CN107696645B - Composite material plate and box body - Google Patents

Composite material plate and box body Download PDF

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Publication number
CN107696645B
CN107696645B CN201610642221.8A CN201610642221A CN107696645B CN 107696645 B CN107696645 B CN 107696645B CN 201610642221 A CN201610642221 A CN 201610642221A CN 107696645 B CN107696645 B CN 107696645B
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composite
composite material
plate
fiber
resin
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CN107696645A (en
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胡海东
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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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • 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
    • B32B1/00—Layered products having a non-planar shape
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D15/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D15/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials
    • B65D15/24—Connections between walls
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • 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
    • B32B2419/00—Buildings or parts thereof
    • 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
    • B32B2439/00—Containers; Receptacles
    • B32B2439/02—Open containers

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The invention discloses a composite material plate containing a reinforcing rib structure, a surface layer metal material and a metal frame system, a box body formed by splicing the composite material plate, and application of the box body in the aspects of containers, water tanks, cooling tower bodies, temporary houses and the like; further, the present invention relates to a pultrusion process to produce a composite material containing a skin material different from the inner layer composite material.

Description

Composite material plate and box body
Technical Field
The invention relates to a composite material plate containing a reinforcing rib structure, a metal frame system and a metal surface layer, a box body formed by splicing the composite material plate, and application of the box body in the aspects of containers, water tanks, cooling tower bodies, temporary houses and the like; further, the present invention relates to a pultrusion process to produce a composite material containing a skin material different from the inner layer composite material.
Background
A case may be made of various materials. For cost reasons, the plates and profiles made of steel, aluminium alloys, plastics and glass fibre reinforced plastics are the main materials for the production of tanks, but these materials have some drawbacks: the steel has high strength and large modulus, is easy to weld, but has too high density, so that the box body is too heavy and needs to be subjected to surface treatment for rust prevention and corrosion prevention; aluminum alloys also have oxidation and corrosion problems; although the density of plastics and general glass fiber reinforced plastics is low, there are problems of low strength and rigidity and poor weather resistance.
In order to solve the above problems, the present invention provides a composite sheet, which has, on the one hand, a high fiber content and thus a high strength and rigidity; on the other hand, it can be made by pultrusion, prepreg moulding or extrusion processes well known in the industry, with an axial stiffener structure arranged along the pultrusion or extrusion direction or parallel to most of the individual fibers, with good structural rigidity and can be produced continuously; on the other hand, the material with the functions of increasing transverse strength, resisting impact, resisting weather, not polluting food, decorating surface, resisting skid, resisting wear, resisting corrosion and the like can be compounded on the surface layer so as to meet the individual requirements of different box applications; in another aspect, the composite plate further comprises transverse reinforcing ribs and a metal frame, and has the characteristics of high structural rigidity, light weight and easiness in assembly. Therefore, the composite material plate provided by the invention well overcomes the defects of the traditional material, can reduce the weight of the manufactured box body, reduce the cost and improve the performance, and has great economic value in typical applications such as containers, water tanks, temporary houses, cooling tower bodies and the like. Furthermore, the invention also provides a pultrusion process, which can continuously manufacture the composite material plate with the functional surface material on line, greatly improve the production efficiency and reduce the cost.
Disclosure of Invention
In view of the above, the first aspect of the present invention provides a composite material sheet, characterized in that: 1) the composite material contains a fiber reinforced material as a dispersed phase and a matrix material as a continuous phase; 2) the matrix material accounts for less than 45% of the total volume of the composite material or less than 35% of the total weight of the composite material, and preferably, the matrix material accounts for less than 37% of the total volume of the composite material or less than 27% of the total weight of the composite material; 3) the composite sheet contains a frame made of metal.
In an advantageous embodiment of the invention, a composite panel is provided, characterized in that: the composite sheet has a wavy cross-sectional shape, preferably a sinusoidal cross-sectional shape.
In a further advantageous embodiment of the invention, it provides a composite panel which is characterized in that: the composite panel has a pultrusion process or an extrusion process with axially arranged composite reinforcing ribs integrally formed with the composite panel.
The term "axial" as used herein refers to the direction in which the pultrusion or extrusion process is carried out or parallel to the direction in which the majority of unidirectional fibers are arranged, and "transverse" refers to the direction perpendicular to the "axial" direction. The reinforcing rib is a part protruding from the composite material plate, is integrated with the composite material plate, and can be made of the same material as the composite material plate or different materials from the composite material plate.
