CN113844111B - 一种带有封边的蜂窝板及其制备方法 - Google Patents

一种带有封边的蜂窝板及其制备方法 Download PDF

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CN113844111B
CN113844111B CN202111137989.7A CN202111137989A CN113844111B CN 113844111 B CN113844111 B CN 113844111B CN 202111137989 A CN202111137989 A CN 202111137989A CN 113844111 B CN113844111 B CN 113844111B
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edge sealing
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CN113844111A (zh
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朱华平
翟祖龙
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JIANGSU QIYI TECHNOLOGY CO LTD
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Abstract

本发明属于连续纤维高强度复合蜂窝板技术领域，产品蜂窝板上下表皮为连续纤维增强热塑复合材料制层，上表皮表面设有淋膜面和保护膜，中间结构为聚丙烯蜂窝芯，蜂窝芯的两边设有聚丙烯封边条，所述封边条为锁扣式，可以解决成品复合时会导致两条封边料之间有一定的缝隙；本发明还提供的一种制备方法：采用连续纤维增强热塑材料制备的上下表面，通过热复合工艺将上下表面与蜂窝芯复合制得蜂窝板材；在蜂窝芯的两边循环铺设封边材料，使得每一块蜂窝芯的边缘都贴合封边材料；设置复合机的工作参数，设备加热并保温固定时间，铺设封边材料的蜂窝板材通过传送带送入复合机中进行热塑复合，得到带有封边的蜂窝板。

