CN113290983A - Ultra-light composite material electric heating floor and preparation method thereof - Google Patents

Ultra-light composite material electric heating floor and preparation method thereof Download PDF

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Publication number
CN113290983A
CN113290983A CN202110380441.9A CN202110380441A CN113290983A CN 113290983 A CN113290983 A CN 113290983A CN 202110380441 A CN202110380441 A CN 202110380441A CN 113290983 A CN113290983 A CN 113290983A
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China
Prior art keywords
composite material
floor
skin
electric heating
temperature
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Granted
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CN202110380441.9A
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Chinese (zh)
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CN113290983B (en
Inventor
李华
张辉
惠林海
张璐
张敏
马伟超
王洪茹
魏化震
王少明
金子明
刘建
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Shandong Sanda Technology Development Co ltd
Shandong Non Metallic Material Research Institute
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Shandong Non Metallic Material Research Institute
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • 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
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    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • 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
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    • B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
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    • B32B9/046—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/10—Floors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D27/00—Heating, cooling, ventilating, or air-conditioning
    • B61D27/0036—Means for heating only
    • B61D27/0045—Electric heating
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    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)

Abstract

The invention relates to the technical field of light weight of rail transit equipment, in particular to an ultra-light composite material electric heating floor which is formed by bonding upper and lower skins, a sandwich material plate, a heating assembly and a composite material edge sealing section bar by adopting high-temperature-resistant polyurethane structural adhesive, wherein the skins are glass fiber reinforced resin matrix composite materials adopting benzoxazine as a matrix, and a graphene heating assembly is arranged between the upper skins and the sandwich material plate.

Description

Ultra-light composite material electric heating floor and preparation method thereof
Technical Field
The invention relates to the technical field of light weight of rail transit equipment, in particular to an ultra-light composite material electric heating floor and a preparation method thereof.
Background
Along with the improvement of the design speed per hour of equipment such as high-speed trains and subways, the light weight requirement of rail transit equipment is more and more urgent, and on the premise of ensuring various performance indexes of the trains, designers reduce the redundant weight of the vehicles as much as possible and require that each part reduce the weight as much as possible.
In order to improve the comfort of passengers, the rail vehicle is generally provided with an air conditioning system to perform heating when operating in a cold environment. However, in a severe cold environment, the heat in the train is limited by the heat conduction coefficient of the train body, the temperature loss in the train is large, the temperature of the surface of the floor in the train is low, a general heating system needs to consume more powerful energy and needs to occupy more layout space and ventilation area to meet the requirement of comfort level of passengers, meanwhile, the equipment cost and maintenance expenditure are large, in addition, in the working process of an air conditioner, large noise can be generated in the train, a large amount of condensed water is generated in the train body due to long-term cold and hot alternation conditions, the performance of a heat insulation material of the train body is influenced, and the riding comfort is influenced. Under the circumstances, the rail transit electric heating floor is remarkably different from a domestic heating floor of a civil building, a heating system and a floor body are compounded on the rail transit electric heating floor, the aspects of load bearing, durability, fire resistance, input voltage and the like are different, and the rail transit electric heating floor is required to be lighter, stronger, more fire-resistant and the like, and the requirements of the aspects are difficult to meet by various conventional electric heating floors.
In the prior art, the bearing layer in the chinese patent CN110217249A is a multi-layer solid wood composite plywood, which has the disadvantages of poor fire resistance and environmental resistance, and is difficult to be applied to rail transit, while the technical scheme in the chinese patent CN110217249A adopts a simple connection structure, and the overall strength and rigidity are difficult to meet the requirements of rail transit, so that all the disadvantages are obvious, and for the above reasons, it is necessary to develop an ultra-light composite electric heating floor special for rail transit to fill up the blank in the prior art.