In an advantageous embodiment of the invention, it provides a composite sheet characterized in that: the matrix material is selected from one or a combination of more of thermoplastic polymers and thermosetting polymers. The thermoplastic polymer matrix material is selected from polyvinyl chloride, polyethylene, polypropylene, nylon, polyethylene terephthalate, polyformaldehyde, polybutylene terephthalate, polybutylene, polyvinyl alcohol, thermoplastic polyurethane and polyamide; the thermosetting polymer matrix material is selected from unsaturated polyester resin, vinyl resin, epoxy resin, melamine formal, phenolic resin, polyurethane, cyanate ester and maleic anhydride resin.
In another advantageous embodiment of the invention, a composite panel is provided, characterized in that: the fiber reinforced material is selected from one or more of glass fiber, basalt fiber, boron fiber, quartz fiber, carbon fiber, polymer fiber, natural fiber and metal fiber.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: the cross-sectional shape of the composite material reinforcing rib is selected from: complete or partial circle, ellipse, ring, rectangle, square ring, hexagon, hexagonal ring, U-shaped, L-shaped, T-shaped.
In another advantageous embodiment of the invention, a composite panel is provided, characterized in that: the distance between the central lines of the composite material reinforcing ribs is 30-300mm, preferably 50-200 mm, and more preferably 50-100 mm.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: the width of the bottom of the composite material reinforcing rib is 2-50mm, preferably 2-20 mm, and more preferably 2-10 mm.
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the height of the composite material reinforcing rib is 2-300mm, preferably 5-100 mm, and more preferably 5-50 mm.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: the edge of the composite material plate contains the composite material reinforcing rib;
in another advantageous embodiment of the invention, a composite material sheet is provided, which is characterized in that: the reinforcing rib comprises a structure which is buckled with the adjacent composite material plate with the same structure, and the buckled structure comprises structures which are commonly used in the industry, such as convex-concave grooves, convex-concave table buckling and the like.
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the reinforcing ribs made of metal materials are combined with the edges of the composite material plates in a mode of bolt fastening, bonding and the like, preferably in a mode of self-locking bolt fastening, and more preferably in a mode of bolt fastening, bonding and the like.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: the composite plate also comprises transverse reinforcing ribs, and the material for forming the transverse reinforcing ribs is selected from metal or composite materials or a combination of the metal and the composite materials.
In a further advantageous embodiment of the invention, a composite panel is provided, characterized in that: the transverse reinforcing ribs have a wave shape similar to the cross-section of the composite sheet.
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the transverse reinforcing ribs and the axial reinforcing ribs are combined in a bolt connection mode, an adhesive bonding mode or a mode of matching the transverse reinforcing ribs and the axial reinforcing ribs together.
In another advantageous embodiment of the invention, a composite panel is provided, characterized in that: the composite material plate is combined with the metal reinforcing ribs or the metal frame into a whole through the fiber reinforced resin prepreg tapes; preferably, the resin of the fiber reinforced resin prepreg tape is selected from epoxy resin, aromatic polyurethane, aliphatic polyurethane; the fiber is selected from fabric woven by glass fiber, carbon fiber or organic polymer fiber.
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the thickness of the composite plate is 1.2mm-10mm, preferably 1.5-4 mm, and more preferably 1.7-3 mm.
In a further advantageous embodiment of the invention, a composite panel is provided, characterized in that: the width of the composite material plate is 50 mm-20000 mm, preferably 100-10000 mm, and more preferably 200-8000 mm.
In a further advantageous embodiment of the invention, a composite material sheet is provided which is characterized in that
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the skin layers of the composite panel comprise a different material than the inner composite and provide one or a combination of the following functions: increase transverse strength, impact resistance, weather resistance, no pollution to food, surface decoration, skid resistance, wear resistance and corrosion resistance.
In a further advantageous embodiment of the invention, a composite panel is provided, characterized in that: the composite plate is made by a pultrusion process, a prepreg molding process or an extrusion process.
In another advantageous embodiment of the invention, it provides a composite sheet characterized in that: the inner layer composite material of the composite material plate comprises but is not limited to an aromatic polyurethane composite material, an epoxy resin-based composite material, an unsaturated resin-based composite material and a vinyl resin composite material; the surface layer material includes, but is not limited to, any one of aluminum alloy, steel, stainless steel, plastic, aliphatic polyurethane composite, food grade unsaturated resin matrix composite, vinyl resin matrix composite, paint coating, or combinations thereof.
