CN110978672A - 一种一体成型的夹层结构及工艺 - Google Patents

一种一体成型的夹层结构及工艺 Download PDF

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CN110978672A
CN110978672A CN201911301431.0A CN201911301431A CN110978672A CN 110978672 A CN110978672 A CN 110978672A CN 201911301431 A CN201911301431 A CN 201911301431A CN 110978672 A CN110978672 A CN 110978672A
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李华冠
章月
匡宁
李红丽
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Nanjing Institute of Technology
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Abstract

本发明开一种一体成型的夹层结构及工艺，涉及夹层结构技术领域，包括面层、强度层、芯层；所述强度层增强材料是起圈织物；所述芯层由三维空心网格布和填充三维空心网格布内部空隙的泡沫材料组成；所述面层是金属或者非金属材料。本发明先在模腔内对面层材料进行吸附；然后依次铺贴起圈织物、三维空心网格布和起圈织物；再将环氧树脂导入到目标模具内，固化完成后脱模即可得到夹层结构。通过该工艺获得的夹层结构克服了传统蜂窝、泡沫芯材等夹层结构易分层的缺点，具有工艺简单、操作方便、减重显著、抗冲击能力强等突出优点。

Description

一种一体成型的夹层结构及工艺
技术领域
本发明涉及夹层结构技术领域，特别是涉及一种一体成型的夹层结构及工艺。
背景技术
夹层结构复合材料是由高强度面层和轻质芯材料所构成的一种结构形式。其一般是纤维增强复合材料做面层，泡沫、蜂窝做夹芯材料的一种结构。夹层结构既充分利用了纤维增强复合材料强度高、重量轻的优势，又巧妙借助轻质芯材所获得的截面惯性矩，可以达到理想的结构性能，由于其具有高比强度、高比刚度、减重效果显著等特点，复合材料夹层结构的应用领域越来越广泛，可涉及航空航天、轨道交通等领域。
中国发明专利CN201110173781.0，《金属-增强塑料复合材料制件及其成型方法》提出了将金属板和塑料层预成型后粘合在一起，或者金属板预成型后注射或涂覆塑料层得到金属-增强塑料复合材料。该工艺的缺点是成型工艺较复杂，很难一步法来进行成型。中国发明专利CN201610035556.3，《一种复合层板制件的制备方法》提出了在两个金属板间铺设夹层材料，然后进行抽真空和加热处理得到复合层板制件。该工艺的缺点是面层和芯材容易分层，影响到夹层结构的稳定性、安全性等。
泡沫是一种典型的芯层材料，一般采用酚醛泡沫，而酚醛泡沫一般存在强度差、需高温固化等问题。同时，传统的夹层材料，其强度层和芯层存在明显的界面，从而降低了其力学性能。此外，在夹层结构成型过程中，涉及到面层、强度层、芯层的粘结和固化，成型效率低，很难一次成型。
发明内容
为了克服现有技术中夹层结构存在的生产效率低、抗冲击力不足、面层和芯材易分层等缺陷，本发明提供一种一体成型的夹层结构及工艺。
为实现上述目的，本发明提供了如下方案：
本发明提供一种一体成型的夹层结构及工艺，包括上面层、下面层和芯层；所述芯层设置于所述上面层与所述下面层之间；所述上面层与所述芯层之间以及所述下面层与所述芯层之间均设置有强度层。
可选的，所述上面层和所述下面层为金属或非金属材料。
可选的，所述强度层增强材料为起圈织物。
可选的，所述芯层包括三维空心网格布和填充在所述三维空心网格布内部空隙中的泡沫材料。
可选的，所述泡沫材料为发泡环氧树脂固化而成的。
本发明还提供一种一体成型的夹层结构的工艺，包括以下步骤：
步骤一：在模腔内进行下面层和上面层的排布，并利用模具真空吸附固定；
步骤二：在模具内依次铺贴下部的起圈织物、三维空心网格布和上部的起圈织物；
步骤三：将制备好的发泡环氧树脂导入到模具内；
步骤四：将步骤三中的成型结构放置在烘箱中进行固化成型，得到一体成型的夹层结构。
可选的，步骤四中所述的固化成型包括三级发泡；第一级发泡的温度为40～50℃，保温时间30～40min；第二级发泡的温度为60～70℃，保温时间20～30min；第三级发泡的温度为70～80℃，保温时间20～30min。
可选的，所述模腔内高度为上面层、下面层、强度层和芯层的高度之和。
可选的，所述三维空心网格布采用环氧树脂预定型。
可选的，发泡环氧树脂的发泡倍率为5～7倍，当上面层和下面层材料为金属，其成型空间为发原始泡倍率的0.90～0.92倍；当上面层和下面层材料为非金属材料，其成型空间为发原始泡倍率的0.93～0.95倍。
本发明相对于现有技术取得了以下技术效果：
本发明中的基于环氧树脂发泡的夹层结构，提高了芯层的强度和抗冲击能力，形成一种高性能、无界面的夹层材料；同时，提供了一种无须专有模压设备的夹层材料一体化成型工艺。
本发明通过对环氧树脂的梯度发泡和原始发泡倍率、模腔体积比的控制，实现强度层和芯层的一体、无界面粘接，以及与面层的良好界面结合，并保障发泡材料较好的表观尺寸。
本发明采用起圈织物作为强度层增强材料，其z向毛圈实现了强度层和芯层更高的界面结合，同时采用三维空心网格布对芯层进行增强。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明一体成型的夹层结构及工艺的结构示意图。
附图标记说明：1、上面层；2、上强度层；3、芯层；4、下强度层；5、下面层。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例一：
如图1所示，一种一体成型的夹层结构，包括由上向下依次设置的上面层1、强度层、芯层3、强度层和下面层5；上面层1、下面层5为已表面处理过的铝合金，强度层增强材料为起圈织物，芯层3包括已用少量环氧树脂预定型的三维空心网格布和填充三维空心网格布内部空隙的泡沫材料。
一种一体成型的夹层结构工艺，按照如下步骤制备：
步骤一：在模腔内进行铝合金排布，利用模具真空吸附进行固定，其中真空度为0.093MPa；
步骤二：在模具内依次铺贴起圈织物、三维空心网格布和起圈织物；
步骤三：将制备好的发泡环氧树脂导入到目标模具中；
步骤四：将步骤3)中的成型结构放置在烘箱中进行固化成型，首先40℃固化30min，然后60℃固化30min，最后70℃固化20min。
铝合金的厚度为0.5mm，原始的发泡环氧树脂发泡倍率为5倍，模腔体积为环氧树脂体积的4.5倍；三维空心网格布厚度20mm，起圈织物高度4mm，模具的高度为29mm。
实施例二：
一种一体成型的夹层结构，包括由上向下依次设置的上面层1、强度层、芯层3、强度层和下面层5；上面层1、下面层5为PVC面板，强度层增强材料为起圈织物，芯层3包括已用少量发泡环氧树脂预定型的三维空心网格布和填充三维空心网格布内部空隙的泡沫材料。
一种一体成型的夹层结构工艺，按照如下步骤制备：
步骤一：在模腔内进行PVC面板排布，利用模具真空吸附进行固定，其中真空度为0.095MPa；；
步骤二：在模具内依次铺贴起圈织物、三维空心网格布和起圈织物；
步骤三：将制备好的发泡环氧树脂导入到目标模具中；
步骤四：将步骤3)中的成型结构放置在烘箱中进行固化成型，首先40℃固化40min，然后70℃固化20min，最后80℃固化20min。
PVC面板的厚度为0.4mm，原始的发泡环氧树脂发泡倍率为6倍，模腔体积为环氧树脂体积的5.52倍；三维空心网格布厚度30mm，起圈织物高度5mm，模具的高度为40.8mm。
实施例三：一种一体成型的夹层结构，包括由上向下依次设置的上面层1、强度层、芯层3、强度层和下面层5；上面层1、下面层5为非织造毡，强度层增强材料为起圈织物，芯层3包括已用少量发泡环氧树脂预定型的三维空心网格布和填充三维空心网格布内部空隙的泡沫材料。
一种一体成型的夹层结构工艺，按照如下步骤制备：
步骤一：在模腔内进行非织造毡排布，利用模具真空吸附进行固定，其中真空度为0.097MPa；
步骤二：在模具内依次铺贴起圈织物，三维空心网格布，起圈织物；
步骤三：将制备好的发泡环氧树脂导入到目标模具中；
步骤四：将步骤3)中的成型结构放置在烘箱中进行固化成型，首先50℃固化30min，然后60℃固化30min，最后80℃固化30min。
非织造毡的厚度为0.5mm，原始的发泡环氧树脂发泡倍率为7倍，模腔体积为环氧树脂体积的6.51倍；三维空心网格布厚度40mm，起圈织物高度6mm，模具的高度为53mm。
本说明书中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想；同时，对于本领域的一般技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处。综上所述，本说明书内容不应理解为对本发明的限制。