Description

一种带有封边的蜂窝板及其制备方法
技术领域
本发明属于连续纤维高强度复合蜂窝板技术领域，特别涉及一种带有封边的蜂窝板及其制备方法。
背景技术
连续纤维增强热塑蜂窝板是由连续纤维预浸带多方向铺层与聚丙烯蜂窝芯热塑复合而成，因其具有轻量化、抗压、高强度、耐冲击等优点，被广泛应用到多个技术领域，比如房车、电池护板、厢板、客车地板、集装箱等多个领域，而本发明主要应用在建筑领域，随着建筑行业的发展，轻量化、高强度的建筑模板越来越受到重视，而传统的建筑模板多为木板，本身重量又重，强度不高，重复利用率低，人工运输不方便，木板的制作工艺繁琐、费工费力，而且还会造成大量的木材浪费，同时对环境也有大量的污染，在木材加工时产生的碎渣及气味给周边的生活群众带来了不少困扰，现在的建筑施工多采用组合式钢模板，是一种“以钢代木”的新型模板，因其重量较重、运输不方便、拼缝较多，而且价格也比较贵，施工方难以接受。目前，传统的封边方法有PP封边条通过胶水与蜂窝芯粘接，主要缺陷是粘接强度不够，效率低。为了解决目前建筑模板存在的各种问题，本专利公开了一种带有封边的蜂窝板来代替原来的木板，另外本发明还提供了制备此种蜂窝板的方法，本发明公开的封边方法既简单效率又高，通过连续纤维增强热塑复合板材与聚丙烯蜂窝芯和PP封边条一次性热塑复合成，可以满足不同尺寸的要求，灵活性比较高，并且还实现了高强度、耐摩擦、轻量化且可多次重复利用、方便拆卸和运输的建筑模板。
发明内容
本发明的目的是为了解决现有的建筑模板强度低、重量较重、重复利用率低、不方便运输等问题，而提出的一种带有封边的蜂窝板的制作方法，该工艺制作出的蜂窝板具有高强度、轻量化、耐磨擦、抗冲击等特点。
需要说明的是，说明书和权利要求书的材料采用英文缩写形式，如PP指聚丙烯材料，PET指涤纶树脂，CPP指流延聚丙烯薄膜。
为了实现上述目的，本发明的技术方案如下，
第一步:采用连续纤维增强热塑材料制备的上下表面，通过热复合工艺将上下表面与蜂窝芯复合制得蜂窝板材。
第二步:在蜂窝芯的两边部循环铺设封边材料，使得每一块蜂窝芯的边部都贴合封边材料，蜂窝芯与封边材料交错布置；
第三步:根据需求设置复合机的工作参数，设备加热并保温固定时间，铺设封边材料的蜂窝板材通过传送带送入复合机中进行热塑复合，得到带有封边的蜂窝板。
进一步的，第三步中铺设封边材料的蜂窝板材的热塑复合步骤包括：
铺设封边材料的蜂窝板材经过复合机第一对辊加热，封边材料和上下表面加热融化。
经过上一步骤的蜂窝板材经过复合机第二对辊压合冷却定型，上表面、下表面及封边条与蜂窝芯压合定型为一体，得到带有封边的蜂窝板。
进一步的，制备此种蜂窝板的复合机包括两组“品”字型压合辊，每组由3 个辊构成，上下两组压合辊位置相互对应，相对应的两个辊形成第一对辊和第二对辊，第一对辊起到压合和加热的作用，使得封边材料加热融化，第二对辊主要为压合冷却功能，带有封边材料的蜂窝板材经过第一、第二对辊加热、压合、冷却后，定型得到目标蜂窝板，同时，复合机进料口设置有限位装置，可以控制成品的宽度。
进一步的，封边材料和蜂窝芯可以多排并行进机处理，这样显著提高产能效率。
进一步的，带有封边的蜂窝板中蜂窝芯和封边条交错布置，蜂窝芯设置上表面和下表面，所述上表面和下表面为连续纤维增强热塑复合材料，上表面与蜂窝芯之间还设置有低温胶膜。
进一步的，蜂窝芯两侧为封边条，同样的，封边条两边设置蜂窝芯，两种结构相互交错，所述蜂窝芯的高度与封边条的高度一致，两者贴合进入复合机进行加工，尺寸可根据实际情况随意调节，灵活性较高，可满足不同尺寸的需求。
优选的，所述蜂窝芯的管单元为六角形或者圆形，所述蜂窝芯为聚丙烯材质，所述封边条为热塑性发泡材料，具有高密度底发泡倍率特性，用此材料做出来的蜂窝板具有轻量化、高强度，耐冲击等特点。
进一步的，封条边为可拆卸的锁扣结构，包括内凹封边条和外凸封边条，外凸封边条的接头可嵌入内凹封边条的凹槽，即可以避免蜂窝板边部封边条的拼接处有缝隙，还可以达到连续放料的条件。
优选的，所述上表面上设有PP淋膜层和电晕处理的PET保护膜，使上表面具有耐摩擦、表面光滑、达因指数高、易清洗、可多次重复利用等特点，因下表面不做为功能面，就没有PP淋膜层和PET保护膜，厚度相对上表面厚度薄，剥离也比上部较好。
优选的，所述低温胶膜为CPP胶膜，可提高上表面与蜂窝芯之间的剥离强度，方便蜂窝芯边部进料。
优选的，所述蜂窝芯的密度为100～110kg/m3。
本发明具有下列有益效果：
本发明的封边方法既简单效率又高，通过连续纤维增强热塑复合板材与聚丙烯蜂窝芯和封边条一次性热塑复合成，可以满足不同尺寸的要求，灵活性比较高，并且还实现高强度、耐摩擦、轻量化且可多次重复利用、方便拆卸的功能。
附图说明
为了更清楚的对本发明专利进行描述，下面将对具体实施方式、技术方法、产品结构以附图的形式进行描述：
图1为本发明某一具体实施例中带有封条边的产品结构图。
图2为本发明实施例1的进料方式示意图。
图3为本发明实施例2的另一种进料方式示意图。
图中的编号：1-下表面、2-蜂窝芯、3-封边条、4-低温胶膜、5-上表面、 6-特氟龙传送带、7-第一对辊、8-第二对辊。
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。
在本发明的描述中，需要理解的是，术语“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
实施例一：
如图1下表面1宽幅为两张成品的宽幅，材料为连续性纤维经过预浸制成的单向带，然后经过多方向铺层设计热塑复合材料，因下表面1不做为功能面，就没有淋膜层和PET保护膜，厚度相对上表面5厚度薄，剥离也比上部较好，在下表面1上面放置蜂窝芯2，可以放两块蜂窝芯2同时进机，宽度可根据要求定制，材质均为聚丙烯，管状为六角蜂窝或圆心蜂窝，为了提高抗压，耐冲击性能，可选择较大蜂窝芯的密度，本实施例采用的是100-110Kg/m3的密度的蜂窝芯；在蜂窝芯2的中间和两边放有3条封边条3，材质为聚丙烯发泡材料且带有锁扣式结构的，这样可以达到连续放料的效果，还可避免蜂窝板边部有缝隙，相邻的封边条3与蜂窝芯2紧密相连，同时进机，出机时可在中间的封边条3进行纵切，可出两张成品蜂窝板，既简单效率又高；在进机口处封边条3要紧靠着限位装置来保证产品宽度，可以防止封边条3跑偏的问题，设置限位装置可以保证每一张成品蜂窝板的封边直线度平直，且封边宽度满足设计要求，解放了人工对料问题；在封边条3和蜂窝芯2的上面加一层低温胶膜4，本实施例采用的低温CPP胶膜，可使上表面5与蜂窝芯2的之间剥离大大的提高，在CPP胶膜上面铺设5上表面，相当于两个成品宽度，采用连续性纤维经过预浸制成的单向带，然后经过多方向铺层设计热塑复合而成的上表面5，上表面5上带有PP淋膜层且和经电晕处理过的PET保护膜，目的是使成品的外观面具有耐摩擦、表面光滑、达因指数高的优点；在所有的料准备好之后，就可以同时进到热塑复合机，出机后可根据宽度要求进行在线切割，省时省力，效率高，可节约不少成本。
本实施例的具体步骤如下：
S1：采用连续纤维增强热塑材料制备的上下表面，上表面5包括4层连续纤维增强热塑材料，且表面有一层pp淋膜面和经电晕处理过的PET保护膜，下表面1为两层连续纤维增强热塑材料，在上表面5与蜂窝芯2之间有一层低温胶膜4，经热复合工艺将上下表面与蜂窝芯2复合制得的蜂窝板材，其中选用的蜂窝芯2 的密度为105kg/m3。
S2:在上表面5与蜂窝芯2之间有一层低温胶膜4，因上表面5较厚，可保证上部剥离，中间的封边材料放在蜂窝芯2两边，封边材料与蜂窝芯2紧密贴合，按照这样的三明治结构，依次循环铺设封边材料，使得产品的左右侧为封边材料，调节限位装置控制产品的宽度；
S3:提前把图2复合机工艺参数设定好，复合机预热保温半小时后，按照提前铺好的结构依次由传送带运输经过第一对辊7加热融化，再经过第二对辊8压合使得蜂窝板冷却成型，得到带有封边的蜂窝板，优选的，所述的传送带使用的是特氟龙传送带6，具有耐高温、不粘树脂的特点。
实施例二：
如图3与实施例1结构相同，区别在于进料方式不一样。
本实施例具体步骤如下：
S1：采用连续纤维增强热塑材料制备的上下表面，上表面5包括4层连续纤维增强热塑材料，且表面有一层pp淋膜面和经电晕处理过的PET保护膜，下表面1为两层连续纤维增强热塑材料，在上表面与蜂窝芯之间有一层低温胶膜4，经热复合工艺将上下表面与蜂窝芯2复合制得的蜂窝板材，其中选用的蜂窝芯2 的密度为108kg/m3。
S2:在上表面5与蜂窝芯2之间有一层低温胶膜4，因上表面5较厚，可保证上部剥离，封边材料铺设蜂窝芯2两边，封边材料与蜂窝芯2紧密贴合，按照这样的三明治结构，依次循环铺设封边材料，蜂窝芯2与封边材料相互交错，使得中间层两侧为蜂窝芯2；未加工完全的蜂窝板材通过限位装置调节宽度并横向进料，实施例一的产品的长度当做本实施例的宽度，这样可以多排依次进料，大大的提高了生产效率；
S3:提前把图3复合机工艺参数设定好，复合机预热保温一小时后，按照提前铺好的结构依次由特氟龙传送带6运输经过第一对辊7加热融化，再经过第二对辊8压合使得蜂窝板冷却成型，得到带有封边的蜂窝板。
表1：蜂窝板物理性能实验数据对比。