In another advantageous embodiment of the invention, a composite panel is provided, characterized in that: the inner layer fiber material of the composite material plate is unidirectional continuous fiber, and the surface layer fiber material is selected from fiber fabric or mixture of fiber and fabric.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: 1) the surface layer material of the composite material comprises a metal sheet with holes distributed approximately uniformly; 2) the area of the holes accounts for more than 60% of the total surface of the metal sheet; preferably, greater than 80%; 3) the thickness of the metal sheet is less than 3mm, preferably less than 1.5mm, more preferably less than 1 mm.
In a further advantageous embodiment of the invention, a composite panel is provided, characterized in that: the shape of the holes on the surface metal sheet is selected from one or more of a circle, a quadrangle, a hexagon, a pentagon and a triangle, and preferably, the state length of the holes is less than 40 mm.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: the metal sheet is made of a cold-rolled steel sheet.
In a further advantageous embodiment of the invention, a composite material sheet is provided, characterized in that: 1) the surface of the metal sheet is covered with a layer of fiber fabric reinforced aliphatic polyurethane composite material; preferably, the fibers are organic polymer fibers; 2) the thickness of the fatty polyurethane composite material is less than 1mm, preferably less than 0.5 mm. Preferably, the metal thin plate, the inner composite material plate and the surface aliphatic polyurethane composite material layer are integrally formed through a bath towel material die pressing process; more preferably, the metal sheet has a flange that is not apertured to facilitate the attachment between the composite panels.
In another aspect of the present invention, there is provided a pultrusion process for preparing a composite material characterized by: the pultrusion process comprises the following steps: 1) respectively soaking the inner layer fibers and the surface layer fibers with different resins; 2) the pultrusion die is composed of a pultrusion die 1 and a pultrusion die 2 which are coaxially arranged front and back, and the inner layer fiber soaked by the resin 1 is cured or partially cured through the pultrusion die 1; 3) coating the cured or partially cured inner layer fibers with the surface layer fibers 2 impregnated with the resin 2; 4) the cured or partially cured inner layer fibers are cured into a composite material together with the surface layer fibers covering the surface of the inner layer fibers through a pultrusion die 2. Preferably, resin 1 is an aromatic polyurethane and resin 2 is an aliphatic polyurethane.
In an advantageous embodiment of the invention, a composite panel is provided, characterized in that: the composite panel is made by the pultrusion process described previously.
In a further aspect of the present invention, there is provided a composite material container characterized by: the composite material box body is formed by assembling the composite material plates through connection between metal frames, preferably, the connection mode is any one or combination of welding, bolt connection and adhesive bonding.
In an advantageous embodiment of the invention, it provides a composite box characterized in that: the upright posts of the composite material box body are made of metal materials;
in another advantageous embodiment of the invention, it provides a composite tank characterized in that: the beam of the composite material box body is made of a metal material;
in another advantageous embodiment of the invention, it provides a composite tank characterized in that: 1) the length of the composite material box body is greater than the width and the height; 2) the composite material box body is formed by splicing the composite material plates, the axial reinforcing ribs of the composite material plates are perpendicular to the length direction of the composite material box body, and the transverse reinforcing ribs are parallel to the length direction of the composite material box body.
In a further aspect of the invention, it provides the field of application of composite boxes, characterized in that: applications of the composite material box body include but are not limited to containers for aviation, shipping, railway and highway, water tanks, cooling tower bodies and temporary houses.
Drawings
For further explanation of the composite panels and boxes of the present invention, reference will now be made in detail to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a top and side view of a first preferred embodiment of the present invention;
FIG. 2 is a top and side view of a second preferred embodiment of the present invention;
FIG. 3 is a top and side view of a third preferred embodiment of the present invention;
FIG. 4 is a top and side view of a fourth preferred embodiment of the present invention;
FIG. 5 is a front view and a sectional view of a fifth preferred embodiment of the present invention
FIG. 6 is a front view and a sectional view of a sixth preferred embodiment of the present invention
FIG. 7 is a front, side, top and cross-sectional view of a seventh preferred embodiment of the invention
Detailed Description
Preferred embodiments of the composite sheet and the case of the present invention will be described below with reference to the accompanying drawings.