Disclosure of Invention
The invention provides an ultra-light composite material electric heating floor and a preparation method thereof aiming at various defects in the prior art, the floor is formed by bonding an upper skin, a lower skin, a sandwich material plate, a heating assembly and a composite material edge sealing section bar by adopting high-temperature-resistant polyurethane structural adhesive, wherein the skin is a glass fiber reinforced resin matrix composite material adopting benzoxazine as a matrix, and the graphene heating assembly is arranged between the upper skin and the sandwich material plate.
The specific technical scheme of the invention is as follows:
an ultra-light composite material electric heating floor is composed of upper and lower skins, a sandwich material plate, a heating component and a composite material edge sealing section bar, which are bonded by adopting high temperature resistant polyurethane or epoxy structural adhesive;
the upper skin and the lower skin are made of glass fiber reinforced resin matrix composite materials with benzoxazine as a matrix; the composite material is prepared by adopting a prepreg autoclave molding process, wherein the thickness of a skin is controlled to be 0.8-2.0 mm, and the prepared skin material has the advantages of high structural strength, good flame retardance, good fire resistance, difficulty in layering, low porosity, good dimensional stability and the like.
The sandwich material plate is made of a glass fiber reinforced phenolic foam composite material containing a three-dimensional reinforced structure; the three-dimensional reinforced structure is selected from a lattice reinforced structure in regular pyramid lattice arrangement, or a honeycomb reinforced structure in Z direction, or a combined reinforced structure of three-dimensional grids and composite material columns;
the sandwich material plate can be directly purchased from the market or directly prepared according to the prior art, wherein the specific referenced preparation process comprises the following steps:
preparing a lattice woven structure phenolic foam composite material with a regular pyramid lattice arrangement, mixing expandable phenolic resin, injecting into a mold of a glass fiber preformed body which is filled with the lattice woven structure with the regular pyramid lattice arrangement in advance, foaming, curing, forming and cutting to finish the preparation;
preparing a glass fiber reinforced phenolic foam composite material with a Z-direction reinforced honeycomb reinforced structure or a combined reinforced structure of a three-dimensional grid and a composite material column: firstly, mixing expandable phenolic resin, then injecting into a mould, foaming, curing and molding, then adopting a special weaving puncture machine to puncture glass fiber on the basis of a phenolic foam plate to form a Z-direction reinforced honeycomb reinforced structure or a three-dimensional square combined reinforced structure, and finally brushing and infiltrating the phenolic resin to cure to prepare the phenolic foam composite material;
according to the structural characteristics of the floor, the glass fiber reinforced phenolic foam composite material of the three-dimensional reinforced structure is of a flat plate type structure;
the three-dimensional reinforced structure is preformed, and a lattice weaving structure with regular pyramid lattices can be preferably selected.
The composite material edge sealing section is obtained by taking benzoxazine as a matrix through pultrusion, a connecting step is arranged on the connecting surface of the composite material edge sealing section, and the size of the connecting step ensures that two floors are connected and completed on the same horizontal plane.
The graphene heating assembly is arranged between the upper skin and the sandwich material plate and comprises a graphene electric heating film and a temperature control assembly, wherein the temperature control assembly is provided with an overtemperature protection device and a leakage protection device;
the graphene electric heating film is composed of a two-dimensional nano graphene material and a high-temperature-resistant insulating film, and the electric heating power is 200-500W/m2To (c) to (d); the temperature control system consists of an internal temperature sensor and an external temperature controller, and can accurately control the surface temperature of the ultra-light composite material electric heating floor; the safety assembly comprises an overtemperature protection device and an electric leakage protection device, wherein the overtemperature protection device is formed by connecting a thermal fuse in series to a graphene electric heating film circuit loop, and when the temperature exceeds an early warning value, the thermal fuse is disconnected and a power supply is cut off, so that overtemperature protection on the composite material electric heating floor is realized; the electric leakage protection device is grounded through the conductive layer laid on the surface of the composite material electric heating floor, so that the electric leakage protection of the electric heating floor is realized, and the safety of pedestrians on the floor is guaranteed; the components can be directly purchased from the market;
the upper skin, the lower skin, the sandwich board, the heating component and the composite material edge sealing section are bonded into a whole by adopting high-temperature-resistant polyurethane or epoxy structural adhesive.
