CN102407615A - Light reinforced foam board and preparation method thereof - Google Patents
Light reinforced foam board and preparation method thereof Download PDFInfo
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- CN102407615A CN102407615A CN2011102149002A CN201110214900A CN102407615A CN 102407615 A CN102407615 A CN 102407615A CN 2011102149002 A CN2011102149002 A CN 2011102149002A CN 201110214900 A CN201110214900 A CN 201110214900A CN 102407615 A CN102407615 A CN 102407615A
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Abstract
The invention relates to a light reinforced foam board and a preparation method thereof, which takes a foaming material as a base material and is reinforced by a reinforcement body distributed in the base material, and is characterized in that: the reinforcement is a structural reinforcement, the structural reinforcement is placed in a foaming mold in advance before the foam board is molded, and the foam material is embedded after the foam material is foamed, wherein the structural reinforcement has a hollow structure for the foam material to enter the interior, and the axial direction with the largest bearing capacity of the reinforcement is consistent with the flat pressing direction of the foam board or has an included angle not exceeding 45 degrees with the flat pressing direction. The preparation method comprises a one-step foaming method and a two-step foaming method. The advantages are that: through reasonable design of the structural reinforcement, the hollow structural reinforcement is adopted, and the selection of materials is matched, so that the reinforced foam board with greatly improved Z-direction performance and small increase of equivalent density can be obtained.
Description
Technical field
The present invention relates to field of materials, especially a kind of lightweight reinforced cystosepiment as structural material and preparation method thereof.
Background technology
The light sandwich structure is used widely at Aero-Space, Modern Traffic (high-speed train car body, motor-car or subway car body, caravan compartment, motor bus and minibus car body), boats and ships (yacht manufacturing), production of energy numerous industrial circles such as (fan blades etc.) because of its remarkable specific stiffness and specific strength characteristic; Wherein, the most frequently used core is honeycomb core and structural foam core.The concora crush of honeycomb core (perpendicular to plate face direction) excellent performance, shear strength are high, material cost is cheap relatively, but with the little and easy generation delamination failure of panel bond area, heat insulation performance is low, is difficult to process curved profile, processing cost is high.The structural foam core is then just in time opposite.The great advantage of structural foam core is after the fibrous material (like glass fibre or carbon fiber) of making the sandwich structure panel is range upon range of, can pass through RTM (Resin transfer moulding; Resin transfer moulding) or RIM (Resin infusion moulding; The resin plastic uptake) disposable injecting glue co-curing; Make no matter great goods can both be realized one-shot forming; The processing cost that greatly reduces sandwich structure also can be guaranteed the form accuracy of goods, and the specific area between foam core and the panel makes foam sandwich construction have higher anti-layering and peel strength far above the specific area between honeycomb core and the panel.In addition, through hot pressing, cut into fritter and piece even be foamed into curve form together, be easy to also realize that foam core sandwich is consistent with the arbitrary surface profile of goods.Another strong point of foam core is that heat insulation, insulation and sound insulation property are excellent, especially is suitable for the manufacturing of manned vehicle, traffic above-ground vehicle, high ferro, motor-car, subway or light rail car body.But the concora crush of structural foam core and shearing rigidity and intensity are starkly lower than the honeycomb core of equal densities, bear the scarce capacity of action of lateral load such as bending, impact, and material cost are high.
Nearly all macromolecular material can be processed the light foam plate through foaming, but the foam process of different macromolecular materials is different, and the mechanical property of resulting cystosepiment is also different.The foam process of some macromolecular material is complicated, and with high costs, the mechanical property of the cystosepiment of processing thus is then higher relatively, is called structural foam panels, and the foam central layer in the sandwich structure is mainly taken from this type material; The foam process of another kind of macromolecular material is simple, and the regular-type foam plate of processing is with low cost, is mainly used in fields such as packing, heat insulation, buoyancy, and its mechanical property is generally far below the mechanical property of last class formation cystosepiment.For example; The unit price (every kg price) of the structural foam panels of equal densities such as PVC (polyvinyl chloride), PEI (PEI), PMI (Polymethacrylimide) cystosepiment exceeds more than the one magnitude of hard PU regular-type foam plate unit prices such as (polyurethane); This is that the former concora crush and modulus of shearing and intensity exceed the latter's a one magnitude because in than the low-density scope.Like density is 60kg/m
3The modulus of compressibility and the compressive strength of PMI structural foam panels be respectively 74MPa and 1.47MPa; The modulus of compressibility of the hard PU cystosepiment of equal densities and compressive strength then are respectively 2.8MPa and 0.19MPa; The former exceeds more than the latter's one one magnitude, though the latter is better than the former in the performance aspect heat insulation, insulation, the sound insulation.
Obviously; If can be through the reinforcement means; Basically do not increasing or seldom increasing under the prerequisite of material cost, significantly improving as the modulus and intensity especially concora crush and shearing mechanical property of regular-type foam plates such as PU, it can be used as structural foam panels; And can will have crucial meaning and using value undoubtedly above the mechanical property of present structural foam panels.
The method that the cystosepiment mechanical property is strengthened has two types: one type is called rearmounted method, another kind ofly is called preposition method.