(first preferred embodiment):
fig. 1 is a top view and a side view of a first preferred embodiment of the present invention. The composite material plate 1 shown in the figure is made of polyurethane resin, alkali-free glass fiber yarn, alkali-free glass fiber hemming felt and polyester anti-corrosive cloth through a pultrusion process, and the specific structure of the fiber is as follows from the inner surface to the outer surface of the plate in sequence: (40 g/m 2) one layer of polyester anti-corrosive cloth/(300 g/m 2) one layer of alkali-free glass fiber edge sewing felt/4800 tex alkali-free glass fiber direct yarn/(300 g/m 2) one layer of alkali-free glass fiber edge sewing felt/(40 g/m 2) one layer of polyester anti-corrosive cloth. The pultrusion process adopts two pultrusion dies which are connected in series from front to back end, firstly, aromatic polyurethane resin is used for soaking alkali-free glass fiber yarns, the alkali-free glass fiber yarns are solidified and molded through the first pultrusion die, then, aliphatic polyurethane resin is used for respectively soaking an upper layer alkali-free glass fiber hemming felt and a lower layer alkali-free glass fiber hemming felt and polyester anti-corrosion cloth, the soaked hemming felt and anti-corrosion cloth are coated on the upper surface and the lower surface of a composite plate which is solidified and pulled out from the first pultrusion die and is made of alkali-free glass fiber direct yarns and aromatic polyurethane resin, then, the upper surface and the lower surface of the composite plate enter the second pultrusion die to be solidified and molded simultaneously, and finally, the composite plate is pulled out of the second pultrusion die to form the composite plate 1. The surface material of the composite material plate 1 is a fiber fabric reinforced aliphatic polyurethane composite material, and has the advantages of weather resistance, wear resistance, large transverse strength and the like, and the inner layer material is a unidirectional fiber reinforced aromatic polyurethane composite material, and has the advantages of ultrahigh axial strength and modulus. The composite plate 1 comprises axial reinforcing ribs 2, 3 and 4 with different shapes and heights, wherein the cross section of each axial reinforcing rib 2 is a solid semicircle with the diameter of 10mm, the cross section of each axial reinforcing rib 3 is a solid L-shaped structure with a right boss, the top of each axial reinforcing rib is 20mm wide, the height of each axial reinforcing rib is 40mm, and the bottom of each axial reinforcing rib is 5mm wide; the cross section of the axial reinforcing rib 4 is in a solid L shape with a left groove, the top of the axial reinforcing rib is 20mm wide, the height of the axial reinforcing rib is 40mm, and the bottom of the axial reinforcing rib is 5mm wide; the boss on the right side of the axial reinforcing rib 3 is just matched with the groove on the left side of the axial reinforcing rib 4, so that the two composite material plates 1 can be tightly locked when being spliced. The composite material plate 1 shown in the figure has the thickness of 2mm, the width of 300mm, the length of the composite material plate can be arbitrarily cut according to needs, and the distance between the axial reinforcing ribs is 50 mm; in use, such a composite sheet 1 has very strong axial strength and stiffness, and the densely arranged axial stiffeners 2 help the composite sheet 1 resist external impacts, while the edge arranged stiffeners 3 and 4 both enhance the stiffness of the composite sheet 1 and provide a connection between multiple composite sheets 1. Preferably, a polyester anti-corrosive cloth soaked by aliphatic polyurethane can be laid on the composite material plate 1, then a hot-dip galvanized punched cold-rolled steel plate with a shape similar to that of the composite material plate 1 is laid on the polyester anti-corrosive cloth, then a layer of polyester anti-corrosive cloth is laid on the punched cold-rolled steel plate, and finally the composite material plate with the metal surface layer is manufactured by pressing and forming through a rubber plate at a rising temperature, more preferably, the holes of the cold-rolled punched plate are hexagons with the side length of less than 50mm, and the distance between the adjacent hole sides is less than 10 mm.
(second preferred embodiment):
fig. 2 is a top view and a side view of a second preferred embodiment of the present invention. The second preferred embodiment employs the same pultrusion process as the first preferred embodiment to produce the composite panel 8. The composite material plate 8 is wave-shaped, the wave tops of the inner side and the outer side are distributed with the same axial reinforcing ribs 2 as the second preferred embodiment, and the distance between the axial reinforcing ribs 2 is 100 mm. The height of a single wave of the composite material plate 8 is 50mm, and the width is 100 mm; the composite sheet 8 has a thickness of 1.7mm and a width of 600 mm. An axial groove 19 which is opened upwards is formed in the leftmost wave 9 of the composite material plate 8, and a downward axial boss 18 which is formed in the rightmost wave 10 of the composite material plate 8 can be tightly matched with the groove in the leftmost wave 9.