In addition, the metal connecting piece and the floor water retaining edge which are adopted on the floor are all completed by adopting the prior art.
In addition, the inventor also provides a preparation method of the floor, which comprises the following specific steps:
(1) pultrusion composite material edge sealing section bar and water retaining edge
According to the designed fiber mass content of 60-65%, wrapping glass fiber yarns with a continuous felt to prepare a preformed body, enabling the preformed body to pass through a mold, enabling the preformed body to pass through a benzoxazine resin tank until the preformed body is completely soaked with resin, heating the mold to 120 +/-5 ℃ in a first section, 160 +/-5 ℃ in a second section, 195 +/-5 ℃ in a third section and 145 +/-5 ℃ in a fourth section after soaking, drawing the preformed body through the mold at a constant speed of 30cm/min until the curing degree of the edge sealing section of the composite material is more than 95%, and cutting the edge sealing section of the composite material into sections with a certain length;
(2) autoclave molding composite material skin
The areal density is 1040g/m2According to the weight ratio of resin to fiber of 30:70, resin is uniformly coated on a multi-axial woven cloth felt to prepare a composite material prepreg, and the composite material prepreg is dried;
sequentially laying a polyester film and a layer of demolding cloth on a mold, then spacing a layer of demolding cloth between every two layers of the composite material prepreg, sequentially laying the composite material prepreg on the mold, arranging twenty layers of demolding cloth to prepare a preformed body, and preparing a vacuum bag completely wrapping the preformed body by adopting a high-temperature resistant vacuum bag film;
putting the sealed die into an autoclave, closing the door of the autoclave, vacuumizing to-0.1 MPa, operating a forming program, keeping the temperature and pressure for 1 hour from room temperature to 120 ℃ for half an hour, from 120 ℃ to 180 ℃ for 15 minutes, simultaneously pressurizing to 0-10 Bar, cooling to room temperature for 30 minutes, releasing pressure to normal pressure for 10 minutes, and demolding; cutting the formed skin material into a designed size by adopting high-pressure water;
the skin cut into the designed size can be torn by the demolding cloth to form 10 pieces of skin materials for 5 floors, the upper skin and the lower skin are respectively one, the specific number of layers can be adjusted according to the design requirement to obtain different numbers of skin materials, and the molding parameters of the autoclave are adjusted according to the number of layers;
(3) assembly of an electrical heating assembly
Firstly, placing a heat insulation layer, forming a groove in the center of one side, close to the graphene electric heating film, of the heat insulation layer, placing a temperature measuring instrument probe in the groove, and connecting the temperature measuring instrument probe to a temperature measuring instrument outside the whole assembly through a lead;
then laying a graphene electric heating film on the heat preservation layer, connecting a power line of the graphene electric heating film with an external temperature control assembly, and connecting the temperature measuring instrument with the temperature control assembly;
the electric heating assemblies are independently arranged in each floor, so that each floor can be automatically switched on and off according to the temperature of the floor, the temperature of the whole carriage is balanced, and the purpose of energy saving is realized;
(4) preparation and installation of metal inserts
Embedding and bonding the metal insert on the connecting step of the edge sealing section bar by high-temperature-resistant polyurethane or epoxy structural adhesive;
(5) assembly of edge banding profiles
Assembling the edge sealing section by adopting the existing process;
(6) composite forming of ultralight composite material floor
Placing a lower skin in a floor composite die, coating an epoxy structural adhesive on the surface of the lower skin, and controlling the adhesive consumption to be 70-90g/m2Placing the assembled edge banding section bar on the accurate position of the lower covering, placing the sandwich material in the space in the edge banding section bar, coating epoxy structural adhesive in the sandwich material, filling the gap between the edge banding section bar and the sandwich material, and controlling the adhesive amount to be 70-90g/m2Accurately installing the assembled heating component at a predetermined position on the sandwich material, installing the lead and the temperature control component at a preset position, coating an epoxy structural adhesive on the surface of the heating film, and controlling the adhesive amount to be 70-90g/m2And accurately covering the upper skin on the surface of the heating film according to the design position, checking the accuracy of each position, and then closing the mold, heating and curing to obtain a finished product of the composite floor.