Rearmounted method is after foaming is accomplished, to insert the enhancing body.At present the most successful rearmounted method is so-called Z-pin method, be with the metal needle of diameter tiny (about about 0.5mm) or impregnation carbon fiber pin along the concora crush direction insert in the cystosepiment (owing to x, y coordinate are usually located in the board plane,
zCoordinate is along the thickness direction of plate, so will be called the Z-pin pin along the pin pin that thickness direction is arranged).It is found that, as the pin pin of inserting is become 20 with the cystosepiment exterior normal
0~ 30
0Between angle the time can play collaborative humidification to the flat crush resistance and the cutting performance of cystosepiment; Reinforced effects is best; The X-cor plate that Here it is knows sth. or sb. thoroughly in the industry (inserting the metal of X shape or the foam central layer of carbon fiber pin in pairs), its variation K-cor plate is the syringe needle that stretches out the plate face to be bent flush with the plate face.X-cor and K-cor be all registered to become trade mark.The another kind of rearmounted method of using of in reality, succeeding is a lockstitch; Exactly upper and lower panel cloth and foam central layer are stitched into one with fibers such as aramid fibers; Through RTM or RIM impregnation curing molding, after solidifying, numerous suture impregnations (though having the incomplete possibility of impregnation) that pass central layer play Z again to humidification.Other rearmounted method is attempted like fibre columns method (seeing Chinese invention patent application number 200710071679.3) in addition in addition.Though X-cor and lockstitch are successfully realized commercial Application; But since after the enhancing body and the interface performance between the foam base plate of inserting poor; And the diameter of pin of inserting or line is too tiny; For stoping its whole unstability, need backing material (being cystosepiment) to have enough rigidity and toughness, generally still need adopt structural foam panels to make X-cor or sewing clip laminate.In addition, the method that these are rearmounted to strengthen structures not only complex process, cost is high, and if the pin/line of inserting is overstocked or pin pin diameter slightly greatly also might destroy the globality of cystosepiment.
Preposition method is before foaming, to introduce to strengthen body, adds chopped strand, metal or ceramic particle, tiny balloon, CNT, nano imvite etc. such as the enhancing body being added to foaming again in the blowing agent, comprising.It is found that; It is limited to the increase rate of cystosepiment mechanical property when the addition of these additives hangs down; But then can bring difficulty on the other hand if strengthen addition, higher exactly addition can hinder foaming and intumescing, and makes the pattern in foam hole (perforate or closed pore) be difficult to control.In addition, these additives are all non-structural part (that is, can not use as structure-bearing spare), and the limitation of itself yardstick is difficult to cystosepiment is produced the reinforced effects as X-cor or lockstitch.When only hoping along certain direction ratio as when concora crush (exterior normal of plate face) direction improves performance; It is not very effective evenly sneaking into these non-structures enhancing bodies; Although also the someone attempts in foaming process, applying magnetic field; The feasible ferromagnetic particle that adds oriented alignment to a certain extent realizes that the orientation of mechanical property strengthens, but reinforced effects is still limited.
The reinforced effects that obviously, improve preposition method just must be introduced structure enhancing body.The strong point of before foaming, inserting structure enhancing body has two:
1, the version and the physical dimension of enhancing body can be in very large range unfettered, and this is convenient to realize to the more effective reinforcement of cystosepiment, and rearmounted rule generally can only be inserted the tiny pin of diameter, line structure;
2, foam base plate and the structure after the foaming strengthen enhancing body that interface between the body combines to introduce more than rearmounted method combine with interface between the matrix firm, thereby, can reduce the mechanics performance demands of foamed material own.These two strong points will make the regular-type foam material be used as structural foam becomes possibility.
Summary of the invention
Technical problem to be solved by this invention is to provide a kind of lightweight reinforced cystosepiment, and it all has raising by a relatively large margin on flat crush resistance and cutting performance.
Another technical problem to be solved by this invention is to provide the preparation method of above-mentioned lightweight reinforced cystosepiment.
The present invention solves the problems of the technologies described above the technical scheme of being taked: a kind of lightweight reinforced cystosepiment; With the expanded material is matrix material; And by the enhancing body enhancing that spreads all in the matrix material, described enhancing body is that structural type strengthens body, before the cystosepiment moulding, places foaming mould in advance; Foam the back by the expanded material embedding at expanded material; Wherein, described structural type enhancing body has can supply the inner hollow structure of expanded material entering, and the axial concora crush direction with cystosepiment of enhancing body bearing capacity maximum is consistent or with the concora crush direction angle that is no more than 45 ° is arranged.
Prepare structural type in advance by designing requirement and strengthen body; Design feature and " dispersing " type characteristic with hollow; So that can getting into smoothly, expanded material strengthens body inside; The implication that " disperses " is meant that these structural types strengthen and can not constitute the dead angle that expanded material flows between bodies, that is to say expanded material can these strengthen body flow each other walk and through foaming with they whole embeddings.
Should be noted that; Hollow structure that the present invention mentions and remarkable finger are by the boring structure of shell parcel; And be meant as long as be formed with design hollow (being not the formed cavity of fault in material) in the optional position of inside configuration; And no matter this hollow be remain silent, place's opening or many places opening, in other words, as long as some line of any other point in the structure from structure has non-structural material point (hollow dots); Perhaps describe with mathematical linguistics; As long as after any cross section of structure sections, have two or the above logical zone of simply connected, perhaps one or above many UNICOMs zone just all belong to hollow structure category of the present invention.
The tubular structure of thin-walled for example, its inside is hollow, and the pipe two ends can also can be opening for sealing, is formed by boring that remain silent in two ends or the cannulated structure of an end opening or both ends open.Be pointed out that, get into the inside of hollow-core construction, can also on the pipe thin-walled, also need offer porose or groove etc. in case of necessity for making outside expanded material.
