CN110625962B - 结构复合材料和方法 - Google Patents

结构复合材料和方法 Download PDF

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Publication number
CN110625962B
CN110625962B CN201910990786.9A CN201910990786A CN110625962B CN 110625962 B CN110625962 B CN 110625962B CN 201910990786 A CN201910990786 A CN 201910990786A CN 110625962 B CN110625962 B CN 110625962B
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carrier
filler
polymer
reinforcing layer
layer
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CN110625962A (zh
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G·E·格林
J·W·克朗伯格
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Marhaygue LLC
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Marhaygue LLC
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Abstract

一种结构聚合物复合材料包括一加强层。该复合材料在连续挤出工艺中制造,其中当聚合物在其上挤出时,将加强层拉过直角进料模头。该层包括膜或织物载体、碳纤维填料、玻璃纤维、有机纤维或形成垫的矿物。结合剂可以分散在垫上并施加第二载体。垫经受加热和加压以软化载体和结合剂,使它们渗透到填料的空隙中并与它们机械结合,载体和结合剂彼此化学结合形成加强层。然后将聚合物挤出在加强层上,该加强层可以是平的,具有孔或冲孔,用于与聚合物的复合作用,形成一轮廓,或分段,以提供间隔开的加强层。

Description

结构复合材料和方法
技术领域
本公开涉及聚合复合材料。更具体地,本公开涉及增强的聚合复合材料。
背景技术
在许多需要如立柱、横梁、盖板、框架构件、装饰件和栏杆等结构件的应用中,聚合物材料已取代了木材。窗框和百叶窗由空心乙烯型材制成。室内装饰线和最近的纱门由泡沫聚氯乙烯制成。
塑料与木材相比具有优势,包括更低的成本、更少的维护,但如果不将其它材料(例如木材或金属插入件)作为辅助增强件来增加刚度,其通常不具有木材的固有强度。添加这些类型的辅助增强材料增加了材料和劳动力成本,并且由于需要额外类型的材料而变得复杂。
结构复合材料是已知的。例如,US 4910067公开了一种结构复合材料,其包括一侧具有热塑性层且另一侧具有一层纤维材料的泡沫芯。泡沫由液态树脂形成,液态树脂与纤维材料接触固化,浸渍并结合成纤维增强结构。该参考文献中还教导了制造复合材料的方法。
US 5700555教导了一种复合制品,其包括完全由塑料制成的第一区域和由塑料加上10%至55%天然纤维制成的第二区域,二者均通过共挤压形成。含纤维的区域包括压花以模仿木纹,并且具有足够的多孔性以接受油漆或着色以模拟天然木材的外观。
US 5738935和US 5858522彼此相关且与US 5700555相关,如上所述,且公开了用于制备天然纤维和热塑性复合材料的方法以及由此得到的产品。该方法包括以下步骤:在搅拌机中将天然纤维和热塑性塑料与孔隙度助剂和界面活性剂混合以形成混合物;将该混合物加入到加热的挤出机中;挤出混合物成为复合材料;以及在真空校准装置中将复合材料成形为所需的轮廓。该方法还包括将第二热塑性材料共挤出在天然纤维/热塑性复合材料上用于某些应用(例如窗户、门和护墙板)的步骤。
