CN102257221A - 复合结构元件及其制造方法 - Google Patents

复合结构元件及其制造方法 Download PDF

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Publication number
CN102257221A
CN102257221A CN200980151802XA CN200980151802A CN102257221A CN 102257221 A CN102257221 A CN 102257221A CN 200980151802X A CN200980151802X A CN 200980151802XA CN 200980151802 A CN200980151802 A CN 200980151802A CN 102257221 A CN102257221 A CN 102257221A
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CN
China
Prior art keywords
composite construction
construction element
epoxy resin
fibrage
nano particle
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Pending
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CN200980151802XA
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English (en)
Inventor
M·J·默克尔
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Merkel Composite Technologies Inc
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Merkel Composite Technologies Inc
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Publication date
Application filed by Merkel Composite Technologies Inc filed Critical Merkel Composite Technologies Inc
Publication of CN102257221A publication Critical patent/CN102257221A/zh
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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
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    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
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Abstract

提供一种复合结构元件和制造该复合结构元件的方法。该元件包括聚合物泡沫芯部和通过环氧树脂粘附于聚合物泡沫芯部的至少一层纤维层。在固化前，纳米颗粒悬浮于环氧树脂中；较佳地，在纳米颗粒与树脂混合前先与硬化剂混合。较佳地，聚合物泡沫芯部是诸如聚亚安酯的发热泡沫，且由发热泡沫产生的热量使环氧树脂固化，由此使纤维层粘附于泡沫芯部。纳米颗粒可由碳、陶瓷、钨、碳化物、钛、锆石、铝、银或硼中的至少一种构成。当使用碳纳米颗粒时，复合材料的强度大幅提高，且可热固化环氧树脂的固化时间显著减少。陶瓷纳米颗粒可用于提高渗透阻力并提高增大的弹道保护。

