CN107225804A - 船用金属与夹芯复合材料混合连接结构 - Google Patents
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Abstract
本发明是金属板与夹芯复合材料的混合连接结构，具体构成包括为船用金属板材、轻量化芯材、树脂胶层、纤维增强复合材料以及加强螺栓。其主体结构是轻量化夹芯与预埋L形金属板的对接，同时辅助纤维增强复合材料蒙皮与夹芯的胶接搭接以及纤维增强复合材料蒙皮与金属板的胶接和螺栓连接。本连接结构与复合材料上层建筑采用真空辅助工艺一次成型，并初步固定预埋件L形金属板，固化后采用螺栓连接对预埋件进行二次强化，金属板预埋区外端预留一定空间采用传统焊接工艺与金属主船体相连。本发明显著改善复合材料与金属连接结构承载能力较弱的问题，提高了不同材料混合连接的可靠性，简化了制造装配工艺，有助于大型化复合材料上层建筑的实船应用。
Description
技术领域
本发明涉及船舶复合材料应用和船舶轻量化领域，主要针对轻量化-多功能复合材料上层建筑与金属主船体之间的连接区域，适用于参与总纵弯曲的大型上层建筑。
背景技术
目前金属船舶的上层建筑材料普遍采用船用钢或铝合金，船舶在复杂的海洋环境中运行，上层建筑会受到波浪载荷、重物集中载荷、武器发射时的作用力(舰船)、核爆炸冲击载荷(舰船)、风载、波浪抨击载荷等，船体上层建筑存在强度、刚度、稳定性、疲劳等问题，尤其是在上层建筑底部与主船体的连接区域，作为船舶整体结构的薄弱环节，由于几何形式和材料特性的双重突变，存在明显的应力集中，容易导致局部结构强度损伤和疲劳破环，从而影响船舶整体结构的可靠和安全，降低船舶寿命。
为了解决复合材料上层建筑与金属主船体之间的刚度匹配、强度损伤以及疲劳破坏等问题，实现不同材料结构之间的有效连接。设计不同形式的连接结构，实现金属主船体与复合材料上层建筑的有效搭配，以满足船舶轻量化-多功能的发展需求。比较典型的船舶实例有法国拉斐特护卫舰，在钢质主船体上设计夹芯复合材料机库，在提高舰船隐身性的同时，减小结构重量，提升航速；美国的朱姆沃尔特级驱逐舰设计夹芯复合材料集成上层建筑结构，来增强舰船的隐身性，减轻上层建筑的结构重量，同时降低重心、提高平台稳定性。实践表明，夹芯复合材料所特有的轻质、高强、无磁、透波/吸波等特性，能够满足未来舰船在隐身、减重等方面的发展需求；复合材料耐化学腐蚀、抗疲劳等特性也较传统金属材料更适用于舰船的运行环境。此外，船舶减重意味着有效载荷增加、油耗降低、排放减少，尤其上层建筑减重还可以降低重心，提高稳性。这也符合绿色船舶的发展趋势，呼应了节能减排的社会主题。因此，使用夹芯复合材料是未来船舶上层建筑设计的一个发展方向。基于上述原因提出夹芯复合材料上层建筑搭配金属主船体的创新设计模式。但是考虑到夹芯复合材料与金属板材各自不同的固有属性和受力特征，二者在连接时存在技术难度，为此急需设计制造一种轻质、高强、安全、可靠、制造简单，并且能有效满足工程应用要求的连接结构。
发明内容
本申请人针对上述现有夹芯复合材料上层建筑与金属主船体之间的有效连接问题，进行了改进优化，提供一种结构合理、制造简便的船用金属与夹芯复合材料混合连接结构，具有可靠性好、连接强度高、制造方便的优点。
本发明所采用的技术方案如下：
船用金属与夹芯复合材料混合连接结构，包括分散填充芯材(上层建筑主体芯材和连接区芯材)、L形金属板，以及按照由内至外的顺序覆盖在分散填充芯材和L形金属板端面的胶层以及纤维增强复合材料蒙皮；所述L形金属板的一端预埋入所述分散填充芯材的内部，另一端伸出与所述胶层及纤维增强复合材料蒙皮双搭接，并与金属甲板进行传统方式的连接；所述胶层及复合材料蒙皮向上延伸并覆盖至夹芯复合材料上层建筑的主体芯材的内外端面。机械连接螺栓以双排或多排形式固定于L形金属板与纤维增强复合材料蒙皮的双搭接区域。
其进一步技术方案在于：
所述复合材料蒙皮采用纤维增强树脂基复合材料，所述纤维增强树脂基复合材料中的纤维形式可以采用单向织物、平面织物和其他三向织物；