EP 0599404公开了一种制备采用连续纤维增强的热塑性复合材料的方法。该方法包括以下步骤:(A)从线轴上展开由一束纤维构成的连续长丝;(b)打开连续长丝,基本上通过将其分解成单独的连续纤维;(c)将打开的长丝浸渍并驱动通过固定床,所述固定床由容纳在储槽中的热塑性聚合物粉末构成,所述热塑性聚合物粉末经受连续振动;(d)重新组合长丝并在其周围布置由热塑性聚合物制成的收容柔性护套。
EP 0653290公开了一种用于生产模制热塑性纤维增强制品的连续方法,通过用熔融的第一热塑性树脂涂覆加热的纤维垫芯的表面,所述制品在至少一个表面具有高树脂浓度,然后使纤维垫芯通过挤出区,其中熔融的第二热塑性树脂挤出到所述挤出区上。然后将纤维垫芯和热塑性树脂模制成一成品。所公开的连续方法提供模制成品,例如屋顶瓦、汽车外饰板、房屋壁板等。
US 5565056公开了一种玻璃纤维增强的建筑面板,通过使熔化的第一和第二聚合物网状物通过隔开的模具开口挤出,将随机定向的短玻璃纤维垫放置在第一和第二网状物之间,将网状物和垫压在一起,冷却,由此产生建筑面板。
EP 0747213公开了一种面板,包括填充有锯屑、木屑或刨花的第一聚丙烯层和至少一个附加层,所述附加层至少部分由纤维热塑性材料构成,通过压缩同时部分融合粘结到第一层的一个面上。该附加层保留了纤维图案和结构。
US 6607798公开了一种纤维增强的中空复合中空结构,其中由热塑性树脂制成的中空芯通过含有采用热固性树脂相互粘结的增强长纤维的中间层连接成一体。然后所述结构覆盖有热塑性树脂的外层。
US 9079380公开了聚氯乙烯(PVC)与复合材料的共挤出,形成连续条带,然后可将其切割成合适的长度。PVC仅在背面形成安装法兰和通风支架,正面所有部件均由纤维素纤维和热塑性树脂复合而成。
具有刚度结构水平和低制造成本的聚合物复合材料将是有利的,特别是如果其通过回收先前使用的材料来维护自然资源。
发明内容
本申请公开了一种结构复合材料,主要由聚合物材料制成,但其在连续制造过程中包含至少一个增强的加强层,从而产生良好结合的、非均匀复合材料。因此,所得复合材料的外观及其耐久性保留了聚合物材料的优点并提供了用于结构应用的强化复合材料的强度,且制造成本低。
本方法可用于形成聚合物型材,通过设计型材内部或型材上的一个或多个加强层的位置和组分而设计成,使得复合材料对于其特定应用具有必需的刚度。另外,所述方法和材料使得复合材料的制造成本可能较低,因为加强层可由容易获得的回收材料(包括短纤维)制成,并且不会在强度上有所妥协或者不利地影响结构复合材料的外观。
本申请公开的用于制造结构复合材料的方法包括将填料分散到一载体上以形成一垫。也可将粘合剂分散到所述垫上。然后对载体上的垫进行加热和挤压以使载体(和粘合剂,如果使用的话)熔化并渗入垫中从而形成加强层。通过将所述加强层成型为具有三维尺寸的轮廓或通过以孔或冲孔改进其表面以促进与聚合物层的复合作用来进一步改进所述加强层。然后将聚合物层挤出在加强层上以形成最终产品。该聚合物与载体化学相容;即,在聚合物和载体之间形成抗分层的化学结合。
结合剂也被选择用于与载体化学结合,机械地且还优选地化学地与垫结合,且与挤出的聚合物型材化学结合。层的结合增加了强度并避免了分层。可以将粘合剂施加到载体上以使填料更好地粘附到载体上。
本公开的特征在于,使用至少一对加热夹套辊进行加压和加热的步骤,且当使用第二对加热夹套辊时,随后的一对辊可比第一对更近地夹紧在一起以增加整个垫的填料中液化粘合剂的流动。第二对辊也可以比第一对旋转得更快,以便在冷却前拉伸所述垫。拉伸垫有助于对齐纤维并且可以产生更坚固的加强层。