A layer of wear-resistant leather or carpet is required to be adhered to the uppermost part of the composite material floor, namely the upper covering, so that a final finished product is formed, and the effects of attractiveness and wear resistance are achieved.
Compared with the prior art, the method has the following advantages:
A. the ultra-light composite material electric heating floor can be used for quickly building floors of rail transit equipment such as high-speed rails and subways or for heating in winter of projects such as floors of houses, barracks and field camps, and has the advantages of light weight, high rigidity and strength, good fireproof performance, moisture resistance, corrosion resistance, fatigue resistance, peeling resistance, simple and convenient assembly, and easy maintenance and cleaning.
B. The ultra-light composite material electric heating floor can be industrially prepared according to a certain modulus in advance, and can realize standardized application.
C. The ultra-light composite material electric heating floor adopts a flexible connection mode and is provided with a special tool, the connection time of each floor is less than 5 minutes, and the simple and quick connection and installation of the floors can be realized.
D. The ultra-light composite material electric heating plate has light weight which is less than 10kg/m2The surface density of the double-claw sucker can realize the easy carrying of two people by adopting the double-claw sucker without special mechanical equipment.
E. The ultra-light composite material electric heating floor is simple and convenient to assemble and disassemble, and can be constructed on duty through simple operation training.
Drawings
Figure 1 is a schematic view of the construction of an electrically heated floor according to the present application,
FIG. 2 is a schematic view of a three-dimensional reinforcing structure selected from a lattice reinforcing structure regularly arranged in a pyramid lattice in a sandwich material plate,
FIG. 3 is a schematic view of a three-dimensional reinforcing structure selected from a combination of three-dimensional grid and composite material column in a sandwich material sheet,
FIG. 4 is a schematic representation of a three-dimensional reinforcing structure selected from a Z-direction reinforced honeycomb reinforcing structure in a sandwich material sheet,
figure 5 is a schematic view of a two-sided edge banding profile construction,
figure 6 is a schematic view of the end banding profile construction,
figure 7 is a schematic view of a two-sided edge banding profile with a metal insert installed,
in the figure, 1 is an upper skin, 2 is a heating component, 3 is a sandwich material plate, 4 is a lower skin, 5 is an edge sealing section bar, and 6 is a metal insert.
Detailed Description
The present invention will be described in further detail with reference to the following examples, but it should not be construed that the scope of the above subject matter is limited to the following examples. All the technologies realized based on the above contents of the present invention belong to the scope of the present invention, and the following embodiments are all completed by adopting the conventional prior art except for the specific description.