Description

复合结构元件及其制造方法
技术领域
本发明涉及用于建筑和基础设施中的结构元件，且更具体地涉及具有浸渍有环氧树脂、较佳地粘附于泡沫芯部的纤维层的复合结构元件。
背景技术
传统的复合材料通过包含在复合结构中的各种纤维(碳纤维、凯夫拉尔、玻璃纤维等)来获得它们大部分的强度。对于许多复合材料的应用场合，诸如建筑材料，这些纤维经证明太昂贵，因而限制了它们的使用。
由于成本限制，市场上并没有基于复合材料的结构隔热板。传统的结构隔热板由经聚亚安酯或聚苯乙烯隔热的木结构或钢结构制成。隔热材料被“夹”在两层木制或钢制外层之间。在各层之间用各种胶水粘结。
这些传统的复合材料使用诸如那些上述的昂贵的纤维材料来实现高强度。这限制了它们在诸如建筑和基础设施之类对成本敏感的工业中的使用。用于墙壁、屋顶和地板的其它板系统在成本上可相比较，但具有诸如腐蚀、侵蚀以及隔热芯部和外层之间的层离的固有材料问题。此外，其它板系统要求在用灰泥或泥涂刷墙壁之前将附加层加到它们的外部。
在授予本发明的发明人Merkel并转让给本发明受让人的美国专利6,117,376中描述了一种极好的制造复合材料的方法；在此以参见的方式纳入美国专利6,117,376的内容。在此方法中，生产模具，且碳纤维层或碳纤维皮膜排列在两半模的内表面。用可热固化的环氧树脂来润湿碳纤维层，且将半模闭合起来以形成具有开口的内部空腔。发热泡沫以填满模具的量被引入模具空腔中。泡沫材料膨胀并加热，从而使可热固化的环氧树脂固化。由于提供充裕的泡沫，过量的泡沫从空腔的开口中溢出，但因为泡沫膨胀很快，模具内的压力使碳纤维层被压平抵住模具的内表面。此外，环氧树脂固化(由于泡沫的发热反应产生的热量)并使碳纤维层牢固地粘到内部泡沫上。所得复合材料格外牢固并可以形成基本上任何形状。然而，尽管制造方法简单且低成本并且甚至可在建筑工地上完成，但如上所述，碳纤维太贵以至于无法使所得产品作为实用的建筑材料。
除了新建筑，传统基础设施的维修也出于类似的原因而缺乏(较好的材料)。例如，在维修桥基的柱形支承体时，常规的方法是将预轧钢板焊接到柱体的外部，然后用混凝土装填该结构。这种方法的问题是多方面的。其一，钢和混凝土都极其重，且因此具有较高的货运成本。此外，在实施这种翻新时，柱体的基座必须更换，且桥上的路面必须关闭。最后，要花无法接受地长的时间来完成这个过程。
由此，有对轻质、易于制造以及低成本、能用于新建筑也能用于维修目的的建筑结构和材料的长期以来的需求。
发明内容
本发明是复合结构元件及其制造方法。在一个实施例中，本发明是一种复合结构元件，该复合结构元件具有聚合物泡沫芯部和通过环氧树脂、较佳是可热固化的环氧树脂粘附于聚合物泡沫芯部的至少一层纤维层。纳米颗粒悬浮于环氧树脂，而环氧树脂还呈液态形式。较佳地，聚合物泡沫芯部是发热泡沫，更佳地是聚亚安酯，其中，由发热泡沫产生的热量使环氧树脂固化，由此使纤维层粘附于泡沫芯部。较佳地，复合结构元件还包括设置在聚合物泡沫芯部和纤维层之间的大块层叠层。
在一实施例中，纳米颗粒包括碳纳米颗粒，其较佳地具有约10至200纳米的直径。在另一实施例中，碳纳米颗粒包括直径约60至200纳米和长度约30至100微米的纳米纤维。对于任一种情况，碳纳米颗粒与环氧树脂的重量比较佳地至少为1∶200且不高于1∶2。更佳地，碳纳米颗粒与环氧树脂的重量比较佳地至少为1∶100且不高于1∶10。在一实施例中，碳纳米颗粒与环氧树脂的重量比基本上是1∶10，且结构元件是导热的屋顶板。纳米颗粒还可包括碳、陶瓷、钨、碳化物、钛、锆石、铝、银或硼中的至少一种。
较佳地，纳米颗粒相对于环氧树脂具有较高的导热性，因而，添加纳米颗粒减少环氧树脂的固化时间。