本公开的另一个特征是使用回收的切碎碳纤维或碳纤维带;切碎的玻璃丝纤维;来自废石膏的硬石膏纤维;来自纺织废物或包括棉花、丝绸和合成纤维在内的回收衣物产品的纤维;来自废木材、纸张、纸板或竹子的纤维素纤维;金属丝或其它金属纤维;或前述的任何组合,以及通常废弃的矿物组分如飞灰、沸石和火山灰。纤维不必很长,可以较短,例如短于垫的宽度。
本公开的另一个特征在于载体、结合剂(如果使用)和挤出在其上的聚合物也可以由回收材料制成,例如用于载体和结合剂的聚对苯二甲酸乙二醇酯或高密度聚乙烯,以及用于挤出聚合物的聚氯乙烯。这些材料化学相容,因为它们倾向于在它们之间形成化学结合。
本公开的另一个特征是,加强层可以包括多种类型的纤维、至少一个载体和多于一个填料层。
本公开的另一个特征是在于,当载体在传送带上滚动时,可以通过将纤维振动到载体上来分散纤维,所产生的随机取向在载体上提供大致相等的强度且平行于其长度。
本公开的另一个特征在于当根据所制造的产品的工程配置将加强层拉过直角进料模头时聚合物可以在一个或多个加强层上被挤出。
本公开的又一特征在于,加强层可以包括一个或多个适当间隔开的平坦层,在挤出聚合物基体内形成一个或多个三维轮廓,或这些的组合,因为可以方便地制造同时提供剪切和弯曲强度的结构水平。
通过结合附图仔细阅读具体实施方式,这些和其它特征及其优点对聚合物挤出领域的技术人员将是显而易见的。
附图说明
在附图中,
图1为用于制造本结构复合材料的设备的示意图;
图2为用于制造本结构复合材料的方法的流程图;
图3A-3H示出用于增强的刚度和挠曲强度的增强结构和位置的示例;
图4为根据本方法和设备制造的结构复合产品(即门侧柱)的示例;以及
图5示出了使用图4的门侧柱作为例子分析结构复合产品内的强化分布的简单方法,得出对其刚度和挠曲强度的保守预测。
具体实施方式
本文所述的结构复合材料是具有抗压强度和刚度的非均匀组合物,使其能够在各种各样的应用中用作木材的替代品,包括适用建筑规范要求的那些应用。另外,本发明的结构复合材料可以替代具有比木材更高的强度模量的其它材料,例如铝。术语非均匀是指至少其中一些成分集中在结构复合材料内而不是均匀分散。可以对本复合材料进行设计,意指可以选择其外部形状和其组分及其位置和形状以满足该复合材料将放置到的特定任务所需的强度和刚度。举个简单的例子,本结构复合材料可以设计为具有与中性轴间隔开的加强件,类似于工字梁的凸缘,在垂直于横截面的一个或两个轴线上提供增加的强度和刚度。因为这样的结构复合材料可以设计为用于承载,所以该复合材料在本文中被称为结构复合材料。
现在参照图1和2,本复合材料具有至少一个增加最终结构复合材料刚度的加强层。通过将聚合物挤出到加强层上将一加强层结合到聚合物挤出物中,使加强层在一侧,聚合物在另一侧,因此加强层从外部可见,或者,通过挤出使聚合物部分或全部包围加强层,在这种情况下,加强层从外部不可见。
加强层包括第一载体10。本文所采用的术语载体意指为柔韧材料的连续片材的织物或膜,其可以例如缠绕到线轴或芯14上,以便其可以卷出用作连续制造工序的一部分。载体10可以由高密度聚乙烯(HDPE)或聚对苯二甲酸乙二醇酯(PET)或与所选聚合物化学或机械结合的其它材料制成,例如改性的聚对苯二甲酸乙二醇酯(PETG),其具有在本方法中有用的性质,如低熔点温度。本复合材料中HDPE的密度范围可以为0.93-0.97g/cm3或970kg/m3
如果使用织物作为载体10,则织物可以是机织织物或无纺布,并且能够用作上面沉积加强层的其它成分的表面,如现在将描述的那样,且机械地结合且也可与聚合物和结合剂化学结合。
填料18分散到载体10上。填料18可以包括人造和天然纤维、有机物质和矿物质。如果将纤维用作填料18,可以是回收的切碎碳纤维或碳纤维带;废玻璃丝纤维;来自废石膏的硬石膏纤维;来自纺织废物或包括棉花、丝绸和合成纤维在内的回收衣物的纤维;来自废木材、纸张、纸板或竹子的纤维素纤维;金属丝或其它金属纤维;或前述的任何组合。诸如沸石、火山灰以及粉煤灰(煤炭燃烧的废物)这样的矿物质也可以用作填料,以及改变加强层特性、有利于制造工艺或简单地增加体积的其它物质。聚合物可以是聚氯乙烯。