Claims (10)

1.一种一体成型的夹层结构，其特征在于，包括上面层、下面层和芯层；所述芯层设置于所述上面层与所述下面层之间；所述上面层与所述芯层之间以及所述下面层与所述芯层之间均设置有强度层。
2.根据权利要求1所述的一体成型的夹层结构，其特征在于，所述上面层和所述下面层为金属或非金属材料。
3.根据权利要求1所述的一体成型的夹层结构，其特征在于，所述强度层增强材料为起圈织物。
4.根据权利要求1所述的一体成型的夹层结构，其特征在于，所述芯层包括三维空心网格布和填充在所述三维空心网格布内部空隙中的泡沫材料。
5.根据权利要求4所述的一体成型的夹层结构，其特征在于，所述泡沫材料为发泡环氧树脂固化而成的。
6.一种基于权利要求1-5任一项所述的一体成型的夹层结构的工艺，其特征在于，包括以下步骤：
步骤一：在模腔内进行下面层和上面层的排布，并利用模具真空吸附固定；
步骤二：在模具内依次铺贴下部的起圈织物、三维空心网格布和上部的起圈织物；
步骤三：将制备好的发泡环氧树脂导入到模具内；
步骤四：将步骤三中的成型结构放置在烘箱中进行固化成型，得到一体成型的夹层结构。
7.根据权利要求6所述的一体成型的夹层结构的工艺，其特征在于，步骤四中所述的固化成型包括三级发泡；第一级发泡的温度为40～50℃，保温时间30～40min；第二级发泡的温度为60～70℃，保温时间20～30min；第三级发泡的温度为70～80℃，保温时间20～30min。
8.根据权利要求6所述的一体成型的夹层结构的工艺，其特征在于，所述模腔内高度为上面层、下面层、强度层和芯层的高度之和。
9.根据权利要求6所述的一体成型的夹层结构的工艺，其特征在于，所述三维空心网格布采用环氧树脂预定型。
10.根据权利要求6所述的一体成型的夹层结构的工艺，其特征在于，发泡环氧树脂的发泡倍率为5～7倍，当上面层和下面层材料为金属，其成型空间为发原始泡倍率的0.90～0.92倍；当上面层和下面层材料为非金属材料，其成型空间为发原始泡倍率的0.93～0.95倍。
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