CN113858728A - 3D woven composite floor and manufacturing process thereof - Google Patents

3D woven composite floor and manufacturing process thereof Download PDF

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Publication number
CN113858728A
CN113858728A CN202111207310.7A CN202111207310A CN113858728A CN 113858728 A CN113858728 A CN 113858728A CN 202111207310 A CN202111207310 A CN 202111207310A CN 113858728 A CN113858728 A CN 113858728A
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China
Prior art keywords
layer
glass fiber
parts
woven
composite floor
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Granted
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CN202111207310.7A
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Chinese (zh)
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CN113858728B (en
Inventor
张春来
沈连涛
李恒
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Changchun Inter City Railway Vehicle Accessories Co ltd
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Changchun Inter City Railway Vehicle Accessories Co ltd
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Priority to CN202111207310.7A priority Critical patent/CN113858728B/en
Publication of CN113858728A publication Critical patent/CN113858728A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • 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
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • 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
    • B29C70/30—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
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
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    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/047—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood 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
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    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B5/18—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 features of a layer of foamed material
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    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D167/06—Unsaturated polyesters having carbon-to-carbon unsaturation
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/18—Fireproof paints including high temperature resistant paints
    • C09D5/185—Intumescent paints
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
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    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
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    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • C08J2363/10—Epoxy resins modified by unsaturated compounds

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)

Abstract

The invention provides a 3D woven composite floor and a manufacturing process thereof, and belongs to the technical field of floors. The composite floor sequentially comprises from top to bottom: the upper fireproof layer, the upper glass fiber composite cloth layer, the upper glass fiber gridding cloth layer, the 3D knitted PU core material layer, the sound insulation layer, the lower glass fiber gridding cloth layer, the lower glass fiber composite cloth layer and the bottom fireproof layer; the whole composite floor is infiltrated and reinforced by resin glue; the periphery of the 3D woven PU core material layer is provided with fireproof plates. The invention also provides a manufacturing process of the 3D woven composite floor. The composite floor has the advantages of sound insulation, fire prevention, light weight, peeling resistance, aging resistance, medium resistance, moisture resistance, high strength and difficult deformation.