当将纤维用作填料18时,纤维可以为任何长度。切碎的碳纤维和玻璃丝纤维效果良好,对于大多数应用来说,比长纤维可能更具成本效益,特别是如果它们是来自其它制造业务的废品。类似地,硬石膏晶须可以经济地由石膏制成,石膏是许多工业工艺的废产物,其非常坚固,并且化学结合到聚氯乙烯(PVC)上,特别是如果用聚乙烯醇和戊二醛预处理的话。长纤维和短纤维的混合物也可以用作填料18。在一个方面,填料18将形成从一侧到另一侧几乎填满第一载体10并且与载体10一样长的层。
分散填料18的材料可以通过在第一载体10的大部分上产生材料分布的任何方法实现,例如通过在第一载体10卷出时将填料18振动或铺开到第一载体10上。例如,可以将一定量的填料18放入料斗22中。当填料18下降到料斗22底部时,辊子26将最下面的填料移动通过刀片30,刀片30控制向前通过的填料18的量。填料然后落到刷辊34上。随着第一载体10的移动,刷辊34将填料18刷到第一载体10上。
为了帮助在第一载体10上形成填料18的垫38,可以在分散填料18前将粘合剂40施加到第一载体10。料斗42中的粘合剂40可以在填料18分散前通过喷嘴46喷洒到载体10上。如果垫38层叠,也许使用一系列料斗22,就可以实现另外的粘合剂喷涂,以使填料层形成设计的深度和均匀性。
可用于形成垫38的填料18的量取决于复合产品的用途,包括其机械性能以及可用的填料的选择及其特性和价格。因此,分散到第一载体10上的填料18的量可具有至少1厘米的厚度。
可以将结合剂50施加到第一载体10上的垫38上。结合剂50可以是液体或在加热时形成液体的粉末的形式。结合剂50分散在垫38上,以使其落入垫38表面上由沉积的填料18形成的间隙和空间中。结合剂50可以以适合于其分布的任何方式施加,例如从料斗54喷洒、振动、滴落或吹出。结合剂50可以是选择为与第一载体10相容的材料,例如HDPE或PET(PETG或PETE),并且可以是雾、液体、粉末或颗粒的形式,例如研磨回收的PETG。
第二载体58可以从第二芯48施加在垫38上。第二载体58可以由与第一载体10相同的材料制成,例如HDPE或PET(PETG或PETE)。第一载体10和填料18以及可选地与结合剂50和粘合剂40结合以形成加强层62。
加强层62穿过加热夹套辊60、64,加热夹套辊60、64施加热量和压力以软化和液化第一载体10、结合剂50和第二载体58,使得它们流过垫38的填料18。夹套辊60、64可以用于加热和加压,或者可以首先通过单独的装置(例如红外加热器)进行加热,然后进行加压。可以使用一组以上的夹套辊60、64。夹套辊60、64可以间隔开,使得具有载体10的垫38在它们之间通过时分阶段受压。夹套辊64的间距可以比夹套辊60更靠近,以递增地施加更多的压力以便在整个垫38中注入结合剂50,从而结合剂50进入垫38并与第一和第二载体10、58结合。
可选地,连续的夹套辊60、64可以依次以更快的速度旋转,从而在加强层62仍然冷却时拉伸加强层62,从而部分地将填料18的纤维,特别是如果它们是切碎纤维时,沿拉伸方向以类似于木材中的纤维的方式对齐,从而赋予层62相较于以长纤维可达到的强度而言更大的强度。
取决于第一载体10和第二载体58选择的材料,结合剂50结合填料18并且可以机械地或化学地结合到第一载体10和第二载体58。如果第一载体10和第二载体58是PET(PETG或PETE)或HDPE膜,则由该相同材料制成的结合剂50将与其化学结合。如果载体10是织物,则结合可以是机械的,因为结合剂渗透在织物的线和纤维之间。
本文的化学结合是指在两种不同材料的原子或分子之间形成化学键。机械结合或复合作用用于表示流体材料环绕固体材料流动,并且在冷却时将固体材料捕获到冷却材料的基体中。
如上所述,加强层62可以以分批工艺或连续挤出工艺制造。