Prism structure for example again, most the identical or different cylinder skeletons of cross section are vertically arranged, and constitute the prism-shaped hollow structure; Or the identical or different cylinder skeleton of most cross sections connects into an integral body by the identical or different horizontal cylinder in cross section again after vertically arranging, and constitutes the prism-shaped hollow structure.
Network structure for example again is made into fishing net shape sheet material, or by forming mesh sheet material after the sheet stamping, is constituted netted hollow structure by this sheet material or sheet material again by silk, the line of rigidity.
In addition, should not occur under the unstability situation, with these strengthen body bearing capacities the strongest be disposed axially in the direction that the cystosepiment performance needs most reinforcement.In general, the flat crush resistance of cystosepiment is most important, therefore will strengthen the axial of body and arrange along the concora crush direction.
On the basis of such scheme, the diameter that the diameter of described structural type enhancing body perhaps strengthens the external circle of contact is 5～500mm, and the layout density in cystosepiment is 1～10000/1000000mm
2
Concrete, the diameter that strengthens the diameter of body or strengthen the external circle of contact can be 5,10,20,30,40,50,60,70,80,90,100,120,150,180,200,220,250,280,300,320,350,380,400,420,450,480 or 500mm.
Concrete, strengthen the layout density of body in cystosepiment and can be 1,4,5,8,10,15,20,50,100,150,200,300,400,500,600,700,800,900,1000,1200,1500,1800,2000,2200,2500,2800,3000,3200,3500,3800,4000,4200,4500,4800,5000,5500,6000,7000,8000,9000 or 10000/1000000mm
2
Further, diameter or circumscribed diameter preferable range that described structural type strengthens body are 10～200mm, and the layout density preferable range in cystosepiment is 6～3000/1000000mm
2
On the basis of such scheme, it is a kind of in tubular structure, prismatic structure, skeleton shape structure, cell structure, truss structure, the network structure or their combination that described structural type strengthens body.
Except above these several kinds of structures, it can also be other versions such as polyhedral structure, plank frame, alveolate texture, nest like structure that structural type strengthens body, but with tubular structure for better.
On the basis of such scheme, the cross section of said tubular structure is a kind of in circle, ellipse, triangle, quadrangle, pentagon, the hexagon.Wherein, be that circular tubular structure is best with the cross section.The cross section can be that to remain silent also can be opening section.
On the basis of such scheme, said prismatic structure is the assembly of single prism or a plurality of single prisms, and wherein, single prismatic structure is a kind of in triangular prism, quadrangular, pentagonal prism, six prisms.The cross section can be that to remain silent also can be opening section.
On the basis of such scheme, said gridiron is a kind of in " well " font of being barricaded as of grid, triangle, the sphere of movements for the elephants shape.
On the basis of such scheme, described majority structural type strengthens that body is triangular in shape in matrix material, quadrangle, pentagon or hexagon are arranged.
Concrete; Tubular structure type enhancing body with circular cross-section is an example; Most such enhancing body arranging in cystosepiment can be square,, in the square region of each unit length of side, arrange a pipe that is; A pipe is respectively arranged at four jiaos of places of the square region of each unit length of side in ground perhaps of equal value; Also can be to arrange, that is, respectively arrange a pipe at three angle point places of the equilateral triangle of each unit length of side by equilateral triangle.Can also arrange by non-equilateral triangle or other geometries of particular requirement.
On the basis of such scheme, described structural type strengthens body for to be processed by a kind of or its combination in metal material, ceramic material, common high molecular materials, fibre-reinforced high molecular based composites, bamboo wood, the timber.
Metal material such as aluminium alloy, magnesium alloy, titanium alloy, stainless steel, corronil etc.
In the fibre-reinforced high molecular based composites, can be glass fibre, carbon fiber, basalt fibre, graphite fibre, carborundum (SiC) fiber, aramid fiber, superhigh molecular weight polyethylene fibers, cotton fibriia or reed fiber etc. in order to the fiber that strengthens.
On the basis of such scheme, the component of described expanded material comprises raw material and blowing agent, and other components can also comprise catalyst, stabilizing agent, plasticizer, surfactant etc.Wherein, described raw material are one or more combinations in the macromolecular material that can realize foaming, ceramic material, the metal material, and described raw material are graininess, Powdered or liquid.Be preferably mobile better liquid.
The macromolecular material that can realize foaming such as PVC, PEI, PMI, PP (polypropylene), PE (polyethylene), PU, PS (polystyrene), ABS (acrylonitrile-styrene-butadiene copolymer), phenolic resins, epoxy resin etc.; Ceramic material that can foam such as aluminium oxide, kaolin, silicon nitride, boride etc., even can be metal material such as fine aluminium, the stainless steel foamed material etc. of processing foam.
Blowing agent to macromolecular material can be heat cured, also can be thermoplastic.For example, adopt foaming injection machine with the PU foaming liquid of two components after the filling gun front end mixes, inject in the closed mould.Through foaming, with the complete embedding of enhancing structure in the mould.Foaming can be adopted the die sinking foaming, can be foaming inclosed molds also, need end plate of removing and mould be fixed before the foaming inclosed molds.