所述纤维增强树脂基复合材料为预浸基体树脂的纤维或未浸基体树脂的纤维中的任意一种，上述纤维选自碳纤维、玻璃纤维和芳纶纤维或以上三种纤维中的任意一种；
所述分散轻量化填充芯材可以为轻木芯材(Balsawood)、聚氯乙烯(PVC)泡沫、丙烯睛-苯乙烯(SAN)、泡沫聚氨酷(PU泡沫)和聚甲基丙烯酸亚胺(PMI)泡沫芯材材料中的任意一种；
所述胶层的材料为乙烯基树脂、环氧树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种；
所述纤维增强树脂基复合材料的基体树脂选自乙烯基树脂、环氧树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种；
所述预浸基体树脂为乙烯基树脂、环氧树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种；
所述机械连接螺栓选自普通的船用金属螺栓。
本发明的有益效果如下：
本发明设计合理、结构可靠、连接强度高、制造简单和装配方便，本发明采用真空辅助成型工艺与夹芯复合材料上层建筑一体化成型，避免二次连接带来的强度降低和工艺不稳定等问题，大大提高了不同材料连接结构的一致性及可靠性；将L形金属板预埋到复合材料连接结构的设计中，使得复合材料连接结构可以直接与金属甲板进行焊接或机械连接，克服船舶常用热固性树脂基复合材料无法直接与金属板材有效连接的问题，简化了制造工艺，有助于实船建造；在金属板与纤维增强复合材料蒙皮的双搭接区域进行螺栓连接，对弱承载的胶接结构进行二次加强，提高了连接结构在的面内、面外多种载荷作用下的整体强度。本发明通过将L形金属板的一端预埋入分散填充芯材内部，避免了在连接区薄弱位置进行复合材料芯材与金属板的材料突变，同时L形金属板能有效保护过渡区芯材，缓解应力集中，延缓初始失效。此外L形金属板与复合材料上层建筑的主体芯材接触面积较大，有助于受力截面的应力疏散，因而本发明既能有效提高多材料混合结构的连接强度，又大大提高了混合连接结构的在承受面外载荷时的抗弯性能。
附图说明
图1为本发明的结构示意图。
具体实施方式
下面结合附图，说明本发明的具体实施方式。
如图1所示，船用金属与夹芯复合材料混合连接结构包括轻量化芯材2、金属板5，以及按照由内至外顺序覆盖在分散轻量化芯材2、金属板5端面的胶层1及纤维增强复合材料蒙皮3；该轻量化芯材还可称为填充芯材；所述金属板5呈L形，该L形金属板的一端预埋入所述轻量化轻量化芯材2的内部，另一端伸出所述胶层1及纤维增强复合材料蒙皮3并与金属甲板6连接；所述胶层1及纤维增强复合材料蒙皮3向上延伸并覆盖至复合材料上层建筑主体芯材2-1的内外端面。该轻量化芯材2和L形金属板5一起构成混合连接结构的中间部，该混合连接结构的两侧部均由纤维增强复合材料蒙皮3形成，该纤维增强复合材料蒙皮3和轻量化芯材2之间通过树脂胶层1粘接固定，该纤维增强复合材料蒙皮3和L形金属板5之间通过树脂胶层1粘接固定；该机械连接螺栓4将纤维增强复合材料蒙皮3、L形金属板5和树脂胶层1固定在一起。上述主体芯材2-1及覆盖在主体芯材2-1端面的复合材料蒙皮3，胶层1构成了船舶上层建筑的夹芯复合材料结构。上述分散轻量化轻量化芯材2、金属板5，以及覆盖在分散轻量化轻量化芯材2、金属板5两端面的胶层1、纤维增强复合材料蒙皮3及机械连接螺栓4构成了混合连接结构。金属板5伸出胶层1、纤维增强复合材料蒙皮3的部分直接与金属甲板6进行固定相连，比如焊接连接或其他金属间的连接，并需要预留足够的长度，防止不耐高温的热固性纤维增强复合材料及胶层在焊接时受损或融化，影响复合材料混合连接结构。
上述纤维增强复合材料蒙皮3采用纤维增强树脂基复合材料，纤维增强树脂基复合材料中的纤维形式可以采用单向织物、平面织物和其他三向织物。纤维增强树脂基复合材料为预浸基体树脂的纤维或未浸基体树脂的纤维中的任意一种，上述纤维选自碳纤维、玻璃纤维和芳纶纤维或以上三种纤维中的任意一种。所述预浸基体树脂选自不饱和聚酯树脂、环氧树脂、乙烯基树脂、酚醛树脂中的任意一种。