Claims (1)

1.一种带有封边的蜂窝板的制备方法，其特征在于，包括下列步骤：
S1:采用连续纤维增强热塑材料制备的上下表面，通过热复合工艺将上下表面与蜂窝芯复合制得蜂窝板材；
S2:在蜂窝芯的两边部循环铺设封边材料，使得每一块蜂窝芯的边部都紧密贴合封边材料，蜂窝芯与封边材料交错布置；
S3:根据需求设置复合机的工作参数，设备加热并保温半个小时，铺设封边材料的蜂窝板材通过特氟龙传送带送入复合机中进行热塑复合，得到带有封边的蜂窝板；其中铺设封边材料的蜂窝板材的热塑复合步骤：
S31:铺设封边材料的蜂窝板材经过复合机第一对辊加热，封边材料和上下表面加热融化；
S32:经过S31步骤的蜂窝板材经过复合机第二对辊压合冷却定型，得到带有封边的蜂窝板；
其中带有封边的蜂窝板中蜂窝芯(2)和锁扣式封边条(3)交错布置，所述蜂窝芯(2)的密度为100～110kg/m3；封条边(3)包括内凹封边条和外凸封边条，外凸封边条的接头可嵌入内凹封边条的凹槽；蜂窝芯(2)设置上表面(5)和下表面(1)，所述上表面(5)和下表面(1)为连续纤维增强热塑复合材料，上表面(5)与蜂窝芯(2)之间还设置有CPP胶膜；上表面(5)上设有PP淋膜层和电晕处理的PET保护膜，上表面(5)的厚度大于下表面(1)；蜂窝芯(2)两侧为封边条(3)，所述蜂窝芯(2)的高度与封边条(3)的高度一致；所述蜂窝芯(2)的管单元为六角形或者圆形，所述蜂窝芯(2)为聚丙烯材质，所述封边条(3)为热塑性发泡材料。
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