复合材料的纤维层较佳地包括织物聚酯垫和/或玻璃纤维垫中的至少一种。玻璃纤维垫包括碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫中的至少一种。纤维层可包括两玻璃纤维垫，每个玻璃纤维垫是碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫。
在一较佳实施例中，本发明的复合结构元件是结构隔热板。在此实施例中，至少一层纤维层还包括位于泡沫芯部相对两侧上的两纤维层，两纤维层都通过纳米颗粒浸渍的环氧树脂粘附于泡沫芯部。选配地，结构隔热板可包括粘附于两纤维层中的一层的第一外表面的一体干墙装饰物，且/或结构隔热板可包括粘附于两纤维层中的另一层的第二外表面的外部砌体(masonry)。
在另一实施例中，纳米颗粒包括至少一种陶瓷，较佳为碳化硼，且结构元件提供弹道防护。
在另一实施例中，纳米颗粒是碳，且结构元件是形成于现有的承载元件周围的结构包裹物。更具体来说，结构包裹物可包括桥基包裹物，且现有的承载元件是桥的支承柱。在此实施例中，包裹物基本上包围所有桥的支承柱，泡沫芯部沿柱体长度的至少约80％延伸。
本发明还包括一种制造复合结构元件的方法。在本发明的方法中，纳米颗粒首先混合到环氧树脂，较佳为可热固化环氧树脂中。设置至少一层纤维层，且用纳米颗粒浸渍的环氧树脂来该润湿纤维层。然后，引入热源来使环氧树脂固化。较佳地，引入热量的步骤提供与润湿的纤维层热连通的催化发泡发热材料。在一实施例中，两层润湿的纳米颗粒浸渍的纤维层设置在模具中，且将发热泡沫引入与两纤维层直接接触并引入到两纤维层之间，由此使环氧树脂固化并将纤维层粘结到泡沫上，以形成夹在两纤维层之间的泡沫芯部。替代地，具有壁、至少一个开口和内部的挠性接纳件(receptacle)可位于两纤维层之间，且发热泡沫经由开口引入该接纳件内部。因此，借助于从通过接纳件壁的发热泡沫释放的热量来使环氧树脂固化。
在将纳米颗粒添加到环氧树脂的过程中，较佳地，混合步骤包括以下几步：将纳米颗粒添加到环氧树脂的硬化剂，然后用树脂混合纳米颗粒浸渍的硬化剂。较佳地，纳米颗粒混合步骤实施成在使用碳纳米颗粒时，纳米颗粒与环氧树脂的重量比至少是1∶200且不高于1∶2，且更佳地，至少是1∶100且不高于1∶10。然而，在纳米颗粒混合步骤中添加的纳米颗粒可包括碳、陶瓷、钨、碳化物、钛、锆石、铝、银或硼中的至少一种。
在本发明方法的另一实施例中，润湿的纳米颗粒浸渍的纤维层在固化(较佳地在现场)前置于现有的承载元件周围。模具和第二润湿纳米颗粒浸渍的纤维层置于第一纤维层周围并与第一纤维层间隔开。然后，发热泡沫引入模具中两润湿纤维层之间。这样，可快速加强或维修诸如桥的支承柱的现有的承载元件，而不停用该柱体。在这些类型的情况下，沿现有的承载元件长度的至少约80％来设置泡沫。
本发明提供一种方法，由此，通过将纳米颗粒包含到环氧树脂复合基质中可使用相对便宜的纤维。所得的复合结构接近传统复合结构的强度和性能，同时减少成品的成本。
附图说明
图1是按照本发明制成的复合结构隔热板的侧面剖视图。
图2是按照本发明的具有多个部件的复合结构隔热板的局部立体图。
图3是按照本发明的复合结构隔热板的另一局部立体图，为清楚表示而移除了外表面的一部分。
图4是本发明作为桥基翻新的一种用途的侧面剖视示意图。
图5是形成图4的桥基翻新的侧面立体示意图。
具体实施方式
现在将参见图1至5给出本发明的说明。应当理解，这些附图实际上是示例性的，且绝不用于限制由下面公开的权利要求书限定的本发明的范围。
