CN113462125B - Resin foam preform, member made of resin foam preform, and method for producing the same - Google Patents
Resin foam preform, member made of resin foam preform, and method for producing the same Download PDFInfo
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- CN113462125B CN113462125B CN202110792774.2A CN202110792774A CN113462125B CN 113462125 B CN113462125 B CN 113462125B CN 202110792774 A CN202110792774 A CN 202110792774A CN 113462125 B CN113462125 B CN 113462125B
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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
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- 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
- B29C70/36—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 impregnating by casting, e.g. vacuum casting
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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Abstract
The invention discloses a resin foam prefabricated part, a light component made of the resin foam prefabricated part by paving and pasting and a preparation method, wherein the resin foam prefabricated part is paved and pasted on a special-shaped shell and then is heated, cured and molded to obtain the resin foam prefabricated part, and the molding method comprises the following steps: uniformly mixing resin, a diluent, a curing agent, an accelerator, a coupling agent and a toughening material in a mass ratio of 100 (0-5): (2-70): (0-2): (0.5-2): 2-5) under vacuum, uniformly laying composite hollow spheres in a forming mold, injecting the resin mixture, storing in a low-temperature environment, cutting and trimming the obtained resin foam preform according to the shape of the special-shaped shell, tightly attaching the resin foam preform to the inner surface of the special-shaped shell, and heating, curing and forming under vacuum to obtain the light member. The invention skillfully utilizes the characteristics of high viscosity of resin at low temperature and extremely low viscosity at high temperature, greatly simplifies the manufacturing process of the resin foam prefabricated part, and the prepared resin foam prefabricated part has good integrity and low water absorption rate.
Description
The technical field is as follows:
the invention belongs to the technical field of composite foam, and particularly relates to a resin foam prefabricated part, a component made of the resin foam prefabricated part in a paving mode and a preparation method of the component.
Background art:
resin foam is used as a high-performance composite material with low density, high strength and low water absorption rate, is an indispensable basic material for modern marine oil, natural gas and deep diving technologies, and in practical application, the resin foam material is used for preparing standard blocks, the standard blocks are bonded with each other, and the bonded and preformed standard blocks are machined according to a specific model shape to prepare a product with a certain shape. According to the method for preparing the pre-formed standard block and machining the pre-formed standard block, the manufacturing process of the standard block is not limited by a die, the method has certain universality, but the mechanical property of a product prepared by the standard block through a bonding forming method is poor compared with that of an integrally forming method, and a large amount of resin foam materials are changed into waste materials due to cutting into different shapes in machining, so that the utilization rate of raw materials is reduced, and the manufacturing cost is increased.
Meanwhile, for the light member filled with the resin foam, when the light member is prepared by adopting a direct pouring mode, the pouring material is not uniformly poured due to the large size of the member, and the material shortage occurs locally, so that the overall performance of the manufactured light member is poor, and the application is influenced.
The invention content is as follows:
in view of the above technical problems, the present invention aims to provide a resin foam preform, a member made of the resin foam preform and a method for manufacturing the same, so as to reduce the manufacturing cost of the member and improve the overall performance of the member.
The technical scheme adopted by the invention for solving the technical problem is as follows:
a resin foam preform is obtained by freezing a light hollow sphere layer filled with a resin mixture, wherein the temperature of the freezing treatment is-10 ℃ to 0 ℃.
Preferably, the light hollow ball comprises one or two of a microbead and a composite hollow ball; the micro-beads are one or more of hollow glass micro-beads, hollow silicon dioxide micro-beads, hollow ceramic micro-beads, phenolic resin hollow micro-beads, carbon hollow micro-beads and fly ash floating beads; the composite hollow sphere is one or more of a polystyrene composite hollow sphere coated by resin, fiber powder and aerogel, and the average diameter of the composite hollow sphere is 4-15 mm.
Preferably, the resin mixture is one or more of an epoxy resin system, a phenolic resin system, an unsaturated resin system and other resins with a bonding effect.