一旦第一载体10和第二载体58以及结合剂50已经冷却,则加强层62向前移动到直角进料模头66,在该处将一个或多个聚合物层72、76挤出在其上以形成结构复合材料68。聚合物层72、76可以是采用或不用发泡剂挤出的聚氯乙烯。
通过形成多个加强层62或通过形成一个加强层62并将其切割成较窄的条带可以在结构复合材料68中包括一个以上的加强层62。加强层62可以用作薄的平坦层(如制造成的那样),或者如果需要可以变形以具有第三尺寸以提供多维刚度。可以将加强层62切割成两个或更多个条带或部分,优选地成对或成组地间隔开,以赋予比在一体件中使用相同的加强层62或者从加强层62切割的条带放置得更接近能够实现的更大的挠曲强度。
可以在拉动加强层62通过直角进料模头66前改进加强层62,以在加强层62和聚合物层72、76之间提供机械结合。通过在加强层62中形成孔或冲孔,两者都将加强层62的部分驱动到由加强层62以其它方式限定的平面外,聚合物可以流入并穿过由加强层62限定的平面,从而增加加强层62和聚合物层72、76之间的互锁。这些改进可以通过加强层6通过的2附加的辊子、模具、冲床或切割器实现。
在挤出结构复合材料68后,通过进给的锯、激光、水射流或其它切割装置将其切割成所需的长度。
用于制造结构复合材料的方法在图2中示意性地示出。该方法包括卷出第一载体10的步骤,第一载体10可以由塑料薄膜或织物制成。将填料18分散在第一载体10上以形成垫38。粘合剂40可以施加到第一载体10上,以便将包含填料18的材料保持在第一载体10上的适当位置。也可以将结合剂50分散在垫38上。
一旦垫38形成,就对其进行加热以熔化第一载体10和结合剂50(如果使用的话),使它们流入填料18中。为了促使液化的第一载体10和结合剂50流入填料18,对垫38进行挤压。这两个步骤可以使用成对的加热夹套辊60、64同时完成,加热夹套辊60、64加热和挤压垫38。此外,如果使夹套辊64比在前的夹套辊60稍微更快地旋转,则加热的夹套辊60、64能够拉伸垫38。当结合剂50凝固时拉伸垫38倾向于使填料18对齐以改善刚度。夹套加热辊64的速度增量可以通过适量的实验来确定。
然后,完成的加强层62可以形成为具有在多于一个方向上提供刚度的轮廓(profile)。术语“轮廓”意指加强层由二维层弯曲或形成以在第三维度上延伸,例如U形、W形或L形。完成的加强层62也可以切割成条带或段,其定位成改善不同方向上的整体刚度。在添加聚合物前,条带可以间隔开并远离复合结构元件的中性轴。一直角进料模头可用于在加强层62的条带周围挤出聚合物。
现在参考图3A-3H,示出了一些代表性的方式,通过这些方式加强层可以在复合产品内分布。为简洁起见,每个结构复合材料显示为简单的矩形横截面,其中在聚合物中显示了一个或多个加强层。按照惯例,在工程分析中,外部载荷由向下指向的箭头表示。
在图3A所示的示例中,加强层80大致平行于相对薄的成品复合制品84的顶表面和底表面之间并且在其中间延伸。为了增加加强层80的刚度,对其以孔88穿透,聚合物92可以通过孔88流动以通过复合作用将其自身固定到加强层80,这是当加强层80结合到聚合物92的基体中时发生的结合作用。
在图3B所示的示例中,单个加强层96大致平行于相对薄的成品复合制品100的顶表面和底表面之间并且在其之间延伸。为了增加加强层96的刚度,可以从一侧或两侧冲压,如图所示,以具有凹陷104,凹陷104也导致加强层96和聚合物108的基体之间的复合作用。
图3C示出了根据本公开的一个方面,在聚合物基体120中的加强层112、116的简单且高效的增强分布。加强层112、116水平设置,彼此平行并垂直于负载方向,且在复合制品124的横截面内在该方向上间隔开。结果表现得非常像钢制工字梁,其中顶部和底部的厚水平凸缘由通常较薄的垂直钢腹板分开。当从上方加负载时,工字梁的上凸缘、加强层112垂直于梁的横截面处于压缩状态,而下凸缘、加强层116处于拉伸状态。由于沿着加强层112、116的宽度的每个点经受类似的拉伸或压缩,因此在发生失效前,可以将整个宽度加载到复合制品124的组合物的几乎失效应力。