在图1中以剖视图示出按照本发明的结构板10的简化图。板10包括夹在两纤维层14和16之间的泡沫芯部12。纤维层浸渍有悬浮有纳米颗粒的环氧树脂；环氧树脂使纤维层14和16粘附于泡沫芯部12，同时悬浮的纳米颗粒增加复合材料的强度或其它特性。因为环氧树脂和泡沫进行化学反应并形成良好粘结区域15(见图3)，所以，纤维层与泡沫芯部的层离很少或没有改变。例如，悬浮于浸渍的环氧树脂中的碳纳米微粒使强度显著增加，而强度大到可使用诸如玻璃纤维或聚酯的较便宜的纤维层，但还能实现与使用贵得多的织物碳纤维垫类似的强度特性。
外层20适于朝向建筑物的外部，并且可包括常规的外部砌体，诸如灰泥、砖块等。在环氧树脂已完全固化后(见下面)，外层20可直接敷加到纤维层14的外表面。类似地，内层22适于朝向建筑物的内部并可包括常规的内部表面材料，诸如干墙、墙纸、木镶板等。
芯部插入件30设置在泡沫芯部12内部，并表示通常用于建筑物中的多种不同的可成一体的常规建筑结构中的任一种。
图2示出结构板10，结构板的内层22的一部分以局部立体图示出且为了清楚起见移除了结构板的泡沫芯部。图2中，例如示出多个不同的示例性芯部插入元件30，例如：加劲脊31、水管道32和供水接头33；电缆34和照明开关35；电器插口36；接线盒37和电缆连接器38；及类似物。此外，周缘结构元件，诸如底系定板40(也在图1中示出)、顶部装填物42、顶板44和类似的元件可包括在板10内或板上。可设想，本发明的板可包括任何和所有这些类型的元件及其它类似的未示出的元件，但不必须包括它们中的一个以落入本发明的范围内。
如下制造按照本发明的结构板。对于较佳的结构板，使用碳纳米颗粒。处于适当浓度(下面将讨论)的碳纳米颗粒悬浮于液态环氧树脂中。具体而言，碳纳米颗粒较佳地添加到环氧树脂的硬化剂部分，这是因为这部分较薄，且纳米颗粒更容易均匀地悬浮和分布在硬化剂部分中。一旦纳米颗粒在整个硬化剂中均匀分布，则用树脂来混合具有纳米颗粒的硬化剂悬浮液。这对于进一步在整个环氧树脂混合物中混合纳米颗粒是有利的，这是因为硬化剂分子找出树脂分子并有助于碳纳米颗粒分布在整个环氧树脂中。由此，在混合物中碳纳米颗粒很少或不会聚结，且昂贵的混合装置不是必要的。
碳纳米颗粒与环氧树脂的较佳的重量比从1∶200至多达1∶2，尽管更佳地，此范围在1∶100至1∶10。根据合成板期望的特性，可以调节此比例。
对于每100克的环氧树脂使用少于0.5克的碳纳米颗粒产生非常少的强度益处。对于每100克的环氧树脂使用多于50克的碳纳米颗粒会产生不适于使用的糊状易碎的混合物。
无论如何，都用纳米颗粒和环氧树脂溶液来润湿各纤维层，从而形成复合材料。然后，使用美国专利6,117,376中描述的方法或使用高压釜来使复合材料固化。具体而言，如上所述，生产模具且将一种或多种形式的纤维层排列在半模的内表面。在发明人之前的专利中，如果并非全部由碳纤维制成，纤维层也较佳地至少是碳纤维加强的。由此，尽管产品具有极好的强度和耐久性，但对批量生产规模的实际使用来说太过昂贵。
替代地，纤维层可由便宜得多的材料，诸如聚酯、尼龙或玻璃纤维制成。在一较佳实施例中，如果使用聚酯，则其应当呈织物聚酯垫的形式。如果使用玻璃纤维，则其可以是碎断束丝的玻璃纤维垫或连续的细丝玻璃纤维垫(或两者均是)。纤维层可包括两玻璃纤维垫，每个玻璃纤维垫是碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫。较佳地，使用一层玻璃纤维和一层聚酯或尼龙作为垫层。无论使用什么，都用纳米颗粒浸渍的可热固化的环氧树脂来润湿纤维层，且将半模闭合起来以形成具有开口的内部空腔。发热泡沫以填满模具的量引入模具空腔中。泡沫材料膨胀并加热，从而使可热固化的环氧树脂固化。由于提供充裕的泡沫，过量的泡沫从空腔中的开口中溢出，但因为泡沫膨胀很快，模具内的压力使纤维层被压平抵住模具的内表面。
此外，环氧树脂固化(由于泡沫的发热反应产生的热量)并使纤维层牢固地粘到内部泡沫上。所得的复合材料格外牢固并可以形成基本上任何形状。同样，如上所述，可在泡沫内模制各种其它的结构元件。