(third preferred embodiment):
fig. 3 is a top view and a side view of a third preferred embodiment of the present invention. The third preferred embodiment employs the composite material sheets 1 of the first preferred embodiment and shows how the composite material sheets 1 of the first preferred embodiment are joined. In the splicing process, firstly, the epoxy resin glass fiber prepreg tape is laid in the groove in the axial reinforcing rib 4, and then clamping pressure is applied to the axial reinforcing ribs 3 and 4 under a high temperature condition to solidify the epoxy resin glass fiber prepreg tape, so that the two composite material plates 1 are combined into a whole.
(fourth preferred embodiment):
fig. 4 is a top view and a side view of a fourth preferred embodiment of the present invention. The fourth preferred embodiment uses the composite sheets 8 of the second preferred embodiment and shows how the composite sheets 8 of the second preferred embodiment are attached to each other. In the connection, the epoxy resin glass fiber prepreg tape is laid in an axial groove 19 on the leftmost wave 9 of the composite material plate 8, the pressure is applied to the leftmost wave 9 and the rightmost wave 10 on the adjacent composite material plate 8 at high temperature to enable an axial boss 18 and the axial groove 19 on the waves 9 and 10 to be tightly buckled, and the epoxy resin glass fiber prepreg tape is solidified at high temperature so as to splice two or more composite material plates 8 into a large plate. Preferably, polyester anti-corrosive cloth soaked by aliphatic polyurethane can be laid on a large plate spliced by the composite material plates 8, then a hot galvanizing punching cold-rolled steel plate with a shape similar to that of the composite material 8 is laid on the polyester anti-corrosive cloth, then a layer of polyester anti-corrosive cloth is laid on the punching cold-rolled steel plate, and finally the composite material plate with the metal surface layer is manufactured by pressing and forming the rubber plate up and down at a raised temperature through a rubber plate.
(fifth preferred embodiment):
fig. 5 is an elevation view and a section view of a fifth preferred embodiment of the present invention, which employs the composite material sheet 1 of the first preferred embodiment and employs transverse stiffeners 6 integrally connected to axial stiffeners 3, 4 on the composite material sheet 1 by adhesive and snap fasteners 7. The transverse reinforcing ribs 6 are made of hot galvanized channel steel, the cross section dimension is 100mm x 4mm, and the distance between the central lines of the transverse reinforcing ribs 6 is 1200 mm. The transverse reinforcing ribs 6 connect the plurality of composite material plates 1 into a large plate, and meanwhile, the transverse strength and rigidity of the composite material plates 1 are enhanced. Around the composite material sheet 1 are arranged transverse frames 20 and axial frames 21. The transverse frame 20 and the axial frame 21 are both made of hot galvanized steel angles of 50mm by 3 mm. In the plate splicing process, firstly, epoxy resin glass fiber prepreg tapes are laid on frames formed by welding a transverse frame 20 and an axial frame 21, then, large plates formed by splicing composite material plates 1 are placed on the epoxy resin glass fiber prepreg tapes, pressure is applied to the composite material plates 1 and the frames 20 and 21, and the epoxy resin glass fiber prepreg tapes are cured at high temperature to obtain the composite material large plate with the metal frame.