The preparation method of the resin foam preform comprises the following steps:
(1) Preparing materials: uniformly mixing resin, a diluent, a curing agent, an accelerator, a coupling agent and a toughening material in a mass ratio of 100 (0-5) to (2-70) to (0-2) to (0.5-2) to (2-5) under vacuum to obtain a resin mixed material A;
(2) Layering: uniformly laying the light hollow spheres in a forming die;
(3) Grouting: injecting the resin mixture A uniformly mixed in the step (1) into the forming die in the step (2);
(4) Freezing treatment: and (3) placing the forming die filled with the resin mixture A for 1-3 hours in an environment of-10-0 ℃ to obtain the resin foam prefabricated body.
In step (2), the hollow lightweight spheres are laid in three types: a. laying microbeads in a forming die; b. laying at least one layer of composite hollow spheres in a forming mould; c. and laying at least one layer of composite hollow spheres and microbeads in the forming mould.
Preferably, in step (2), forming die includes apron, framed and bottom plate, framed both ends all are provided with the injecting glue mouth, the bottom plate bottom is provided with the hot plate, be provided with the heating heated board below the hot plate, framed height and the thickness phase-match of the dysmorphism component of pasting of will spreading.
A resin foam prefabricated part component comprises a component shell and a resin foam prefabricated part filling layer, and the light component is obtained by paving a resin foam prefabricated part on the inner surface of the component shell and then heating and curing the resin foam prefabricated part.
Preferably, the surface of the resin foam preform is attached with a fiber reinforced resin composite material, the fiber in the fiber reinforced resin composite material is glass fiber, carbon fiber, boron fiber or aramid fiber, and the resin is unsaturated polyester, vinyl resin, polyurethane, epoxy resin or phenolic resin.
The molding method of the resin foam prefabricated part comprises the following steps:
(1) Preparing materials: preparing a resin foam preform according to the size of the lightweight member;
(2) Paving: paving the resin foam prefabricated body close to the inner surface of the component shell, and paving one or more layers of resin foam prefabricated bodies according to the structural size of the light component;
(3) Edge treatment of the paving layer: performing edge treatment aiming at the condition that the paving layer is not in place at the edge, preparing a resin mixture B, and filling the resin mixture B in the area where the resin foam prefabricated body is not in place, wherein the resin mixture B is prepared by the following steps: the mass ratio of the microbeads is 100: (20 to 45) in a ratio corresponding to the types of the resin and the beads used for the resin foam preform;
(4) Curing and forming: and heating and curing the component shell on which the resin foam prefabricated body is paved under a vacuum condition to obtain the light component.
Preferably, in the step (2), after the resin foam preform is laid in the component housing, the fiber reinforced resin composite material is continuously laid on the surface of the resin foam preform.
Preferably, in the step (4), the curing temperature is 60-150 ℃ and the curing time is 1-12 h.
Preferably, the thickness of the resin foam preform is 5mm to 30mm.
The invention has the following positive beneficial effects:
the invention discloses a resin foam prefabricated body, a component made of the resin foam prefabricated body in a paving mode and a preparation method, wherein the viscosity characteristics that resin has high viscosity at low temperature and extremely low viscosity at high temperature are skillfully utilized, namely, at higher temperature, materials such as resin, micro-beads and hollow composite balls are fully and uniformly mixed, mixed air bubbles are removed completely, at low temperature, the viscosity of mixed slurry is increased, the mixed slurry has no fluidity, the uniform distribution state of the materials can be kept, no gas enters the materials, the internal materials still maintain a vacuum state, and the mixed slurry is soft and light semi-finished products, so that the finally prepared product has compact texture and extremely low water absorption rate.
The resin foam prefabricated body can be molded at will according to the structural condition of a shell of a light component to be paved and then heated and cured to form a required product. The resin foam prefabricated body has a certain storage period, is convenient to use, has small influence on the preparation process by the structure of the light member, and is beneficial to mass production of the light members with different structures.
The forming method of the resin foam prefabricated part greatly simplifies the manufacturing process of the resin foam prefabricated part, the materials are uniformly distributed, the manufactured light-weight part is good in integrity, meanwhile, the resin foam prefabricated part is fully used for manufacturing the light-weight part, the generation of waste materials is reduced, and the manufacturing cost is greatly reduced.