图3D示出了另一种简单的分布,此处具有多个加强构件128、132、136,垂直设置,平行于负载方向。虽然这种结构不太有利于几何形状,但由于只有聚合物138中的每个加强构件128、132、136的边缘可以加载到接近失效应力,而更靠近中心的部分承受较少的载荷,因此在许多情况下仍然是有用的。
图3E的示例示出了垂直和水平加强层140、144、148、152的组合,形成盒状复合制品156,能够在失效前承受来自各种方向的载荷。
图3F示出了复合制品162中的单个加强层158。加强层158已经折叠成三维形状,包括顶部和底部加强平面166、170,由垂直腹板174连接。在一些情况下,制造商可以方便地以这种方式使单个加强层158变形而不是将其切开。
图3G和3H示出了将单个加强层178、178’折叠成具有比图3F中所示的结构更大的水平对称性的三维轮廓的替代方法。此外,由于含纤维的增强材料在拉伸时通常比在压缩时强度更大,如果没有充分支撑,它往往会起皱,这些型材在顶部放置更大量的加强材料以进行压缩而少量放在底部以接受拉伸。机械工程师尤其可以认识到图3G中所示的分布,这是由于当采用钢材制造时,经过微小改动,形成了UNI-STRUT(Atkore International的商标)和类似的钢框架系统的通道结构。
现在参照图4,示出了用于门侧柱的复合产品180,其使用本方法形成并且结合了多个加强层182、184、186、188、190、192和194,每个加强层包括可能从原始更宽的加强层分离的窄条带。加强层182、184、186、188和190以及加强层192和194的间隔主要在水平方向上提供刚度,而加强层192、194和加强层182、190以及184、186、188的间隔提供垂直方向的刚度。如图所示,加强层182、184、186、188、180、192和194不必是平的,且可以弯曲或形成任何其它形状,以便于制造,同时对于给定的应用提供所需的剪切和弯曲强度。
存在一种用于估计使用本公开的各方面制造的制品的刚度和挠曲强度的简单方法,因此可评估一个或多个加强层的任何分布并选择最佳结构。该方法基于在工程教科书中常见的用于计算梁的弯曲的方法,且具体地在Prentice-Hall,Inc的E.P.Popov,Mechanics of Materials,第二版,
Figure BDA0002238202080000081
中,这里为了方便而进行了简化。简化是保守的,稍微倾向于低估刚度和强度以获得更大的安全系数。
出于说明的目的,图4中所示的结构构件的横截面在图5中再次示出。假设负载来自上方,对该方向上的刚度和弯曲强度进行估算。对于抵抗来自任何其它方向的力的刚度和弯曲强度,可以简单地旋转横截面,将力的方向再次置于顶部。
首先以实际尺寸或一些方便的整数分数(1/2、1/5等)或其多倍(2、5等)在方格纸上或者更优选地在运行CAD等设计应用程序的计算机屏幕上绘制横截面。例如,这可以通过描如图5A所示的照片或绘图来完成,然后进行比例调整。
然后将封闭的聚合物从图中“移除”(换句话说,保守地说,不考虑它可能贡献的任何强度或刚度)。在图中的任何地方绘制零轴200,尽管最方便地是在底部,如图5B所示。
测量每个加强层的宽度W(这里是182到194)和它与零轴的距离Y,以实际(非标度)英寸表示,并以表格形式记录,例如在电子表格中,以及“h”或“v”表示加强层是水平取向还是垂直取向,因为在分析的后期阶段将对两者进行不同的处理。在使用电子表格时,“h”方便地替换为“0”,而“v”方便地替换为“1”。
对于每一层,W和Y相乘。宽度也相加,将W和Y的乘积相加,然后将结果之和除以宽度之和,以找到零轴200上方的中性轴216的位置:
Y’=∑(W*Y)/∑W,
如图5C右侧的表中所示。
例如,中性轴216位于零轴上方0.482英寸处。然后将表示中性轴216的线添加到图中。找到每个加强层距中性轴的距离Y-Y',平方,然后乘以宽度:
(Y-Y’)2*W。
该表达式表示每层对总体刚度和弯曲强度的相对贡献。
从图5C的表中可以明显看出,离中性轴最远的那些层不成比例地贡献,而靠近它的那些层的贡献可能很小以至于可以忽略不计。本发明的这一特征表现出优于已知现有技术的优点,因为加强材料的放置可以改变,以便即使在使用短纤维、长纤维和短纤维的混合物以及不同种类的纤维的混合物时也能获得更大的刚度和弯曲强度。而且,因为可以切割加强构件,所以加强构件的单个宽度可以通过直角进料模头在单次挤压中提供多个加强层。
仅对于垂直加强层,由于它们的强度分布在距中性轴的一定距离范围内,因此需要进一步的步骤。这样一层的宽度的立方,然后除以12。结构工程师将此视为矩形梁的惯性矩的公式I=bh3/12,因为保守并且为了简单起见,简化其底项,所有的加强层在这里被视为简单的平面。在电子表格中使用“1”表示垂直加强层调用此额外步骤,而对于水平加强层,“0”使其被省略。
(Y-Y')2*W的所有项,对于垂直层仅W3/12项,求和以获得总惯性矩:
Itotal=∑(Y-Y’)2*W+∑vertW3/12。
结果以长度的立方为单位给出。对于分析的示例,结果是0.589立方英寸。惯性矩通常表示为长度的四次方的尺寸。这里的不同之处是由于对于加强层的强度和弹性,使用每英寸宽度磅数而不是每平方英寸磅数。
通过将Itotal乘以加强层材料的弹性模量E可以发现结构构件刚度的保守估计,再次以每英寸宽度磅数表示。对于根据所公开的方法生产的样品,E为约550,000磅/平方英寸。典型厚度为0.08英寸,然后得出44,000磅每英寸宽度。因此,刚刚分析的结构构件的刚度保守估计为44,000lbf/in*0.589in3=25,916in2lbf,这取代了大多数结构计算中的通常EI(I=in4的惯性矩)。
例如,支撑在端部的中心负载梁的最大偏转(忽略梁本身的重量)通常计算为
vmax=PL3/48EI,
其中P是以磅为单位的载荷,L是以英寸为单位的梁长度,E和I如上所定义。P为1磅,L为96英寸,用25,916in2lbf代替EI,得到的偏差vmax等于1*643/25,916=0.711英寸,是一个合理的值。
类似地,梁的弯曲强度——它可以支撑而不损坏的最大弯矩——通常被认为是
Mmax=σmax*Itotal/c,
其中σmax是以磅/平方英寸为单位的最大允许应力,c是从中性轴216到最远的载荷承载元件的距离。
在这种简化的方法中,σmax是加强层的拉伸或压缩强度,单位为磅/英寸宽度。这合意地减少了20%以提供已知的安全系数。I[subtotal]在图5C中替代I。根据所公开的方法,碳纤维增强PET的预期σmax为100,000lb/in2,其厚度为0.08英寸,相当于每英寸宽度6400磅。图5中的示例的最大距离Y-Y'是0.438英寸。再次使用Itotal=0.451in3得出值Mmax等于6400lbf/in*0.589in3/0.438in=8606英寸-磅的准用弯矩。对于像门侧柱这样的小型增强复合材料制品来说,这是一个高得令人惊讶的值——当然高于对天然木材的预期——但是根据测试样品的性能是现实的。
因此,所公开的复合材料和方法相对于所有已知的现有技术的优点是明确的:使用简单的数学方法可以实现加强层放置的灵活性,通过电子表格容易地实现,以评估和优化复合材料制品或结构构件内的放置,以便在材料高经济性的情况下实现几乎任何所需的刚度或弯曲强度。鉴于所公开的方法可以用回收的材料进行,这一优点更加明显。
当介绍本公开或其示例性方面或实施例的元件时,冠词“一(a)”、“一(an)”、“该(the)”和“所述(said)”旨在表示存在一个或多个元件。术语“包括(comprising)”、“包括(including)”和“具有(having)”旨在是包含性的并且意指除了所列元件之外可能还有其它元件。尽管本公开已经针对特定实施例进行了描述,但是这些实施例的细节不应被解释为限制。

Claims (20)