碳纳米颗粒的附加好处在于有碳纳米颗粒会使可热固化的环氧树脂更快固化(快高达50％)。例如，根据所使用的纳米颗粒与环氧树脂之比，已观测到悬浮有碳纳米颗粒的5分钟环氧树脂在2至3分钟内固化。
一旦固化，复合结构具有各种用途，并且理想地适用于要求轻质、高剪切力、高负载和高拉伸强度的结构部件。较佳的实施例集中在建筑物应用场合并集中在被称为复合结构隔热板(CSIP)的产品周边。CSIP可用于居住和非居住建筑物中的墙壁、地板和屋顶板系统，其中，低成本、高度隔热的结构部件是有利的。CSIP包括聚亚安酯芯部并具有由低成本的碎断束丝玻璃纤维垫和聚酯织物垫构成的外层。外层通过如上所述的纳米颗粒和环氧树脂溶液粘结到聚亚安酯，从而形成适用于建筑物的复合材料。可用任何类型的边来制成CSIP以适应不同的应用场合的不同设计风格。因为CSIP可模制成基本上任何形状，2x4的普通木材可用作夹板，或者如果形成有榫槽系统，则这些板可简单地胶合在一起。
CSIP极其牢固且轻质并相对于木制SIP和混凝土块来说是有利的。CSIP胜过夹心板的国际规范委员会验收标准(ICC-ES AC04)和由木结构板片构成的、用气动或气动力驱动的紧固件附连于冷压成型钢框架的剪切壁组件的验收标准(ICC-ES AC230)。
CSIP的构架成本大约与那些木制SIP相同并且是混凝土块的约40％，且货运成本(由于其极其轻质的结构和如有需要可在工地上制成的能力)也低于木制框架、木制SIP或混凝土。CSIP极高度耐腐蚀和抗虫(像混凝土，不像木制框架或木制SIP)，且CSIP还非常易于操作和易于组装(像木制SIP，不像混凝土)。CSIP还具有比木制SIP或混凝土块更好的隔音效果。为了另外能隔音，碳纳米管可在混合过程中添加到环氧树脂和在注入模具前加到泡沫中。此外，上述间接提到，CSIP的外侧准备好接纳灰泥或其它类似的砌体，而内侧可设置有一体干墙涂漆；木制框架，木制SIP或混凝土块都不具有这种设计灵活性。
由于碳纳米颗粒较好地保持热量，这种特性还使由本发明的方法制造的CSIP成为极好的隔热体；它们通常具有R-30的墙壁R值和R-60的屋顶R值。这相比于典型的木制SIP(R-15的墙壁R值，R-30的屋顶R值)或混凝土块(R-19的墙壁R值，R-30的屋顶R值)都是非常有利的。因此，CSIP使屋瓦和结构墙都非常好。屋瓦的一种较佳的配方是对于每100克环氧树脂用10克碳纳米颗粒；此配方使如此制成的屋瓦具有极好的热特性。屋顶板CSIP减少建筑物的热岛效应，这是因为它们具有较高的热辐射并释放存储的热量。
由于CSIP是结构元件，因此它不必限制于新建筑的应用场合，它还可用于比重新建造或使用传统钢翻新更快、更低成本和更实用地翻新已现有的基础设施。图4和5示出对桥基支承柱的这样一种翻新。在图4中，由柱体110在地下支承示例性的路面100。如对于受到磨损并暴露于各种因素的所有柱体最终发生地那样，开始形成裂缝112。可替代使用根据本发明的结构材料的包裹物120，而不会替换整个桥或甚至用另一柱体替换整个柱体或者甚至使柱体覆以钢和混凝土套来进行常规翻新安装。
图5示出典型的圆柱形桥柱110。对于这种应用场合，较佳地直接向柱体110敷加碳纳米颗粒浸渍的环氧树脂的涂层，然后将至少一层纤维层粘附于涂敷有环氧树脂的柱体。较佳地，将足够的环氧树脂敷加到柱体以使环氧树脂渗透并完全润湿纤维层。设置有由至少两模具部分142和144构成的中空圆柱形模具140。至少一层纤维层置于每个模具部分142和144中并用纳米颗粒浸渍的环氧树脂进行润湿。模具140闭合在柱体110周围，且尺寸定成在置于模具140上的纤维层和置于柱体110周围的纤维层之间有间隙。至于平板，发热泡沫材料被引入到模具和柱体之间的间隙中。泡沫膨胀并释放热量，这使环氧树脂固化并使整个翻新结构硬化。这样结果是可在现场安装并实行翻新，而不要求如对于常规钢套翻新来说关闭桥上的路面(只要桥基的损坏并未发展到比将要考虑到桥上的交通更严重的地步)。