Description of the drawings:
fig. 1 is a schematic structural view of a forming die of the present invention.
The specific implementation mode is as follows:
the invention will be further explained and illustrated with reference to specific examples:
example 1
A resin foam preform is obtained by freezing a light hollow sphere layer filled with an epoxy resin mixed material, wherein the temperature of the freezing treatment is-3 ℃, and the composite hollow sphere is a hollow glass microsphere.
The preparation method of the resin foam preform comprises the following specific steps:
(1) Preparing materials: weighing the materials according to the mass ratio of the resin to the diluent to the curing agent to the coupling agent to the toughening material of 100; wherein: the resin is epoxy resin, the diluent is allyl glycidyl ether, the curing agent is methyl tetrahydrophthalic anhydride, the coupling agent is a silane coupling agent, and the toughening material is polysulfide rubber;
(2) Layering: laying hollow glass beads in a forming die;
(3) Grouting: pouring the uniformly mixed resin mixed material A into a forming die in a diversion net drainage mode;
(4) Freezing treatment: after grouting, placing the mould in a low-temperature environment of-3 ℃ for storage, and obtaining the resin foam prefabricated body.
In step (2), the forming die comprises a cover plate 1, a die frame 2 and a bottom plate 3, glue injection ports 4 are formed in two ends of the die frame 2, a heating plate 5 is arranged at the bottom of the bottom plate 3, and a heating insulation plate 6 is arranged below the heating plate 5, wherein the height of the die frame 2 is matched with the thickness of a special-shaped component to be paved.
The light member is obtained by paving the resin foam preform on the inner surface of the member shell and then heating and curing the resin foam preform, and the inner surface of the member shell is flat.
The forming method of the resin foam prefabricated part comprises the following specific steps:
(1) Preparing materials: preparing a resin foam preform according to the size of the inner surface of the lightweight member;
(2) Paving: paving a layer of resin foam prefabricated body on the inner surface of a component shell, and pressing materials tightly to enable the materials to be tightly attached to the shell; the thickness of the resin foam preform is 10mm;
(3) Curing and forming: sealing the surface of the light member shell on which the layer of resin foam prefabricated body is paved by using a vacuum bag film, vacuumizing, putting the light member shell into an oven for heating and curing at 100 ℃ for 3 hours, and demoulding after curing to obtain the light member.
The density of the light member is 0.45g/cm through high pressure, the water absorption rate is 5MPa in hydrostatic pressure, and the water absorption rate is 0.90% under 10 hours of pressurizing.
Example 2
A resin foam preform is obtained by freezing a light hollow sphere layer filled with an epoxy resin mixed material, wherein the temperature of the freezing treatment is-5 ℃. The light hollow sphere layer is a composite hollow sphere which is a resin-coated hollow sphere and has a diameter of 12mm.
The preparation method of the resin foam preform comprises the following specific steps:
(1) Preparing materials: weighing materials according to the mass ratio of the resin to the diluent to the curing agent to the coupling agent to the toughening material of 100.5; wherein: the resin is epoxy resin, the diluent is n-butyl glycidyl ether, the curing agent is 593 curing agent, the coupling agent is silane coupling agent, and the toughening material is polysulfide rubber;
(2) Layering: evenly tile the one deck with the combined material clean shot in the forming die that fig. 1 shows, wherein: the composite hollow ball is a resin-coated hollow ball, the diameter of the composite hollow ball is 12mm, and the height of the mold frame is consistent with the size of the light member;
(3) Grouting: directly injecting the uniformly mixed resin mixed material A into a forming die in a pressing mode;
(4) Freezing treatment: after grouting, placing the mould in a low-temperature environment of minus 5 ℃ for storage, and obtaining the resin foam prefabricated body.
A resin foam prefabricated part component comprises a component shell and a resin foam prefabricated part filling layer, wherein the light component is obtained by paving a resin foam prefabricated part on the inner surface of the component shell and then heating and curing the resin foam prefabricated part, the light component is a special-shaped component, and the inner surface of the component shell is a curved surface.