Example 1
As shown in fig. 1-7, an ultra-light composite material electric heating floor is composed of an upper skin 1, a heating component 2, a sandwich material plate 3, a lower skin 4 and a composite material edge sealing section bar 5, which are bonded together by adopting high temperature resistant polyurethane or epoxy structural adhesive;
the upper skin and the lower skin are made of glass fiber reinforced resin matrix composite materials with benzoxazine as a matrix; the composite material is prepared by adopting a prepreg autoclave molding process, wherein the thickness of a skin is controlled to be 0.8-2.0 mm, and the prepared skin material has the advantages of high structural strength, good flame retardance, good fire resistance, difficulty in layering, low porosity, good dimensional stability and the like;
the sandwich material plate is made of a glass fiber reinforced phenolic foam composite material containing a three-dimensional reinforced structure; the three-dimensional reinforced structure is selected from a lattice reinforced structure in regular pyramid lattice arrangement, or a honeycomb reinforced structure in Z direction, or a combined reinforced structure of three-dimensional grids and composite material columns; the sandwich material plate can be directly purchased from the market or directly prepared according to the prior art, wherein the specific referenced preparation process comprises the following steps:
preparing a lattice woven structure phenolic foam composite material with a regular pyramid lattice arrangement, mixing expandable phenolic resin, injecting into a mold of a glass fiber preformed body which is filled with the lattice woven structure with the regular pyramid lattice arrangement in advance, foaming, curing, forming and cutting to finish the preparation;
preparing a glass fiber reinforced phenolic foam composite material with a Z-direction reinforced honeycomb reinforced structure or a combined reinforced structure of a three-dimensional grid and a composite material column: firstly, mixing expandable phenolic resin, then injecting the mixture into a mould, after foaming and curing molding, adopting a special weaving puncture machine to puncture glass fiber on the basis of a phenolic foam plate to form a Z-direction reinforced honeycomb reinforced structure or a three-dimensional square combined reinforced structure, and finally brushing and infiltrating the phenolic resin to cure to prepare the phenolic foam composite material.
According to the structural characteristics of the floor, the glass fiber reinforced phenolic foam composite material of the three-dimensional reinforced structure is of a flat plate type structure;
the three-dimensional reinforced structure is preformed, and a lattice woven structure with regular pyramid lattices is preferably selected;
the composite material edge banding section is obtained by pultrusion with benzoxazine as a matrix, connecting steps are arranged on the connecting surfaces of the composite material edge banding section, and the size of the connecting steps ensures that two floors are connected and used as two-side edge banding sections on one horizontal plane (as shown in figure 5); meanwhile, end edge sealing profiles can be adopted at two ends of the floor (as shown in figure 6);
the graphene heating assembly is arranged between the upper skin and the sandwich material plate and comprises a graphene electric heating film and a temperature control assembly, wherein the temperature control assembly is provided with an overtemperature protection device and a leakage protection device;
the graphene electric heating film is composed of a two-dimensional nano graphene material and a high-temperature-resistant insulating film, and the electric heating power is 200-500W/m2To (c) to (d); the temperature control system consists of an internal temperature sensor and an external temperature controller, and can accurately control the surface temperature of the ultra-light composite material electric heating floor; the safety assembly comprises an overtemperature protection device and an electric leakage protection device, wherein the overtemperature protection device is formed by connecting a thermal fuse in series with a graphene electric heating film circuit, when the temperature exceeds an early warning value,the thermal fuse is disconnected, and a power supply is cut off, so that the overtemperature protection of the composite material electric heating floor is realized; the electric leakage protection device is grounded through the conductive layer laid on the surface of the composite material electric heating floor, so that the electric leakage protection of the electric heating floor is realized, and the safety of pedestrians on the floor is guaranteed; the components are all directly purchased from the market;
the upper skin, the lower skin, the sandwich board, the heating assembly and the composite material edge sealing section bar are bonded into a whole by adopting high-temperature-resistant polyurethane or epoxy structural adhesive;
in addition, the metal connecting piece and the floor water retaining edge which are adopted on the floor are all completed by adopting the prior art.
