patent/JP5685244B2/en not_active Expired - Fee Related
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| US6740381B2 (en) * | 1999-12-28 | 2004-05-25 | Webcore Technologies, Inc. | Fiber reinforced composite cores and panels |
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| CN109209671A (en) * | 2017-06-29 | 2019-01-15 | 通用汽车环球科技运作有限责任公司 | For reinforcing the continuous fiber grid of polymer composites |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2010509101A (en) | 2010-03-25 |
| EP2086746A1 (en) | 2009-08-12 |
| WO2008147393A9 (en) | 2009-07-09 |
| JP2013056558A (en) | 2013-03-28 |
| CN101646548A (en) | 2010-02-10 |
| JP5685244B2 (en) | 2015-03-18 |
| EP2086746A4 (en) | 2012-05-02 |
| BRPI0716707A2 (en) | 2014-03-04 |
| CA2673013A1 (en) | 2008-12-04 |
| AU2007354365A1 (en) | 2008-12-04 |
| WO2008147393A1 (en) | 2008-12-04 |
| AU2007354365B2 (en) | 2012-09-27 |
| CA2673013C (en) | 2015-05-26 |
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