The molding method of the resin foam prefabricated part comprises the following specific steps:
(1) Preparing materials: preparing a resin foam preform according to the size of the inner surface of the lightweight member;
(2) Paving: cutting the resin foam prefabricated body according to the shape of the special-shaped shell of the light component, then paving the cut resin foam prefabricated body on the inner surface of the special-shaped shell, and pressing the material to enable the material to be tightly attached to the shell; the thickness of the resin foam preform was 15mm.
(3) Edge treatment of the paving layer: preparing a resin mixture B, and coating the resin mixture B on an area where the resin foam prefabricated body is not laid in place or an area with pores, wherein the resin mixture B is prepared according to the following steps of: curing agent: the mass ratio of the hollow silica microspheres is 100:50:20, wherein the curing agent is 593 curing agent;
(4) Curing and molding: sealing the surface of the special-shaped shell body which is paved with the resin foam prefabricated body by using a vacuum bag film, vacuumizing, putting the special-shaped shell body into an oven for heating and curing at the curing temperature of 90 ℃ for 5 hours, and demoulding after curing to obtain the light special-shaped component.
And carrying out high-density ethanol-water separation on the processed underwater special-shaped component, wherein the density of the processed underwater special-shaped component is 0.37g/cm, the water absorption rate is 5MPa in hydrostatic pressure, and the pressing time is 0.90% under 10 hours.
Example 3
The difference from example 2 is that:
the resin foam prefabricated body is obtained by freezing a light hollow sphere layer filled with an unsaturated resin mixed material, wherein the temperature of the freezing treatment is-8 ℃. The light hollow sphere layers comprise two types, namely a microsphere and a composite hollow sphere, wherein the microsphere is a hollow ceramic microsphere, and the composite hollow sphere is a hollow sphere coated with fiber powder and has the diameter of 10mm and 4mm.
The preparation method of the resin foam prefabricated body comprises the following steps of (1) preparing: weighing the following materials in a mass ratio of 100: the resin is unsaturated resin, the curing agent is methyl ethyl ketone peroxide, the accelerator is a cobalt-based accelerator, the coupling agent is a titanate coupling agent, and the toughening material is carboxyl-terminated liquid nitrile rubber.
In the step (2), layering: laying a layer of composite hollow spheres with the diameter of 10mm in a mould, laying a layer of composite hollow spheres with the diameter of 4mm above the mould to meet the size requirement of the special-shaped part, and at the moment, continuously laying hollow ceramic microspheres in the mould until the composite hollow spheres are fully laid.
In the step (3), grouting: grouting by adopting a flow guide net drainage mode, namely paving the flow guide net above the composite hollow spheres and the hollow microspheres in multiple sections.
In the step (4), freezing treatment: the cold treatment temperature was-8 ℃.
A forming method of a resin foam prefabricated part comprises the following steps of (3) edge treatment of a paving layer: the resin mixture B is prepared by mixing the following components in percentage by weight: curing agent: accelerator (b): the mass ratio of the microbeads is 100:2:1.5:30, the used material corresponds to the material of the resin foam prefabricated body;
in the step (4), curing and forming: the curing temperature is 80 ℃, and the curing time is 6h.
The other operation steps are the same as those of the embodiment 2, and the composite material hollow sphere is a fiber-coated hollow sphere.
The density of the prepared special-shaped part is 0.35g/cm for carrying out thin-wall cultivation, the water absorption rate is 0.92 percent under the hydrostatic pressure of 5Mpa and the pressing time of 10 h.
Example 4
The difference from example 2 is that:
the resin foam prefabricated body is obtained by freezing a light hollow sphere layer filled with a phenolic resin mixed material, wherein the light hollow sphere layer comprises two types, namely a microsphere and a composite hollow sphere, the microsphere is a fly ash floating bead, the composite hollow sphere is an aerogel coated hollow sphere, and the diameter of the aerogel coated hollow sphere is 7mm.