A kind of preparation method of above-mentioned lightweight reinforced cystosepiment adopts following one-step method foaming preparation, or adopts two-step method foaming preparation:
One-step method foaming: structural type is strengthened body be arranged in the foaming mould, again expanded material is injected in (pour into or squeeze into) foaming mould, simultaneously structural type is strengthened the space filling of inside and outside after the expanded material foaming, process the strengthening foam plate by designing requirement;
Two-step method foaming: earlier expanded material injecting structure type is strengthened in the body; The internal voids that after the foaming structural type is strengthened body is filled; Structural type after will filling again strengthens body and is arranged in the foaming mould by designing requirement; In foaming mould, inject (pour into or squeeze into) expanded material for the second time, fill in the space that after the expanded material foaming structural type is strengthened between the body, processes the strengthening foam plate.
Concrete; Preparing one has enough rigidity, has movably foaming mould of an end casing at least; Preferably be with the mould of heating and attemperating unit; Be furnished with in the mould in hollow structure type enhancing body or the hollow structure enhancing body and be pre-charged with foam, foam process can adopt but be not limited to forms such as extrusion foaming, injection foaming, moulding foaming, calendering foaming, powder foam, spray coating foaming.
After foaming is accomplished, take out and be embedded with cystosepiment or the foam block that strengthens structure, again foam block is cut along thickness direction, cystosepiment is promptly strengthened.
The invention has the beneficial effects as follows:
Strengthen the design of body through the rational structure type, adopt the structural type of hollow to strengthen body, the selection of compounding ingredient, can obtain Z to performance significantly improve, equivalent density increases little strengthening foam plate.
Description of drawings
Fig. 1 strengthens body for the structural type that the prismatic structure by four triangular-sections constitutes.
Fig. 2 strengthens body for the structural type that the prismatic structure by three quadrangular section constitutes.
Fig. 3 strengthens body for the structural type that the prismatic structure by three hexagonal cross-sections constitutes.
Fig. 4 strengthens the sketch map that body is square and arranges for the tubular structure type of circular cross-section among the embodiment 1 in cystosepiment.
Fig. 5 embeds the photo that aluminium-alloy pipe strengthens the PU cystosepiment of body among the embodiment 1.
Fig. 6 strengthens body sketch map of arranging triangular in shape in cystosepiment for the tubular structure type of circular cross-section among the embodiment 2.
Fig. 7 is that " well " font grid structural type among the embodiment 4 strengthens body.
Fig. 8 is the photo that is used for the netted enhancing body of structure " well " font grid among the embodiment 5.
Fig. 9 is converted into the triangular prism with equal length right-angle side among the embodiment 7 by sheet material.
Hollow cover plate or the base plate of Figure 10 for cutting into by sheet material among the embodiment 7.
The specific embodiment
Embodiment 1
Mould (area 1330000 mm at 1.9m ' 0.7m ' 0.03m
2) in, by every 10000mm
2The tubular structure type of arranging a circular cross-section strengthens body (seeing sketch map 4), strengthens the thick 1mm of body wall, diameter 50mm; Length 30mm; Identical with the degree of depth of mould, being arranged in parallel altogether 133 strengthens body, strengthens the axially consistent with the depth direction of mould of body; Promptly the concora crush direction with cystosepiment is consistent, and it is fixing in mould to strengthen body.
Strengthen body and adopt 5 kinds of different materials manufacturings respectively:
(A) stainless steel tube, density 7.8g/cm
3, elastic modelling quantity 210GPa, compressive strength 1000MPa, 133 heavy 4.7907kg of pipeline section;
(B) aluminium-alloy pipe, density 2.7g/cm
3, elastic modelling quantity 71GPa, compressive strength 350MPa, 133 heavy 1.6585kg of pipeline section;
(C) magnesium-alloy tube, density 1.74g/cm
3, elastic modelling quantity 45GPa, compressive strength 270MPa, 133 heavy 1.0693kg of pipeline section;
(D) carbon-fibre reinforced epoxy resin pipe, density 1.65g/cm
3, elastic modelling quantity (along tube axial direction) 135GPa, compressive strength (along tube axial direction) 900MPa, 133 heavy 1.0135kg of pipeline section;
(E) glass fiber reinforced epoxy resin pipe, density 2.05g/cm
3, elastic modelling quantity (along tube axial direction) 42GPa, compressive strength (along tube axial direction) 700MPa, 133 heavy 1.2595kg of pipeline section.
Adopt foaming inclosed molds, the mould upper cover plate is pressed in the upper end that each circular cross-section strengthens body, and fix with mould.Injection density is 20kg/m in mould
3PU expanded material (containing blowing agent) since with the extruding of die cavity wall and pipe face, the about 30kg/m of the foam density of being sent
3, the heavy 1.18kg of foam.Suppose that (carrying on the 100mm ' 100mm) strengthens body by the circular cross-section of being buried and takes on unit are fully; Promptly; Ignore fully foam to strengthening foam plate Z to the contribution of intensity and rigidity, the equivalent performance parameter that calculates 5 kinds of different strengthening foam plates that strengthen bodies is following:
(A) density 149.6kg/m
3, Z is to modulus 3.23GPa, and Z is to compressive strength 15.4MPa;
(B) density 71.1kg/m
3, Z is to modulus 1.09GPa, and Z is to compressive strength 5.39MPa;
(C) density 56.3kg/m
3, Z is to modulus 0.69GPa, and Z is to compressive strength 4.16MPa;
(D) density 54.9kg/m
3, Z is to modulus 2.08GPa, and Z is to compressive strength 13.9MPa;
(E) density 61.1kg/m
3, Z is to modulus 0.65GPa, and Z is to compressive strength 10.8MPa.