Example 2
A preparation method of an ultra-light composite material electric heating floor comprises the following specific steps:
(1) pultrusion composite material edge sealing section bar and water retaining edge
According to the designed fiber mass content of 65%, wrapping glass fiber yarns with a continuous felt to prepare a preformed body, penetrating the preformed body through a mold, enabling the preformed body to pass through a resin groove of benzoxazine until the preformed body is completely soaked with resin, heating the mold to a first section of 120 +/-5 ℃, a second section of 160 +/-5 ℃, a third section of 195 +/-5 ℃ and a fourth section of 145 +/-5 ℃ after soaking, drawing the mold at a constant speed of 30cm/min until the curing degree of the edge sealing section of the composite material is more than 95%, and cutting the edge sealing section of the composite material into a section with a certain length;
(2) autoclave molding composite material skin
The areal density is 1040g/m2According to the weight ratio of resin to fiber of 30:70, resin is uniformly coated on a multi-axial woven cloth felt to prepare a composite material prepreg, and the composite material prepreg is dried;
sequentially laying a polyester film and a layer of demolding cloth on a mold, then spacing a layer of demolding cloth between every two layers of the composite material prepreg, sequentially laying the composite material prepreg on the mold, arranging twenty layers of demolding cloth to prepare a preformed body, and preparing a vacuum bag completely wrapping the preformed body by adopting a high-temperature resistant vacuum bag film;
putting the sealed die into an autoclave, closing the door of the autoclave, vacuumizing to-0.1 MPa, operating a forming program, keeping the temperature and pressure for 1 hour from room temperature to 120 ℃ for half an hour, from 120 ℃ to 180 ℃ for 15 minutes, simultaneously pressurizing to 0-10 Bar, cooling to room temperature for 30 minutes, releasing pressure to normal pressure for 10 minutes, and demolding; cutting the formed skin material into a designed size by adopting high-pressure water;
the skin cut into the designed size can be torn by the demolding cloth to form 10 pieces of skin materials for 5 floors, the upper skin and the lower skin are respectively one, the specific number of layers can be adjusted according to the design requirement to obtain different numbers of skin materials, and the molding parameters of the autoclave are adjusted according to the number of layers;
(3) assembly of an electrical heating assembly
Firstly, placing a heat insulation layer, forming a groove in the center of one side, close to the graphene electric heating film, of the heat insulation layer, placing a temperature measuring instrument probe in the groove, and connecting the temperature measuring instrument probe to a temperature measuring instrument outside the whole assembly through a lead;
then laying a graphene electric heating film on the heat preservation layer, connecting a power line of the graphene electric heating film with an external temperature control assembly, and connecting the temperature measuring instrument with the temperature control assembly;
the electric heating assemblies are independently arranged in each floor, so that each floor can be automatically switched on and off according to the temperature of the floor, the temperature of the whole carriage is balanced, and the purpose of energy saving is realized;
(4) preparation and installation of metal inserts
Embedding and bonding the metal insert 6 on the connecting step of the edge sealing section bar by high-temperature resistant polyurethane or epoxy structural adhesive;
(5) assembly of edge banding profiles
Assembling the edge sealing section by adopting the existing process;
(6) composite forming of ultralight composite material floor
Placing a lower skin in a floor composite die, and coating epoxy on the surface of the lower skinThe structural adhesive is controlled at 70-90g/m2Placing the assembled edge banding section bar on the accurate position of the lower covering, placing the sandwich material in the space in the edge banding section bar, coating epoxy structural adhesive in the sandwich material, filling the gap between the edge banding section bar and the sandwich material, and controlling the adhesive amount to be 70-90g/m2Accurately installing the assembled heating component at a predetermined position on the sandwich material, installing the lead and the temperature control component at a preset position, coating an epoxy structural adhesive on the surface of the heating film, and controlling the adhesive amount to be 70-90g/m2And accurately covering the upper skin on the surface of the heating film according to the design position, checking the accuracy of each position, and then closing the mold, heating and curing to obtain a finished product of the composite floor.
A layer of wear-resistant leather or carpet is required to be adhered to the uppermost part of the composite material floor, namely the upper covering, so that a final finished product is formed, and the effects of attractiveness and wear resistance are achieved.