The preparation method of the resin foam prefabricated body comprises the following steps of (1) preparing: weighing materials according to the mass ratio of the resin to the coupling agent to the toughening material of 100.3, and uniformly stirring, wherein the resin is phenolic resin, and the coupling agent is a silane coupling agent. Layering in step (2): the composite hollow sphere is a layer of aerogel-coated hollow sphere with the diameter of 7mm, and then hollow ceramic microspheres are continuously paved into the mold until the composite hollow sphere is fully paved.
In the step (4), freezing treatment: the cold treatment temperature was-10 ℃.
A method for forming a resin foam prefabricated part comprises the following steps of (2) paving: cutting the resin foam prefabricated body according to the shape of the special-shaped shell of the light component, then paving the cut resin foam prefabricated body on the inner surface of the special-shaped shell, and pressing the material to enable the material to be tightly attached to the shell; the thickness of the resin foam prefabricated body is 10mm, two layers of resin foam prefabricated bodies are paved on the special-shaped shell, and air bubbles between the two layers of resin foam prefabricated bodies are completely removed during paving;
in the step (3), edge processing of the paving layer: the resin mixture B is prepared by mixing the following components in parts by weight: the mass ratio of the microbeads is 100:30, the used material corresponds to the material of the resin foam prefabricated body;
in the step (4), curing and forming: the curing temperature is 120 ℃, and the curing time is 4h.
The other preparation steps were identical to example 2.
The density of the prepared special-shaped part is 0.37g/cm through cultivation, the water absorption rate is 0.95% under the hydrostatic pressure of 5MPa and the pressing time of 10 hours.
Example 5
The difference from the embodiment 2 is that,
the preparation method of the resin foam prefabricated body comprises the following steps of (1) preparing materials: weighing the following materials in a mass ratio of 100 to 5.
Layering in step (2): and respectively laying the composite hollow sphere and the hollow glass beads in the mould shown in figure 1, wherein the hollow beads are laid in the gap of the composite hollow sphere until the composite hollow sphere is completely covered.
Grouting in step (3): grouting by adopting a flow guide net drainage mode, namely paving the flow guide net above the composite hollow spheres and the hollow microspheres in multiple sections.
The light component is obtained by sequentially paving the resin foam preform and the fiber reinforced resin composite material layer on the inner surface of the component shell and then heating and curing the resin foam preform and the fiber reinforced resin composite material layer, wherein the fiber reinforced resin composite material is a glass fiber reinforced epoxy resin composite material.
In the method for molding a resin foam preform member, in step (2), the following are laid: cutting the resin foam prefabricated body according to the shape of the light member special-shaped shell, then paving and pasting the resin foam prefabricated body on the inner surface of the special-shaped shell, compacting the material to enable the material to be tightly attached to the shell, and then paving and pasting a layer of glass fiber reinforced epoxy resin composite material prepreg on the surface layer of the resin foam prefabricated body;
and (4) curing and forming: the curing temperature is 90 ℃ and the curing time is 6h.
The other preparation steps were identical to example 2.
The density of the prepared special-shaped part is 0.40g/cm through cultivation, the water absorption rate is 0.91% under the hydrostatic pressure of 5MPa and the pressing time of 10 hours.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A resin foam preform member comprising a member shell and a resin foam preform filling layer, characterized in that: the component is prepared according to the following steps:
(1) Preparing materials: preparing a resin foam preform according to the size of the lightweight member;
(2) Paving: paving the resin foam prefabricated body close to the inner surface of the component shell, and paving one or more layers of resin foam prefabricated bodies according to the structural size of the light component;
(3) Edge treatment of the paving layer: performing edge treatment aiming at the condition that the paving layer is not in place at the edge, preparing a resin mixture B, and filling the resin mixture B in the area where the resin foam prefabricated body is not in place, wherein the resin mixture B is prepared by the following steps: the mass ratio of the microbeads is 100: (20 to 45) in a ratio corresponding to the types of the resin and the beads used for the resin foam preform;
(4) Curing and forming: heating and curing the component shell on which the resin foam prefabricated body is laid under a vacuum condition to obtain the composite material;
the resin foam preform is prepared by the following steps:
(1) Preparing materials: uniformly mixing resin, a diluent, a curing agent, an accelerator, a coupling agent and a toughening material in a mass ratio of 100 (0-5) to (2-70) to (0-2) to (0.5-2) to (2-5) under vacuum to obtain a resin mixed material A;
(2) Layering: uniformly laying the light hollow spheres in a forming die;
(3) Grouting: injecting the resin mixture A uniformly mixed in the step (1) into the forming die in the step (2);
(4) Freezing treatment: and (3) placing the forming die filled with the resin mixture A for 1-3 hours in an environment of-10-0 ℃ to obtain the resin foam prefabricated body.