Be not difficult to find out that the Z of above-mentioned (C), (D), (E) three kinds of strengthening foam plates surpasses close density respectively to elastic modelling quantity and compressive strength, and (density is 60kg/m
3) PVC structural foam panels modulus and intensity (being respectively 35MPa and 0.25MPa) nearly more than 20 times or 20 times; Though and (B) density of strengthening foam plate slightly improves, the specific modulus ratio of density (modulus with) and the specific strength ratio of density (intensity with) also almost are 20 times of the corresponding performance of PVC structural foam panels.
Adopting aluminium-alloy pipe is the reinforcement PU cystosepiment (because the root face effect of cutting causes pipe end " thickness " to surpass the tube wall actual (real) thickness) as shown in Figure 5 that reinforcing material is processed, and actual modulus and the intensity of strengthening the PU cystosepiment should be higher than above-mentioned simplification calculated value.This cystosepiment that various schemes obtain can be used for the manufacturing of traffic above-ground carbodies such as fan blade, caravan, high ferro.
Embodiment 2
The material that the tubular structure type of 5 kinds of circular cross-sections strengthens body respectively with embodiment 1 in identical; But arrange by equilateral triangle; The place, summit that in each length of side is the equilateral triangle of 100mm respectively arranges a pipe, arranges altogether that in the mould of 2.3m ' 0.8m ' 0.03m 180 strengthen bodies, the every long 30mm of pipe; Strengthen the axially consistent of body, promptly with the concora crush direction consistent (as shown in Figure 6) of cystosepiment with the depth direction of mould.
Strengthen the inside and outside foam-filled by hard PU of body, the averag density of foam is 30kg/m
3Suppose that the carrying on the unit cell (being that the length of side is the equilateral triangle of 100mm) strengthens the edge effect that cystosepiment is taken on and ignored to body by the circular cross-section of being buried fully, it is following to calculate in such cases 5 kinds of different equivalent performance parameters that strengthen the strengthening foam plate that the body materials obtain:
(A) density 168.1kg/m
3, Z is to modulus 3.73GPa, and Z is to compressive strength 17.8MPa;
(B) density 77.5kg/m
3, Z is to modulus 1.26GPa, and Z is to compressive strength 6.22MPa;
(C) density 60.4kg/m
3, Z is to modulus 0.8GPa, and Z is to compressive strength 4.8MPa;
(D) density 58.9kg/m
3, Z is to modulus 2.4GPa, and Z is to compressive strength 16MPa;
(E) density 65.9kg/m
3, Z is to modulus 0.75GPa, and Z is to compressive strength 12.4MPa.
Embodiment 3
The material, physical dimension and the arrangement mode in foaming mould that strengthen body are identical with embodiment 1 or embodiment 2, but adopt phenolic resins as the blowing agent raw material.Though a little less than the performance of PU cystosepiment, a considerable advantage of phenol formaldehyde foam is that fire protecting performance is good to phenol formaldehyde foam aspect insulation, heat-proof quality, it has special premium properties aspect fire-retardant.It is in light weight, and rigidity is big, and dimensional stability is good, resistance to chemical attack; Good heat resistance, difficult combustion is put out certainly, low smog; Flame resistant penetrates, and meets fire and does not have unrestrained thing, and cheap advantage makes phenol formaldehyde foam have special applications in fields such as track traffic, traffic above-ground, manned vehicles and is worth.Yet the greatest weakness of phenol formaldehyde foam is that fragility is big, and toughness is not enough, is difficult to improve through rearmounted methods such as X-pin pin or lockstitch the deficiency of its mechanical property.But; Through the one-step method foaming, be about to structural type enhancing body and be evenly distributed in the foaming mould, expanded material is injected in the foaming mould foam then; The space that strengthens the inside and outside is filled, and the reinforcement phenolic foam board of processing just can show the mechanical property behind the efficient hardening.
Through in mould, injecting phenolic resins expanded material (comprising blowing agent), suppose that the equivalent phenol formaldehyde foam of circular cross-section enhancing inside and outside is respectively 60kg/m
3Ignore the contribution of enhancing inside and outside foam to flat crush resistance equally, so, the reinforcement phenol formaldehyde foam performance parameter behind the enhancing pipe of 5 kinds of different materials of interpolation is following:
(A) stainless pipe enhancing, square arranging, equivalent density 179.1kg/m
3, Z is to modulus 3.23GPa, and Z is to compressive strength 15.4MPa;
(B) tube and pipe of aluminium alloy enhancing, square arranging, equivalent density 100.6kg/m
3, Z is to modulus 1.09GPa, and Z is to compressive strength 5.39MPa;
(C) magnesium alloy circular tube enhancing, square arranging, equivalent density 85.9kg/m
3, Z is to modulus 0.69GPa, and Z is to compressive strength 4.16MPa;
(D) carbon fibre composite pipe enhancing, square arranging, equivalent density 84.5kg/m
3, Z is to modulus 2.08GPa, and Z is to compressive strength 13.9MPa;
(E) glass fiber compound material pipe enhancing, square arranging, equivalent density 90.6kg/m
3, Z is to modulus 0.65GPa, and Z is to compressive strength 10.8MPa;
(F) stainless pipe enhancing, equilateral triangle are arranged equivalent density 197.6kg/m
3, Z is to modulus 3.73GPa, and Z is to compressive strength 17.8MPa;
(G) tube and pipe of aluminium alloy enhancing, equilateral triangle are arranged equivalent density 106.9kg/m
3, Z is to modulus 1.26GPa, and Z is to compressive strength 6.22MPa;
(H) magnesium alloy circular tube enhancing, equilateral triangle are arranged equivalent density 89.9kg/m
3, Z is to modulus 0.8GPa, and Z is to compressive strength 4.8MPa;
(I) carbon fibre composite pipe enhancing, equilateral triangle are arranged equivalent density 88.3kg/m
3, Z is to modulus 2.4GPa, and Z is to compressive strength 16MPa;
(J) glass fiber compound material pipe enhancing, equilateral triangle are arranged equivalent density 95.4kg/m
3, Z is to modulus 0.75GPa, and Z is to compressive strength 12.4MPa.