此外，本发明的复合纳米颗粒翻新比钢套翻新轻许多并只要花约一半时间。最后，本发明的翻新并不要求更换柱基，而这对于钢套翻新来说是要求的。
桥基包裹物可整个包住支承柱，但并不必须那么做。桥支承柱的大部分损坏和失效发生在柱体的底部三分之一处。同样，如图4中所示，包裹物的泡沫芯部只需延伸柱体长度的下面80％，从而留出上面20％仅用带有纳米颗粒浸渍的环氧树脂的纤维层来覆盖。
碳纳米颗粒的较佳的直径大小范围从10纳米到高达200纳米。适用的碳纳米颗粒可以是生成态的、热解剥裂的(多环芳烃表面的)或热处理过的。生成态的纳米颗粒最便宜，且有助于使CSIP的总成本降低。替代地，可使用70至200纳米宽和50至100微米长的碳纳米纤维。作为碳的替代物，可使用碳化硅和碳化钛纳米颗粒。所有上述纳米颗粒可从美国加利福尼亚州洛杉矶市的美国元件公司(American Elements)获得；碳纳米颗粒和纳米纤维由美国俄亥俄州锡达维尔市的应用科学公司(Applied Sciences，Inc.)以烙花(Pyrograph)为名称适宜生产；合适的碳纳米颗粒还可从美国新泽西州阿斯伯里市的阿斯伯里碳公司(Asbury Carbons)购得。
如上所述，本发明允许用便宜得多的玻璃纤维层或聚酯层(或两者)来替换建筑物中昂贵的织物碳纤维。在本发明的结构板的一个实施例中，大块层叠聚酯层与碎断束丝或连续细丝的玻璃纤维层一同使用。一种较佳的大块层叠聚酯由美国俄亥俄州布鲁克维尔市的纤维格拉斯特公司(Fibre Glast)的型号2258-A1(呈2毫米或4毫米)制成。一种较佳的连续细丝玻璃纤维层由欧文斯柯宁(Owens-Corning)作为连续细丝垫型号44986-NAM(较佳为8盎司垫)生产。替代聚酯，可使用尼龙。
尽管一些环氧树脂更有利地用于某些应用场合中，但数千种环氧树脂可用于形成CSIP。例如，海洋树脂非常适用于高湿度环境中的户外场合或用于翻新靠近水体或在水体中的桥的支承柱。可使用的其它类型的环氧树脂是可室温固化的树脂(不过其可通过加入来自发热泡沫的热量而加速它们的固化)；抗燃/阻燃树脂，用于居住和商业空间；以及耐高冲击力的树脂，用于弹道和装甲应用场合。发明人已成功使用的一种环氧树脂系统是由美国密歇根州麦迪逊高地市的CASS聚合物公司(CASS Polymers)制成的EL-319系列。使用带有EL-319硬化剂或EL-319-1更长使用寿命的硬化剂的EL-319树脂生产极其阻燃(约四小时)和其它方面多用途的结构板。
发热泡沫的较佳类型是聚亚安酯，尤其是闭孔泡沫。开孔泡沫通常对结构板提供足够支承来说不够牢固。泡沫密度对于结构板的隔热值和强度也很重要，但要求的密度对于各应用场合是不同的。闭孔4-lb密度泡沫具有每强度比的最佳R值且最适于大多数的CSIP应用场合。闭孔6-lb密度泡沫具有比4-lb泡沫更高的强度，但更低的R值，6-lb泡沫对于具有多个芯部插入元件30(例如，见图1至2)的板来说更有用；板具有的芯部插入元件越多，板就变得越不牢固。
更高密度的泡沫(例如，8-lb或16-lb)具有更高的强度但更低的隔热特性。密度低于4-lb泡沫的泡沫(例如，2-lb泡沫)可以极其轻质且是极好的隔热体，但对于使用CSIP的大多数场合来说却不具有足够的结构强度。无论如何，出于强度、耐燃或耐虫、隔音或其它原因，添加剂可添加到泡沫中。例如，将碳纳米管加到CSIP的泡沫中会大大增加其隔音特性。
CSIP板的一个较佳实施例使用带有作为垫片的一层大块层叠聚酯的一层E型碎断束丝玻璃纤维垫一起作为纤维层。用抗燃环氧树脂(例如，CASS聚合物公司的EL-319系列)来润湿纤维层，该纤维层以2克碳纳米颗粒比100克环氧树脂的比例浸渍有碳纳米颗粒。4-lb或大豆基6-lb聚亚安酯泡沫用作芯部。