(sixth preferred embodiment):
FIG. 6 is an elevation view and a sectional view of a sixth preferred embodiment of the present invention, which employs the composite material sheet 8 of the second preferred embodiment, and on both the inner side and the outer side of the composite material sheet 8, there are arranged transversely arranged inner wave ribs 15 and outer wave ribs 14 having the same wave shape as the composite material sheet 8; the inner corrugated reinforcing ribs 15 and the outer corrugated reinforcing ribs 14 are welded together with the inner transverse reinforcing ribs 16 and the outer transverse reinforcing ribs 13, respectively; the edge of the large plate formed by splicing the composite material 8 is surrounded by an inner frame formed by welding an inner layer transverse frame 23 and an inner layer axial frame 18, and an outer frame formed by welding an outer layer transverse frame 22 and an outer layer axial frame 17, and two ends of the inner transverse reinforcing rib 16 and the outer transverse reinforcing rib 13 are respectively welded on the inner frame and the outer frame. In the plate splicing process, epoxy resin glass fiber prepreg tapes are laid on the inner surface and the outer surface of the composite material plate 8 and the positions, which need to be combined with the transverse reinforcing ribs 14 and 15 and the frames 17, 18, 22 and 23, and pressure is applied to the inner frame, the inner transverse reinforcing rib 16 and the outer transverse reinforcing rib 13, and the temperature is raised at the same time, so that the epoxy resin glass fiber prepreg tapes are cured, and the composite material large plate with the metal inner frame, the metal outer frame and the transverse reinforcing ribs is manufactured. In the preferred embodiment, the inner corrugated reinforcing ribs 15, the outer corrugated reinforcing ribs 14, the inner transverse reinforcing ribs 16 and the outer transverse reinforcing ribs 13 are all made of hot galvanized channel steel, and the cross-sectional dimensions are 50mm by 3 mm; the dimensions of the inner transverse stiffeners 16 and the outer transverse stiffeners 13 are 50mm by 3 mm; the space between the inner corrugated channel steel 15 and the outer corrugated channel steel 14 and the space between the inner transverse reinforcing ribs 16 and the outer transverse reinforcing ribs 13 are 1200mm, the inner transverse frames 23 and the inner axial frames 18 and the outer transverse frames 22 and the outer axial frames 17 are all hot galvanized angle steel, and the cross section sizes are 100mm x 3 mm.
(seventh preferred embodiment):
fig. 7 is a front view, a side view and a sectional view of a seventh preferred embodiment of the present invention, illustrating how composite material large boards with metal frames in the fifth preferred embodiment and the sixth preferred embodiment are assembled into a box body. In the actual assembly process, the box body can be assembled by welding the metal frame, and can also be prepared by locking the metal frame through bolts. In a preferred embodiment, the box body is made by using the composite material large plate made in the fifth preferred embodiment as a bottom plate, and the composite material large plate made in the sixth preferred embodiment as a side plate and a top plate.
While the composite panel construction and box of the present invention has been described in connection with the preferred embodiment, those of ordinary skill in the art will recognize that the foregoing examples are illustrative only and are not to be construed as limiting the invention. The invention, therefore, may be modified within the spirit and scope of the appended claims. Such variations are intended to fall within the scope of the invention as claimed.

Claims (20)

1. A composite sheet characterized by: 1) the composite material contains a fiber reinforced material as a dispersed phase and a matrix material as a continuous phase; 2) the matrix material accounts for less than 45% of the total volume of the composite material or less than 35% of the total weight of the composite material; 3) the composite plate is provided with an inner layer material and a surface layer material wrapping the inner layer material, the base material comprises a first resin base body and a second resin base body, the inner layer material of the composite plate comprises a first composite material formed by a unidirectional continuous fiber reinforced first resin base body, and the surface layer material comprises a second composite material formed by a fiber fabric reinforced second resin base body; 4) the composite plate is integrally formed by two pultrusion dies which are connected in series from front to back end, wherein the inner-layer first composite material is cured or partially cured by the first pultrusion die, and the surface-layer second composite material coats the inner-layer first composite material output from the first pultrusion die and enters the second pultrusion die for curing; 5) the composite material plate output from the pultrusion die is provided with a plurality of composite material reinforcing ribs which are axially arranged and integrally formed with the composite material plate, each composite material reinforcing rib comprises a first edge reinforcing rib and a second edge reinforcing rib, each first edge reinforcing rib is provided with a boss, each second edge reinforcing rib is provided with a groove, and a plurality of composite material plates can be buckled and spliced through the bosses and the grooves to form a composite material large plate.
2. The composite sheet of claim 1, wherein: the composite sheet has a wavy cross-sectional shape.
3. The composite sheet according to claim 1, wherein: the matrix material is selected from one or a combination of more of thermoplastic polymers and thermosetting polymers: the thermoplastic polymer matrix material is selected from polyvinyl chloride, polyethylene, polypropylene, polyethylene terephthalate, polyformaldehyde, polybutylene terephthalate, polybutylene, polyvinyl alcohol, thermoplastic polyurethane and polyamide; the thermosetting polymer matrix material is selected from unsaturated polyester resin, vinyl resin, epoxy resin, melamine formal, phenolic resin, polyurethane, cyanate ester and maleic anhydride resin.