Test examples
In order to verify the performance of the composite material floor obtained by the present application, the inventor compares the performance of the composite material floor with that of a conventional metal heating floor which is commonly used in the past, and specific results are as follows:
Figure BDA0003011388720000071
therefore, the composite material electric heating floor obtained by the invention has good safety performance, good sound insulation and fire resistance, lower thickness and light weight, and has the weight of less than 10kg/m2The surface density of the double-claw sucker can realize the easy carrying of two people.
Meanwhile, the inventor also carries out related performance detection on the composite material electric heating floor, and the result is as follows:
Figure BDA0003011388720000072
Figure BDA0003011388720000081
for the test results of items 4 to 7 in the above table, the inventors supplement the following:
the test of the bearing strength of the simulated high-heeled shoes is qualified, the technical index of the composite material heating floor also meets the requirement that 1000N of pressure is applied on the area of 6mm multiplied by 5mm, the maximum deformation is less than or equal to 0.5mm, and the composite material heating floor is obviously superior to the conventional composite material floor;
when the falling ball impact resistance is qualified, the technical indexes of the composite material heating floor provided by the invention also meet the requirements that a sample piece m is 324g +/-5 g, a steel ball with the diameter of 42.8mm +/-0.2 mm falls from a position of 0.8m, no visible crack exists, and the diameter of a pit is less than 10 mm; the floor is obviously superior to the conventional composite material floor;
when the impact and vibration detection is qualified, the technical indexes of the composite material heating floor can meet the requirements of IEC61373 in tables 1 and 2; the floor is obviously superior to the conventional composite material floor;
the technical indexes of the composite material heating floor can meet the requirement of D3 program 4 circulation in ISO9142-2003 appendix D when the anti-aging test is qualified; the floor is obviously superior to the conventional composite material floor;
therefore, the technical indexes of the composite material heating floor obtained by the application meet the requirements of the field, and the composite material heating floor is obviously superior to the conventional composite material floor.

Claims (6)

1. An ultra-light composite material electric heating floor is characterized in that: the composite material edge sealing composite material consists of an upper skin (1), a heating component (2), a sandwich material plate (3), a lower skin (4) and a composite material edge sealing section bar (5), which are bonded by adopting high-temperature resistant polyurethane or epoxy structural adhesive;
the upper skin (1) and the lower skin (4) are made of glass fiber reinforced resin matrix composite materials with benzoxazine as a matrix; specifically, benzoxazine is used as a resin matrix, a multi-axial woven fabric felt is used as a reinforcing material, the resin content is controlled to be 30-40 wt%, the composite material is prepared by adopting a prepreg autoclave molding process, and the thickness of a skin is controlled to be 0.8-2.0 mm;
the sandwich material plate (3) is made of a glass fiber reinforced phenolic foam composite material containing a three-dimensional reinforced structure;
the composite material edge sealing section (5) is obtained by taking benzoxazine as a matrix and performing pultrusion, and a connecting step is arranged on the connecting surface of the composite material edge sealing section;
the heating assembly (2) comprises a graphene electric heating film and a temperature control assembly.
2. The ultralight composite electrically heated floor of claim 1, wherein: the three-dimensional reinforced structure is selected from a lattice reinforced structure in regular arrangement of pyramid lattice, a honeycomb reinforced structure in Z direction, or a combined reinforced structure of three-dimensional grids and composite material columns.
3. The ultralight composite electrically heated floor of claim 1, wherein: the temperature control assembly is provided with an overtemperature protection device and an electric leakage protection device; the graphene electric heating film is composed of a two-dimensional nano graphene material and a high-temperature-resistant insulating film, and the electric heating power is 200-500W/m2In the meantime.
4. The ultralight composite electrically heated floor of claim 1, wherein: the metal insert (6) is pre-embedded and bonded on the connecting step of the edge sealing section bar through high-temperature resistant polyurethane or epoxy structural adhesive.