在另一实施例中，陶瓷纳米颗粒可替换和/或加入碳纳米颗粒以提供或增加结构板可提供的弹道防护。传统的防弹板片由诸如碳化硼(B4C)、氧化铝(Al2SO3)或碳化硅(SiC)的固体陶瓷构成。然而，B4C和类似材料的固体陶瓷板极其昂贵。替代地，按照本发明，用陶瓷纳米颗粒浸渍的环氧树脂来润湿诸如聚酯或玻璃纤维的纤维层，且纤维层进行热固化。对于防弹板片或防弹板来说泡沫芯部不是必要的。如此制成的板几乎与相同材料的固体陶瓷板一样牢固，但又便宜得多。
由上述方法制成的较小的板还可用作防弹衣、车辆装甲和其它弹道用途的防弹插入板或组件。可设置较大的板作为常规CSIP的芯部插入元件30(见图1)并对结构板提供弹道保护特性。最适于这种用途的陶瓷纳米颗粒包括B4C和氧化铝。
本发明并不局限于以上说明。例如，尽管碳纳米颗粒已描述成用于结构场合且陶瓷纳米颗粒已描述成用于弹道应用场合，但也可使用碳和陶瓷纳米颗粒的混合物。此外，附加的特性可经由添加其它类型的纳米颗粒而加到CSIP。例如，EMI/RFI屏蔽可用于要求监听保护的军事和工业场合。铝、铜、镍和银的纳米颗粒可连同碳和/或陶瓷纳米颗粒(两者或之一)用于此目的。
描述本发明的某些实施例后，应当理解，本发明不限于上述说明或示例性附图。而是，本发明的范围由下面公开的权利要求书来限定，且本领域的普通技术人员之一将理解其任何等同物。

Claims (37)

1.一种复合结构元件，包括：
聚合物泡沫芯部；
通过环氧树脂粘附于所述聚合物泡沫芯部的至少一层纤维层；且
纳米颗粒悬浮于所述环氧树脂中，而所述环氧树脂还呈液态形式。
2.如权利要求1所述的复合结构元件，所述聚合物泡沫芯部包括发热泡沫，其特征在于，由所述发热泡沫产生的热量使所述环氧树脂固化，由此使所述纤维层粘附于所述泡沫芯部。
3.如权利要求1所述的复合结构元件，其特征在于，还包括设置在所述聚合物泡沫芯部和所述纤维层之间的大块层叠层。
4.如权利要求1所述的复合结构元件，其特征在于，所述聚合物泡沫芯部包括聚亚安酯。
5.如权利要求1所述的复合结构元件，其特征在于，所述纳米颗粒包括碳纳米颗粒。
6.如权利要求1所述的复合结构元件，其特征在于，所述纳米颗粒具有约10至200纳米的直径。
7.如权利要求5所述的复合结构元件，其特征在于，所述碳纳米颗粒包括直径约60至200纳米和长度约30至100微米的纳米纤维。
8.如权利要求5所述的复合结构元件，其特征在于，所述碳纳米颗粒与所述环氧树脂的重量比至少是1∶200且不高于1∶2。
9.如权利要求5所述的复合结构元件，其特征在于，所述碳纳米颗粒与所述环氧树脂的重量比至少是1∶100且不高于1∶10。
10.如权利要求1所述的复合结构元件，其特征在于，所述纳米颗粒包括碳、陶瓷、钨、碳化物、钛、锆石、铝、银或硼中的至少一种。
11.如权利要求1所述的复合结构元件，其特征在于，所述纤维层包括：
织物聚酯垫；以及
玻璃纤维垫。
12.如权利要求11所述的复合结构元件，其特征在于，所述玻璃纤维垫包括碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫中的至少一种。
13.如权利要求1所述的复合结构元件，其特征在于，所述纤维层包括聚酯垫。
14.如权利要求1所述的复合结构元件，其特征在于，所述纤维层包括碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫中的至少一种。
15.如权利要求1所述的复合结构元件，其特征在于，所述纤维层包括两玻璃纤维垫，每个所述玻璃纤维垫是碎断束丝玻璃纤维垫或连续细丝玻璃纤维垫。
16.如权利要求5所述的复合结构元件，其特征在于，所述碳纳米颗粒与所述环氧树脂的重量比基本上是1∶10，且所述结构元件包括导热屋顶板。
17.如权利要求5所述的复合结构元件，其特征在于，所述结构元件包括结构隔热板。
18.如权利要求17所述的复合结构元件，其特征在于，所述至少一层纤维层还包括位于所述泡沫芯部的相对两侧上的两纤维层，所述两纤维层都通过所述纳米颗粒浸渍的可热固化环氧树脂粘附于所述泡沫芯部。