These performances are 60kg/m with the density of not strengthening
3Pure phenolic aldehyde rigid foam plate compare, Z improves respectively more than 100 times to modulus and compressive strength.
Embodiment 4
Foaming mould is identical with embodiment's 1; But structural type strengthens body adopts gridiron; (the cell structure cross sectional dimensions that is made up of this lath in the 100mm ' 100mm) is as shown in Figure 7 in unit are; " well " font grid that the lath thick for 0.5mm, that 30mm is wide is formed, the width of lath and the depth direction of mould, promptly consistent with the thickness direction (concora crush is square) of cystosepiment.The every along its length interval 25mm in the bottom of lath has the opening of 5mm wide (along the stave lengths direction), 10mm dark (along the lath width), is convenient to expanded material and passes these each checked spun antung grid of openings entering.
Cover the upper head plate of mould and with after itself and the framed locking, the relative position that the gridiron type strengthens body just is fixed in the mould.In this case, can adopt the scheme of other stationary grizzly.Strengthen the body material with embodiment 1: comprise (A) stainless steel, (B) aluminium alloy, (C) magnesium alloy, (D) carbon-fibre reinforced epoxy resin and (E) glass fiber reinforced epoxy resin; Wherein, carbon fiber and glass fibre are arranged along lath width (being the degree of depth of mould) direction respectively.The density of supposing foam is 30kg/m
3, also suppose unit are (carrying on the 100mm ' 100mm) strengthens body by " well " font grid structural type that is buried fully takes on, and what calculated is following by 5 kinds of different equivalent performance parameters that strengthen the strengthening foam plate that the body materials obtain:
(A) density 149.6kg/m
3, Z is to modulus 4.2GPa, and Z is to compressive strength 20MPa;
(B) density 83.4kg/m
3, Z is to modulus 1.42GPa, and Z is to compressive strength 7MPa;
(C) density 64.2kg/m
3, Z is to modulus 0.9GPa, and Z is to compressive strength 5.4MPa;
(D) density 62.4kg/m
3, Z is to modulus 2.7GPa, and Z is to compressive strength 18MPa;
(E) density 61.1kg/m
3, Z is to modulus 0.84GPa, and Z is to compressive strength 14MPa.
Embodiment 5
Present embodiment is identical with the scheme of embodiment 4, but the plate of structure grid is the web plate of similar " expanded metal lath ", referring to Fig. 8.The ratio of quality (intensity with) and the specific stiffness ratio of quality (rigidity with) characteristic is compared and not only had more excellent specific strength to this web plate with solid slab, and numerous mesh that runs through expanded material flowing in foaming process of being more convenient for.
Embodiment 6
In the steel die of 1.3m ' 1m ' 1m, be that three summits of the equilateral triangle of 50mm arrange that the tubular structure type of three circular cross-sections strengthens body, strengthens the wall thickness 0.5mm of body in each length of side; External diameter 25mm, length 1000mm, being arranged in parallel altogether 604 strengthens body; It is identical with the degree of depth of mould to strengthen the height degree; Be that it is axially consistent with the depth direction of mould, also consistent with the thickness direction (concora crush direction) of cystosepiment, it is fixing in mould to strengthen body.
The sidewall upper edge diameter line that strengthens body in the round tube shape structure type some diameters of fighting each other are the perforation of 8mm, form mesh.Strengthen body and adopt 5 kinds of different materials; Comprise: (A) stainless steel, (B) aluminium alloy, (C) magnesium alloy, (D) carbon fibre reinforced plastic and (E) fiberglass reinforced plastics, wherein carbon fiber and glass fibre respectively along the axially-aligned of pipe and matrix adopting heat distortion temperature above 200
0The high temperature resistant vinylite of C.
The PVC molten mass that will be mixed with foaming agent through extruding machine is clamp-oned in the die cavity, and wherein the temperature in the die cavity reaches 180 ℃, under this temperature, accomplishes the PVC foaming, obtains being embedded with the PVC foam square column that the pipe shape strengthens body after the cooling.Use cutting machine square column is cut into the thick sheet material of 25mm, wherein, the edge of a knife of cutting machine is axially vertical with the interior pipe of arranging of post.Thus, obtain the PVC structural foam panels that Z direction strength and rigidity significantly improve, if the density of PVC is 30mm, the similar mechanical of the corresponding cystosepiment of the Z of resulting Reinforced PVC structural foam panels in performance and embodiment 2.These cystosepiments can be used for the manufacturing of fan blade, yacht etc.