Description

3D woven composite floor and manufacturing process thereof
Technical Field
The invention belongs to the technical field of floors, and particularly relates to a 3D woven composite floor and a manufacturing process thereof.
Background
Interior floor panels for railroad car bodies are typically made of wood, aluminum honeycomb, or other materials. The floor is classified into a plurality of types according to the material structure, such as plywood floor, aluminum honeycomb floor, phenolic resin composite floor, balsa composite floor, PET composite floor, PMI composite floor and the like; the floor board can be classified according to the application, such as urban rail floor, subway floor, high-speed rail floor, inter-city motor train floor, etc.; classified according to functions, the floor board is a sound insulation floor board, a fireproof floor board, a light floor board, an environment-friendly floor board and the like.
With the rapid development of the Chinese railway passenger car, the railway passenger car is accepted by more and more people as a heavy vehicle in a city, and meanwhile, the requirements of people on environmental protection, sound noise, fire safety and light weight at the beginning of design in the car are higher and higher, and more attention is paid to indoor floors. At present, the indoor floor of the railway passenger car is mainly an aluminum honeycomb floor and a plywood wood floor. The fireproof performance of the wood plywood floor can hardly meet the existing standard requirements, the weight is also difficult to optimize and reduce, and the problem of moisture absorption and expansion is also difficult to solve; the aluminum honeycomb floor is difficult to meet the standard requirements on heat insulation indexes, a new heat insulation material needs to be additionally added, in the aspect of structural fire prevention, according to the requirements in EN45545-3, the aluminum honeycomb floor cannot reach the standard under the condition that no protective measures are taken, meanwhile, the aluminum honeycomb floor is difficult to control within 11 kg/square meter in weight, and due to the use of a gluing process, the aluminum honeycomb floor is easy to peel off and glue off in the use process, so that unstable factors of the service life are caused. In the prior art, a phenolic resin composite floor, which is a floor using phenolic resin impregnated glass fiber and phenolic foam as a reinforcing material of a core material, changes the fireproof performance and reduces the weight index, but the adhesive peeling risk, the sound insulation problem, the environmental protection problem, the moisture absorption problem and the like are challenged and become the defects of the product.
Disclosure of Invention
The invention aims to provide a 3D woven composite floor and a manufacturing process thereof.
In order to achieve the purpose, the technical scheme of the invention is as follows:
the invention firstly provides a 3D woven composite floor, which comprises the following components in sequence from top to bottom:
the upper fireproof layer, the upper glass fiber composite cloth layer, the upper glass fiber gridding cloth layer, the 3D knitted PU core material layer, the sound insulation layer, the lower glass fiber gridding cloth layer, the lower glass fiber composite cloth layer and the bottom fireproof layer; the whole composite floor is infiltrated and reinforced by resin glue;
fire-proof plates are arranged around the 3D woven PU core material layer;
the upper fireproof layer and the bottom fireproof layer comprise the following components in parts by mass:
95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent;
the 3D woven PU core material layer is made of a material with the density of 35-45kg/m3PIR or PU material is foamed, and the foamed material is obtained by structurally weaving glass fibers with tensile strength of more than 1500 mpaE.
The resin adhesive comprises the following components in parts by weight:
97-98 parts of epoxy vinyl resin, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor and 1-2 parts of curing agent.
Preferably, the accelerating agent is cobalt solution.
Preferably, the polymerization inhibitor is p-benzoquinone liquid.
Preferably, the curing agent is methyl ethyl ketone peroxide.
Preferably, the sound insulation layer is an oak board.
Preferably, the upper fireproof layer is 0.5-1mm thick, the upper glass fiber composite cloth layer is 0.5-1mm thick, the upper glass fiber gridding cloth layer is 0.5-1mm thick, the sound insulation layer is 2-3mm thick, the lower glass fiber gridding cloth layer is 0.5-1mm thick, the lower glass fiber composite cloth layer is 0.5-1mm thick, and the bottom fireproof layer is 0.5-1mm thick.
Preferably, the thickness of the 3D woven PU core material layer is 11-15 mm.
Preferably, the four sides of the 3D woven composite floor are further provided with Z-shaped interfaces which are assembled with each other.
The invention also provides a manufacturing process of the 3D composite floor, which specifically comprises the following steps:
step one, preparing main material resin: according to the mass portion, 97-98 portions of epoxy vinyl resin, 1-1.5 portions of accelerating agent and 0.2-0.5 portion of polymerization inhibitor are added into a stirring barrel in sequence and stirred for 30-40 minutes to be fully mixed;
step two, preparing a bottom fireproof layer: according to the mass portion, 95-97 portions of unsaturated polyester resin, 2-3 portions of foaming type flame retardant, 1-1.5 portions of accelerating agent, 0.2-0.5 portion of polymerization inhibitor, 1-2 portions of color paste and 1-2 portions of curing agent are added into a stirring barrel in sequence and stirred for 30-40 minutes, so that the unsaturated polyester resin, the color paste and the curing agent are fully mixed, and the mixed bottom surface fire-proof layer is sprayed or brushed on the surface of a mould in a rolling way;
sequentially laying the glass fiber composite cloth and the glass fiber gridding cloth on the bottom fire-proof layer to respectively form a lower glass fiber composite cloth layer and a lower glass fiber gridding cloth layer;
placing the oak board on the upper surface of the lower glass fiber gridding cloth layer to form a sound insulation layer;
step five, the density of the main core material is 35-45kg/m3Foaming PIR or PU material, controlling the thickness to be 11-15mm, structurally weaving the foaming material by using E glass fiber with the tensile strength of more than 1500mpa to form a 3D core material with a triangular non-deformation structure, and placing the 3D core material on a sound insulation layer to form a 3D woven PU core material layer;
laying glass fiber mesh cloth and glass fiber composite cloth on the 3D knitted PU core material layer in sequence to form an upper glass fiber net interlayer and an upper glass fiber composite cloth layer respectively, laying the fireproof plate between the upper glass fiber net interlayer and the lower glass fiber net interlayer, tightly adhering the fireproof plate to the 3D knitted PU core material layer, sealing and vacuumizing the laid material, and keeping the material in a guiding state;
step seven, standing the main material resin prepared in the step one for 10min, weighing the main material resin into a clean plastic container according to the weight of 6kg per square meter of the product, adding a curing agent of methyl ethyl ketone peroxide, and uniformly mixing to obtain a resin adhesive;
step eight, introducing the resin adhesive prepared in the step seven into the mold in the step six in a vacuum state through a rubber inlet pipe, and curing for 24-26 hours to obtain a plate;