5. A preparation method of an ultra-light composite material electric heating floor is characterized by comprising the following steps: the method comprises the following specific steps:
(1) pultrusion composite material edge sealing section bar and water retaining edge
According to the designed fiber mass content of 60-65%, wrapping glass fiber yarns with a continuous felt to prepare a preformed body, enabling the preformed body to pass through a mold, enabling the preformed body to pass through a benzoxazine resin tank until the preformed body is completely soaked with resin, heating the mold to 120 +/-5 ℃ in a first section, 160 +/-5 ℃ in a second section, 195 +/-5 ℃ in a third section and 145 +/-5 ℃ in a fourth section after soaking, drawing the preformed body through the mold at a constant speed of 30cm/min until the curing degree of the edge sealing section of the composite material is more than 95%, and cutting the edge sealing section of the composite material into sections with a certain length;
(2) autoclave molding composite material skin
The areal density is 1040g/m2Uniformly coating resin on the multi-axial woven cloth felt according to the weight ratio of resin to fiber of 30:70 to prepare a composite material prepreg, and airing;
sequentially laying a polyester film and a layer of demolding cloth on a mold, then spacing a layer of demolding cloth between every two layers of the composite material prepreg, sequentially laying the composite material prepreg on the mold, arranging twenty layers of demolding cloth to prepare a preformed body, and preparing a vacuum bag completely wrapping the preformed body by adopting a high-temperature resistant vacuum bag film;
putting the sealed die into an autoclave, closing the door of the autoclave, vacuumizing to-0.1 MPa, operating a forming program, keeping the temperature and pressure for 1 hour from room temperature to 120 ℃ for half an hour, from 120 ℃ to 180 ℃ for 15 minutes, simultaneously pressurizing to 0-10 Bar, cooling to room temperature for 30 minutes, releasing pressure to normal pressure for 10 minutes, and demolding; cutting the formed skin material into a designed size by adopting high-pressure water;
(3) assembly of an electrical heating assembly
Firstly, placing a heat insulation layer, forming a groove in the center of one side, close to the graphene electric heating film, of the heat insulation layer, placing a temperature measuring instrument probe in the groove, and connecting the temperature measuring instrument probe to a temperature measuring instrument outside the whole assembly through a lead;
then laying a graphene electric heating film on the heat preservation layer, connecting a power line of the graphene electric heating film with an external temperature control assembly, and connecting the temperature measuring instrument with the temperature control assembly;
(4) preparation and installation of metal inserts
Embedding and bonding the metal insert on the connecting step of the edge sealing section bar by high-temperature-resistant polyurethane or epoxy structural adhesive;
(5) assembly of edge banding profiles
Assembling the edge sealing section by adopting the existing process;
(6) composite forming of ultralight composite material floor
Placing in a floor composite mouldThe lower skin is coated with epoxy structural adhesive, and the adhesive consumption is controlled to be 70-90g/m2Placing the assembled edge banding section bar on the accurate position of the lower covering, placing the sandwich material in the space in the edge banding section bar, coating epoxy structural adhesive in the sandwich material, filling the gap between the edge banding section bar and the sandwich material, and controlling the adhesive amount to be 70-90g/m2Accurately installing the assembled heating component at a predetermined position on the sandwich material, installing the lead and the temperature control component at a preset position, coating an epoxy structural adhesive on the surface of the heating film, and controlling the adhesive amount to be 70-90g/m2And accurately covering the upper skin on the surface of the heating film according to the design position, checking the accuracy of each position, and then closing the mold, heating and curing to obtain a finished product of the composite floor.
6. The method for preparing the ultra-lightweight composite material electric heating floor as claimed in claim 5, wherein the method comprises the following steps: and (3) cutting the floor covering into skin with a designed size in the step (2), tearing the skin through demolding cloth to form 10 pieces of skin materials for 5 floors, adjusting the specific number of layers of the upper skin and the lower skin according to design requirements to obtain different numbers of skin materials, and adjusting the molding parameters of the autoclave according to the number of layers.
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Patentee before: SHANDONG NON-METALLIC MATERIAL INSTITUTE