19.如权利要求18所述的复合结构元件，其特征在于，还包括粘附于所述两纤维层中的一层的第一外表面的一体干墙装饰物。
20.如权利要求19所述的复合结构元件，其特征在于，还包括粘附于所述两纤维层中的另一层的第二外表面的外部砌体。
21.如权利要求2所述的复合结构元件，其特征在于，所述纳米颗粒相对于所述环氧树脂具有较高的导热性，添加所述纳米颗粒减少所述环氧树脂的固化时间。
22.如权利要求1所述的复合结构元件，其特征在于，所述纳米颗粒包括至少一种陶瓷，且所述结构元件包括弹道防护元件。
23.如权利要求22所述的复合结构元件，其特征在于，所述陶瓷纳米颗粒包括碳化硼和氧化铝中的至少一种。
24.如权利要求2所述的复合结构元件，其特征在于，所述纳米颗粒包括碳，且所述结构元件包括形成于现有的承载元件周围的结构包裹物。
25.如权利要求24所述的复合结构元件，其特征在于，所述结构包裹物包括桥基包裹物，且所述现有的承载元件是桥的支承柱。
26.如权利要求25所述的复合结构元件，其特征在于，所述包裹物基本上包围所有所述桥的支承柱，且所述泡沫芯部沿所述柱体长度的至少约80％延伸。
27.一种制造复合结构元件的方法，包括以下步骤：
将纳米颗粒混合到环氧树脂中；
设置至少一层纤维层并用纳米颗粒浸渍的环氧树脂润湿所述纤维层；以及
引入热源以使所述环氧树脂固化。
28.如权利要求27所述的制造复合结构元件的方法，其特征在于，所述引入热量步骤还包括提供与所述润湿的纤维层热连通的催化发泡发热材料的步骤。
29.如权利要求28所述的制造复合结构元件的方法，其特征在于，还包括以下步骤：
将两层润湿的纳米颗粒浸渍的纤维层设置在模具中；
将所述发热泡沫引入与所述纤维层直接接触并引入到所述纤维层之间，由此使所述环氧树脂固化并将所述纤维层粘结到所述泡沫上，以形成夹在所述两纤维层之间的泡沫芯部。
30.如权利要求28所述的制造复合结构元件的方法，其特征在于，还包括以下步骤：
将两纤维层设置在模具中；
放置具有壁、至少一个开口和所述两纤维层之间的内部的挠性接纳件；
将发热泡沫经由所述开口引入所述接纳件的内部；以及
借助于从通过所述接纳件的所述壁的所述发热泡沫中释放的热量来使所述环氧树脂固化。
31.如权利要求27所述的制造复合结构元件的方法，其特征在于，所述混合步骤还包括以下步骤：
将所述纳米颗粒添加到所述环氧树脂的硬化剂；以及然后
用树脂混合所述纳米颗粒浸渍的硬化剂。
32.如权利要求27所述的制造复合结构元件的方法，其特征在于，所述纳米颗粒具有约10至200纳米的直径。
33.如权利要求27所述的制造复合结构元件的方法，其特征在于，所述纳米颗粒混合步骤实施成所述纳米颗粒与所述环氧树脂的重量比至少是1∶200且不高于1∶2。
34.如权利要求27所述的制造复合结构元件的方法，其特征在于，所述纳米颗粒包括碳，且所述纳米颗粒混合步骤实行成所述碳纳米颗粒与所述环氧树脂的重量比至少是1∶100且不高于1∶10。
35.如权利要求27所述的制造复合结构元件的方法，其特征在于，在所述纳米颗粒混合步骤中添加的所述纳米颗粒包括碳、陶瓷、钨、碳化物、钛、锆石、铝、银或硼中的至少一种。
36.如权利要求28所述的制造复合结构元件的方法，其特征在于，还包括以下步骤：
在固化前将所述润湿的纳米颗粒浸渍的纤维层置于现有的承载元件周围；
将模具和第二润湿的纳米颗粒浸渍的纤维层置于所述第一纤维层周围并与所述第一纤维层间隔开；以及
通过将所述发热泡沫引入所述模具中所述两润湿的纤维层之间来实施所述发热泡沫提供步骤。
37.如权利要求36所述的制造复合结构元件的方法，其特征在于，所述泡沫引入步骤还包括对所述现有的承载元件长度的至少约80％提供所述泡沫的步骤。
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