Embodiment 7
In the steel die of 1.3m ' 1m ' 30mm, by every 10000mm
2Arrange a quadrangular; The sheet material that each quadrangular is 1mm by four thickness respectively is converted into to construct behind the triangular prism of equal length right-angle side and forms; Each right angle length of side is 3mm (as shown in Figure 9); Again with the sheet material of length of side 50mm, thickness 1mm cut out mid portion (area that cuts out be 44mm ' 44mm), process skylight shape cover plate and base plate (shown in figure 10).Then, four triangular prisms are passed through bonding or welding with window cover and window base plate respectively at four angle point places, process the single quadrangular structure shown in Fig. 2.Also can process six prisms shown in the triangular prism shown in Fig. 1 and Fig. 3 according to said method.
Adopt 5 kinds of different materials to process the quadrangular structural type respectively and strengthen body:
(A) stainless steel, density 7.8g/cm
3, elastic modelling quantity 210GPa, compressive strength 1000MPa, the heavy 2.174kg of 130 quadrangulars (bonding or weight increase and decrease that welding causes between triangular prism and window cover and the window base plate is omitted in supposition);
(B) aluminium alloy, density 2.7g/cm
3, elastic modelling quantity 71GPa, compressive strength 350MPa, the heavy 0.7525kg of 130 quadrangulars (bonding or weight increase and decrease that welding causes between triangular prism and window cover and the window base plate is omitted in supposition);
(C) magnesium alloy, density 1.74g/cm
3, elastic modelling quantity 45GPa, compressive strength 270MPa, the heavy 0.485kg of 130 quadrangulars (bonding or weight increase and decrease that welding causes between triangular prism and window cover and the window base plate is omitted in supposition);
(D) carbon-fibre reinforced O compoiste material, density 1.65g/cm
3, elastic modelling quantity (along prismatic direction) 135GPa, compressive strength (along prismatic direction) 900MPa, the heavy 0.4599kg of 130 quadrangulars (the bonding weight increase that causes between triangular prism and window cover and the window base plate is omitted in supposition);
(E) glass fiber reinforcement epoxy composite, density 2.05g/cm
3, elastic modelling quantity (along prismatic direction) 42GPa, compressive strength (along prismatic direction) 700MPa, the heavy 0.5714kg of 130 quadrangulars (the bonding weight increase that causes between triangular prism and window cover and the window base plate is omitted in supposition).
The density of supposing polyurethane or phenol formaldehyde foam is 60kg/m
3, also suppose unit are (carrying on the 100mm ' 100mm) is taken on by the quadrangular that is buried fully, and what calculated strengthens the reinforcing polyurethane cystosepiment that obtains or the equivalent performance parameter of strengthening phenolic foam board is following by 5 kinds of different materials quadrangulars:
(A) the strengthening foam plate equivalence density 115.3kg/m of stainless steel quadrangular enhancing
3, Z is to modulus 0.552GPa, and Z is to compressive strength 2.4MPa;
(B) the strengthening foam plate equivalence density 78.9kg/m of aluminium alloy quadrangular enhancing
3, Z is to modulus 0.17GPa, and Z is to compressive strength 0.84MPa;
(C) strengthening foam plate equivalence density 72 kg/m of magnesium alloy quadrangular enhancing
3, Z is to modulus 0.11GPa, and Z is to compressive strength 0.65MPa;
(D) strengthening foam plate equivalence density 71.4 kg/m of carbon fibre composite quadrangular enhancing
3, Z is to modulus 0.32GPa, and Z is to compressive strength 2.16MPa;
(E) strengthening foam plate equivalence density 74.2 kg/m of glass fiber compound material quadrangular enhancing
3, Z is to modulus 0.1GPa, and Z is to compressive strength 1.68MPa.
Embodiment 8
Formula large-scale kickboard in island can be processed by glass steel surface plate holder foam core, and wherein foam core not only requires density low, and requires to press direction to have sufficiently high strength and stiffness along face, and the cost of foam core is low.
In the mould of 4m ' 2m ' 1.5m, be to arrange that the tubular structure type of a circular cross-section strengthens body, strengthens the wall thickness 2mm of body in the quadrangle unit cell of 500mm along each length of side; External diameter 250mm, length 1500mm, being arranged in parallel altogether 32 strengthens body; It is identical with the degree of depth of mould to strengthen the height degree; Be that it is axially consistent with the depth direction of mould, also consistent with the thickness direction (concora crush direction) of cystosepiment, it is fixing in mould to strengthen body.
Strengthen body and adopt 2 kinds of different materials, comprising: (A) 45
#Fine Steel Casting iron, density 7.85g/cm
3, elastic modelling quantity 210GPa, compressive strength 1000MPa; (B) aluminium alloy, density 2.7g/cm
3, elastic modelling quantity 71GPa, compressive strength 350MPa.
With density is 30kg/m
3PU inject foaming in the mould, make to strengthen inside and outside the pipe that disregard the enhancing body, the averag density after the foaming is about 38kg/m all by the embedding of hard PU foam
3Thus, it is following to obtain the equivalent performance parameter:
(A) 45
#The foam pier equivalence density 86.7kg/m that steel pipe strengthens
3, the equivalent compress modulus 1.31MPa of unit cell, equivalent compress intensity 6.2MPa.
(B) the foam pier equivalence density 54.6kg/m of aluminium-alloy pipe enhancing
3, the equivalent compress modulus 0.44GPa of unit cell, equivalent compress intensity 2.2MPa.