1.一种用于制造结构复合材料的方法,所述方法包括以下步骤:
(a)提供第一载体,所述第一载体为织物;
(b)将填料分散到所述第一载体上;
(c)将结合剂施加到所述填料上,所述结合剂与所述第一载体是化学相容的;
(d)将第二载体施加到所述填料、所述结合剂和所述第一载体上,所述第二载体由高密度聚乙烯(HDPE)或聚对苯二甲酸乙二醇酯(PET)或与所选聚合物化学或机械结合的其它材料制成;
(e)加热所述第一载体、所述填料、所述结合剂和所述第二载体;
(f)将所述第一载体、所述填料、所述结合剂和所述第二载体压在一起,其中所述结合剂液化并进入所述填料和所述第二载体,并与所述填料和所述第二载体机械结合以随着所述第一载体、所述填料和所述结合剂冷却形成加强层;
(g)将所述加强层形成为提供强度的形状;以及
(h)然后通过直角进料模头将聚合物挤出到所述加强层上,其中所述聚合物覆盖所述加强层,所述聚合物与所述加强层化学结合,且其中所述直角进料模头相对于所述聚合物定位所述加强层以加强所述聚合物。
2.根据权利要求1所述的方法,其中第二载体为改性的聚对苯二甲酸乙二醇酯(PETG)。
3.根据权利要求1所述的方法,其中所述结合剂为液体。
4.根据权利要求1所述的方法,其中所述结合剂为颗粒状的。
5.根据权利要求1所述的方法,还包括以下步骤:
(g1)将所述加强层切割成条带;以及
(g2)在挤出所述聚合物前分离所述条带。
6.根据权利要求5所述的方法,其中所述结构复合材料具有一中性轴且其中所述条带定位为远离所述结构复合材料的所述中性轴并在所述结构复合材料的所述中性轴的相对侧。
7.根据权利要求1所述的方法,其中所述填料包括纤维。
8.根据权利要求1所述的方法,其中所述填料包括人造纤维。
9.根据权利要求1所述的方法,其中所述填料包括矿物质。
10.根据权利要求7所述的方法,其中所述纤维为硬石膏晶须。
11.根据权利要求1所述的方法,其中所述聚合物为聚氯乙烯。
12.根据权利要求1所述的方法,其中所述第一载体和所述第二载体的至少其中之一由聚对苯二甲酸乙二醇酯制成。
13.根据权利要求1所述的方法,其中所述第一载体和所述第二载体的至少其中之一由高密度聚乙烯制成。
14.根据权利要求1所述的方法,其中一粘合剂施加到所述填料。
15.一种用于制造结构复合材料的方法,所述方法包括以下步骤:
(a)提供第一载体,所述第一载体为织物;
(b)将填料分散到所述第一载体上;
(c)将结合剂分散到所述第一载体上;
(d)将第二载体提供至所述填料上,所述第二载体与所述第一载体是化学相容的,所述第二载体由高密度聚乙烯(HDPE)或聚对苯二甲酸乙二醇酯(PET)或与所选聚合物化学或机械结合的其它材料制成;
(e)加热所述第一载体、所述结合剂和所述第二载体以使所述第一载体、所述结合剂和所述第二载体液化;
(f)将所述第一载体、所述填料、所述结合剂和所述第二载体压在一起,其中所述第一载体、所述结合剂和所述第二载体进入所述填料,且其中所述第一载体、所述结合剂和所述第二载体与所述填料机械结合以随着所述第一载体和所述第二载体冷却形成加强层;以及
(g)然后通过直角进料模头将聚合物挤出到所述加强层上以相对于所述聚合物定位所述加强层,其中所述加强层加强所述聚合物,所述聚合物与所述加强层化学结合以形成防止与所述加强层分层的结构复合材料。
16.根据权利要求15所述的方法,其中所述第二载体为改性的聚对苯二甲酸乙二醇酯(PETG)。
17.根据权利要求15所述的方法,还包括使所述加强层变形的步骤。
18.根据权利要求15所述的方法,还包括在所述加强层的至少一侧冲压所述加强层的步骤。
19.根据权利要求15所述的方法,还包括在所述加强层上形成孔的步骤。
20.根据权利要求15所述的方法,其中所述加强层在挤出以加强所述聚合物成为结构复合材料前使其成形和定位。
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