上述分散的轻量化芯材2为轻木芯材(Balsawood)、聚氯乙烯(PVC)泡沫、丙烯睛-苯乙烯(SAN)、泡沫聚氨酷(PU泡沫)和聚甲基丙烯酸亚胺(PMI)泡沫芯材材料中的任意一种。胶层1为乙烯基树脂、环氧树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种。纤维增强树脂基复合材料的基体树脂选自乙烯基树脂、环氧树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种。
根据实际生产及制造需要，上述分散轻量化轻量化芯材2中主体芯材可以与连接区芯材相同，也可以不相同。对于本发明连接结构的制造可以采用复合材料真空辅助成型工艺。
以上描述是对本发明的解释，不是对发明的限定，本发明所限定的范围参见权利要求，在不违背本发明的基本结构的情况下，本发明可以作任何形式的修改。
Claims (9)
1.船用金属与夹芯复合材料混合连接结构，其特征在于：包括纤维增强复合材料蒙皮(3)、轻量化芯材(2)、L形金属板(5)、树脂胶层(1)以及机械连接螺栓(4)；所述的L形金属板(5)一端嵌入所述轻量化芯材(2)的内部，另一端延伸出来与金属主船体的甲板(6)固定相连；
该轻量化芯材(2)和L形金属板(5)一起构成混合连接结构的中间部，该混合连接结构的两侧部均由纤维增强复合材料蒙皮(3)形成，该纤维增强复合材料蒙皮(3)和轻量化芯材(2)之间通过树脂胶层(1)粘接固定，该纤维增强复合材料蒙皮(3)和L形金属板(5)之间通过树脂胶层(1)粘接固定；
该机械连接螺栓(4)将纤维增强复合材料蒙皮(3)、L形金属板(5)和树脂胶层(1)固定在一起。
2.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述轻量化芯材(2)由上层建筑主体芯材(2-1)和连接区芯材(2-2)组成，该上层建筑主体芯材(2-1)位于L形金属板(5)的上方，该连接区芯材(2-2)形成在L形金属板(5)的内弯部。
3.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：该机械连接螺栓(4)为并排设置的两排或多排。
4.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述纤维增强复合材料蒙皮(3)采用纤维增强树脂基复合材料，所述纤维增强树脂基复合材料中的纤维形式采用单向织物、平面织物或三向织物。
5.如权利要求4所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述纤维增强复合材料蒙皮(3)为预浸基体树脂的纤维或未浸基体树脂的纤维中的一种，上述纤维采用碳纤维、玻璃纤维或芳纶纤维。
6.如权利要求5所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述预浸基体树脂为环氧树脂、乙烯基树脂、不饱和聚酯树脂以及酚醛树脂中的任意一种。
7.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述分散的轻量化芯材(2)为轻木芯材、聚氯乙烯泡沫、丙烯睛-苯乙烯、泡沫聚氨酷和聚甲基丙烯酸亚胺泡沫芯材材料中的任意一种。
8.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：所述树脂胶层(1)的材料为乙烯基树脂、环氧树脂、不饱和聚酯树脂或酚醛树脂中的任意一种。
9.如权利要求1所述的船用金属与夹芯复合材料混合连接结构，其特征在于：机械连接螺栓(4)选自普通的各类型号的船用金属螺栓。
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