The strengthening foam pier that several are such is clipped in the middle of the glass fabric; Upper and lower surfaces and periphery are all coated by cloth; Adopt vinylite to make the fiber impregnation again through the RIM method; The fiberglass sandwich plate of processing after the curing has that density is little, intensity is high, rigidity is big, corrosion-resistant, a advantage that cost is low, can be used for ocean development and comprises the construction seadrome.
Claims (10)
1. lightweight reinforced cystosepiment; With the expanded material is matrix material; And by the enhancing body enhancing that spreads all in the matrix material, it is characterized in that: described enhancing body is that structural type strengthens body, before the cystosepiment moulding, places foaming mould in advance; Foam the back by the expanded material embedding at expanded material; Wherein, described structural type enhancing body has can supply the inner hollow structure of expanded material entering, and the axial concora crush direction with cystosepiment of enhancing body bearing capacity maximum is consistent or with the concora crush direction angle that is no more than 45 ° is arranged.
2. lightweight reinforced cystosepiment according to claim 1 is characterized in that: diameter or circumscribed diameter that described structural type strengthens body are 5～500mm, and the density in cystosepiment is 1～10000/1000000mm
2
3. lightweight reinforced cystosepiment according to claim 1 is characterized in that: it is a kind of in tubular structure, prismatic structure, skeleton shape structure, cell structure, truss structure, the network structure or their combination that described hollow structure type strengthens body.
4. lightweight reinforced cystosepiment according to claim 3 is characterized in that: the cross section of said tubular structure is a kind of in circle, ellipse, triangle, quadrangle, pentagon, the hexagon.
5. lightweight reinforced cystosepiment according to claim 3 is characterized in that: said prismatic structure is the assembly of single prism or a plurality of single prisms, and wherein, single prism is a kind of in triangular prism, quadrangular, pentagonal prism, six prisms.
6. lightweight reinforced cystosepiment according to claim 3 is characterized in that: said gridiron is a kind of in " well " font of being barricaded as of grid, triangle, the sphere of movements for the elephants shape.
7. according to the described lightweight reinforced cystosepiment of one of claim 1 to 6, it is characterized in that: described majority structural type strengthens that body is triangular in shape in matrix material, quadrangle, pentagon or hexagon are arranged.
8. according to the described lightweight reinforced cystosepiment of one of claim 1 to 6, it is characterized in that: described structural type strengthens body for to be processed by a kind of or its combination in metal material, ceramic material, common high molecular materials, fibre-reinforced high molecular based composites, bamboo wood, the timber.
9. lightweight reinforced cystosepiment according to claim 1; It is characterized in that: the component of described expanded material comprises raw material and blowing agent; Wherein, Described raw material are one or more combinations in the macromolecular material that can realize foaming, ceramic material, the metal material, and described raw material are graininess, Powdered or liquid.
10. preparation method to the lightweight reinforced cystosepiment of one of claim 1 to 9 is characterized in that: adopt a kind of foaming preparation in following two kinds of methods:
One-step method foaming: structural type is strengthened body be arranged in the foaming mould, expanded material is injected in the foaming mould, simultaneously structural type is strengthened the space filling of inside and outside after the expanded material foaming, process the strengthening foam plate by designing requirement;
Two-step method foaming: earlier expanded material injecting structure type is strengthened in the body; The internal voids that after the foaming structural type is strengthened body is filled; Structural type after will filling again strengthens body and is arranged in the foaming mould by designing requirement; Injecting frothing material in foaming mould, fill in the space that after the expanded material foaming structural type is strengthened between the body, processes the strengthening foam plate.
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| CN103381673A (en) * | 2013-07-17 | 2013-11-06 | 南昌航空大学 | Sound absorption and insulation foam polyurethane composite structure with combination arrays of soild pipes and hollow pipes |
| CN106891585A (en) * | 2015-12-17 | 2017-06-27 | 比亚迪股份有限公司 | A kind of metallic composite panel and preparation method thereof |
| CN106891583A (en) * | 2015-12-17 | 2017-06-27 | 比亚迪股份有限公司 | A kind of metallic composite panel and preparation method thereof |
| CN107009691A (en) * | 2017-05-16 | 2017-08-04 | 杭州友凯船艇有限公司 | A kind of foamed composite connect band |
| CN107635424A (en) * | 2015-02-04 | 2018-01-26 | 牛津大学创新有限公司 | A kind of shock sucking structure and the helmet with this structure |
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| CN103381673A (en) * | 2013-07-17 | 2013-11-06 | 南昌航空大学 | Sound absorption and insulation foam polyurethane composite structure with combination arrays of soild pipes and hollow pipes |
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| CN115352095A (en) * | 2022-08-11 | 2022-11-18 | 惠州市佳声包装有限公司 | Light tray processing technology |
| CN116102809A (en) * | 2023-01-31 | 2023-05-12 | 江苏大毛牛新材料有限公司 | Ultra-light water material and preparation method thereof |
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| CN117141012B (en) * | 2023-10-31 | 2024-05-24 | 廊坊市飞泽复合材料科技有限公司 | Foam material reinforcing method |
| CN117264372A (en) * | 2023-11-17 | 2023-12-22 | 四川大学 | Light high-strength sandwich-structure epoxy resin foam material, reinforcing layer and preparation method thereof |
| CN117264372B (en) * | 2023-11-17 | 2024-01-26 | 四川大学 | Light high-strength sandwich-structure epoxy resin foam material, reinforcing layer and preparation method thereof |
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Application publication date: 20120411 |