2. The resin foam preform member of claim 1, wherein the hollow lightweight spheres comprise one or both of microbeads, composite hollow spheres; the micro-beads are one or more of hollow glass micro-spheres, hollow silica micro-spheres, hollow ceramic micro-spheres, phenolic resin hollow micro-spheres, carbon hollow micro-spheres and fly ash floating beads; the composite hollow sphere is one or more of a polystyrene composite hollow sphere coated by resin, fiber powder and aerogel, and the average diameter of the composite hollow sphere is 4-15 mm.
3. The resin foam preform member as claimed in claim 1, wherein the resin mixture is one or more of an epoxy resin system, a phenolic resin system, an unsaturated resin system, and other resins having a binding effect.
4. The resin foam preform member as set forth in claim 1, wherein the lightweight hollow spheres are laid in three types: a. laying micro-beads in a forming mould; b. laying at least one layer of composite hollow spheres in a forming mould; c. and laying at least one layer of composite hollow spheres and microbeads in the forming die.
5. The resin foam preform member as recited in claim 1, wherein: the surface of the resin foam prefabricated body is attached with a fiber reinforced resin composite material, fibers in the fiber reinforced resin composite material are glass fibers, carbon fibers, boron fibers or aramid fibers, and resin is unsaturated polyester, vinyl resin, polyurethane, epoxy resin or phenolic resin.
6. The resin foam preform member as recited in claim 1, wherein: in the step (2), after the resin foam prefabricated part is paved in the component shell, continuously paving the fiber reinforced resin composite material on the surface of the resin foam prefabricated part; in the step (4), the curing temperature is 60-150 ℃, and the curing time is 1-12 h.
7. The resin foam preform member as claimed in claim 1, wherein the resin foam preform has a thickness of 5mm to 30mm.
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| JP2010209221A (en) * | 2009-03-10 | 2010-09-24 | Sekisui Plastics Co Ltd | Sound-absorbing modified polystyrene resin foam and method for producing the same |
| JP2014098078A (en) * | 2012-11-14 | 2014-05-29 | Yazaki Corp | Foamed body and method for producing the same |
| CN109514951A (en) * | 2018-09-26 | 2019-03-26 | 济南北方泰和新材料有限公司 | Fiber reinforced light core filled composite material and the subway cockpit cabin of preparation |
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| CN101456963B (en) * | 2009-01-04 | 2011-05-11 | 武汉理工大学 | Method for preparing microsphere composite foam material |
| CN105034411B (en) * | 2015-09-02 | 2018-03-27 | 江苏恒神股份有限公司 | Rapid shaping composite fabric precast body preparation facilities and method |
| CN106863844A (en) * | 2015-12-14 | 2017-06-20 | 中航复合材料有限责任公司 | A kind of manufacture method of foam sandwich construction composite hatch door |
| CN109467726A (en) * | 2018-10-16 | 2019-03-15 | 厦门大学 | Using glass microballoon reinforcing fiber/polymer matrix composites laminate interlaminar strength Enhancement Method |
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| JP2010209221A (en) * | 2009-03-10 | 2010-09-24 | Sekisui Plastics Co Ltd | Sound-absorbing modified polystyrene resin foam and method for producing the same |
| JP2014098078A (en) * | 2012-11-14 | 2014-05-29 | Yazaki Corp | Foamed body and method for producing the same |
| CN109514951A (en) * | 2018-09-26 | 2019-03-26 | 济南北方泰和新材料有限公司 | Fiber reinforced light core filled composite material and the subway cockpit cabin of preparation |
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