4. The composite sheet of claim 1, wherein: the fiber reinforced material is selected from one or more of glass fiber, basalt fiber, boron fiber, quartz fiber, carbon fiber, polymer fiber, natural fiber and metal fiber.
5. The composite sheet according to claim 1, wherein: the distance between the central lines of the composite material reinforcing ribs is 30-300 mm.
6. The composite sheet according to claim 1, wherein: the width of the bottom of the composite material reinforcing rib is 2-50 mm.
7. The composite sheet according to claim 1, wherein: the height of the composite material reinforcing rib is 2-300 mm.
8. Composite sheet according to any one of claims 1 to 7, characterized in that: the composite plate also contains transverse reinforcing ribs, and the material of which the transverse reinforcing ribs are made is selected from metal or composite materials or a combination of the metal and the composite materials.
9. The composite panel of claim 8, wherein the transverse stiffeners have an undulating shape conforming to the cross-section of the composite panel.
10. The composite sheet according to any one of claims 1 to 7, characterized in that: the thickness of the composite plate is 1.2mm-10 mm.
11. The composite sheet according to any one of claims 1 to 7, wherein: the inner layer composite material of the composite material plate comprises an aromatic polyurethane composite material, an epoxy resin-based composite material, an unsaturated resin-based composite material and a vinyl resin composite material; the surface layer material comprises any one of aluminum alloy, steel, stainless steel, plastics, aliphatic polyurethane composite materials, food-grade unsaturated resin matrix composite materials, vinyl resin matrix composite materials and paint coatings or the combination of the aluminum alloy, the steel, the stainless steel, the plastics and the aliphatic polyurethane composite materials.
12. The composite material sheet according to any one of claims 1 to 7, wherein: 1) the surface layer material of the composite material contains metal sheets with holes uniformly distributed; 2) the area of the holes accounts for more than 60% of the total area of the metal sheet; 3) the thickness of the metal sheet is less than 3 mm.
13. The composite sheet of claim 12, wherein: the shape of the holes on the surface layer metal sheet is selected from one or more of a circle, a quadrangle, a hexagon, a pentagon and a triangle.
14. The composite sheet according to claim 12, wherein: the metal sheet is made of a cold-rolled steel sheet.
15. The composite sheet of claim 12, wherein: the surface of the metal sheet is covered with a layer of fiber fabric reinforced aliphatic polyurethane composite material with the thickness less than 1 mm.
16. A pultrusion process for preparing a composite material characterized by: the pultrusion process comprises the following steps: 1) respectively impregnating the inner layer fibers and the surface layer fibers with a first resin matrix and a second resin matrix; 2) the pultrusion die is composed of a pultrusion die 1 and a pultrusion die 2 which are coaxially arranged front and back, and the inner layer fiber which is soaked by the first resin matrix and contains unidirectional continuous fiber is cured or partially cured through the pultrusion die 1 to form a first composite material; 3) coating the cured or partially cured first composite material with face fibers comprising a fiber fabric impregnated with a second resin matrix; 4) the method comprises the steps of enabling a first composite material which is solidified or partially solidified and surface layer fibers which are wrapped on the surface of the first composite material and soaked by a second resin matrix to be solidified into a composite material plate through a pultrusion die 2, enabling a plurality of composite material reinforcing ribs which are axially arranged and integrally formed with the composite material plate to be arranged on the composite material plate output from the pultrusion die, enabling the composite material reinforcing ribs to comprise first edge reinforcing ribs and second edge reinforcing ribs, enabling bosses to be arranged on the first edge reinforcing ribs, enabling grooves to be arranged on the second edge reinforcing ribs, and enabling the composite material plates to be buckled and spliced through the bosses and the grooves to form a composite material large plate.
17. A composite box characterized by: the composite box body is assembled from composite boards according to any one of claims 1 to 15.
18. A composite tank characterized by: the side plates or the top plate of the composite material box body are made of large composite material plates assembled by the composite material plates of any one of claims 1 to 15.
19. A composite box according to claim 17 or 18, wherein: 1) the length of the composite material box body is greater than the width and the height; 2) the axial reinforcing ribs of the composite plate are perpendicular to the length direction.
20. A composite tank as claimed in claim 17 or 18, wherein: the application of the composite material box body comprises the following steps: containers for aviation, marine transportation, railways and highways, water tanks, cooling tower bodies and temporary houses.
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