step nine, demolding the plate manufactured in the step eight in a mold, and placing the plate into a temperature control chamber for post-treatment, wherein the temperature of the temperature control chamber is controlled to be 50-60 ℃, and the constant temperature time is ensured to be more than 20 hours;
step ten, naturally cooling the board after the post-treatment in the step nine to room temperature, and then turning to CNC to process the periphery and the shape;
step eleven, polishing one side of the non-mold surface of the plate qualified in the CNC process by using sand paper to be smooth and flat;
step twelve, preparation of the upper fireproof layer: according to the mass parts, sequentially adding 95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent into a stirring barrel, stirring for 30-40 minutes, fully mixing, and spraying the mixed upper fireproof layer on the polished smooth surface obtained in the step eleven to obtain the floor;
and thirteen, curing the floor obtained in the twelfth step for 24-26 hours, and operating once according to the ninth step to obtain the 3D composite floor.
The invention has the advantages of
1. The invention provides a 3D woven composite floor and a manufacturing process thereof, wherein the composite floor sequentially comprises the following components from top to bottom: the upper fireproof layer, the upper glass fiber composite cloth layer, the upper glass fiber gridding cloth layer, the 3D knitted PU core material layer, the sound insulation layer, the lower glass fiber gridding cloth layer, the lower glass fiber composite cloth layer and the bottom fireproof layer; the invention adopts the integrated forming technology of combining vacuum introduction for each layer, has the advantages of high hardness, wear resistance, heat insulation, good flame retardance and fire resistance, can resist the corrosion of acid, alkali, grease and alcohol of conventional chemical media, has flat surface, difficult deformation, easy maintenance and cleaning and can be well bonded with floor cloths made of different materials.
2. The composite floor adopts the upper and lower glass fiber reinforced gridding cloth layers, the glass fiber gridding cloth has good weak acid resistance, alkalinity resistance, flexibility, high warp-weft tensile strength and good corrosion resistance, is low in cost, convenient to construct and good in operation performance in a reinforcing system, is suitable for various reinforcing systems, and is beneficial to improving the strength, corrosion resistance, flexibility and tensile strength of the floor; the upper and lower glass fiber composite cloth layers are adopted, so that the glass fiber composite cloth has the advantages of both rigidity and toughness, smooth surface, good dimensional stability, fire resistance, mildew resistance and moisture resistance; the fireproof performance, the mildew resistance and the moisture resistance of the floor are improved; the invention adopts the combination of the upper glass fiber mesh layer, the lower glass fiber mesh layer and the glass fiber short fiber felt layer, besides the advantages of the original system, the invention also enhances the strength of the floor when different materials are designed and embedded in the floor, avoids the phenomena of peeling and poor bonding of embedded parts in the existing floor, can prolong the service life and reduce the costs of maintenance, replacement and the like.
3. The resin adhesive of the composite floor comprises epoxy vinyl resin, cobalt liquid, p-benzoquinone liquid and methyl ethyl ketone peroxide, is formed by mixing the epoxy vinyl resin, the cobalt liquid, the p-benzoquinone liquid and the methyl ethyl ketone peroxide, has good fluidity and excellent matching property with fibers, adopts thermosetting materials as main body infiltration materials of the floor, and has the advantages of high strength, good toughness, fire resistance, moisture resistance, chemical medium resistance, heat resistance, noise reduction and the like.
4. The upper fireproof layer and the bottom fireproof layer of the invention both contain unsaturated polyester, and adopt the foaming type flame retardant which has good flame retardant effect, and generates a foaming structure for isolating oxygen when encountering open fire or heat with the temperature of more than 400 ℃, thereby improving the flame retardance of the invention.
5. The floor of the invention is compounded by a multilayer structure, the thickness and the density of a main material layer directly influence the weight of the floor, therefore, the density of the main material layer, namely a fiber reinforced 3D woven core material and a fiber reinforced surface layer is strictly controlled, the core material is controlled to be 35-45kg/m3, and the density of a fiber reinforced layer is controlled to be 1800kg/m3The total thickness can be made to be 18mm-25mm, so as to obtain the floor with moderate weight.
6. The 3D woven composite floor has the surface density of 8-10kg per square meter, the fire resistance of EN45545-HL 2 and HL3 and the sound insulation effect of 27dB-32dB, the main sandwich layer of the composite floor is a fiber reinforced 3D woven structure, the strength is very high, 540kg force is loaded on the area of 0.5 square meter, and the deflection is less than or equal to 1 mm.
Drawings
FIG. 1 is a schematic structural view of a 3D woven composite floor according to the present invention;
FIG. 2 is a schematic cross-sectional structure view of a 3D woven composite floor according to the present invention;
in the figure: 1. the fireproof layer comprises an upper fireproof layer, 2, an upper glass fiber composite cloth layer, 3, an upper glass fiber gridding cloth layer, 4, 3D weaving PU core material layer, 5, a sound insulation layer, 6, a lower glass fiber gridding cloth layer, 7, a lower glass fiber composite cloth layer, 8, a bottom fireproof layer, 9, an installation interface, 10 and a fireproof plate.
Detailed Description
The invention firstly provides a 3D woven composite floor, as shown in figures 1 and 2, which comprises the following components in sequence from top to bottom:
the fireproof insulation board comprises an upper fireproof layer 1, an upper glass fiber composite cloth layer 2, an upper glass fiber net grid cloth layer 3, a 3D woven PU core material layer 4, a sound insulation layer 5, a lower glass fiber net grid cloth layer 6, a lower glass fiber composite cloth layer 7 and a bottom fireproof layer 8; the whole composite floor is infiltrated and reinforced by resin glue;
fire-proof plates 10 are arranged around the 3D woven PU core material layer 4;
the upper fireproof layer 1 and the bottom fireproof layer 8 are made of the same material and comprise the following components in parts by mass:
95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent; the unsaturated polyester resin and the foaming type flame retardant are commercially available; the foaming flame retardant is preferably a mixed foaming flame retardant of aluminum hydroxide and polyurethane; the accelerating agent is preferably cobalt liquid; the polymerization inhibitor is preferably p-benzoquinone liquid, and the curing agent is preferably methyl ethyl ketone peroxide;
the 3D woven PU core material layer 4 is selected from the materials with the density of 35-45kg/m3PIR (polyisocyanurate) or PU (polyurethane) materials are foamed, and the foamed materials are structurally woven by glass fibers with tensile strength larger than 1500mpaE to form a triangular non-deformable structure.
The resin adhesive comprises the following components in parts by weight:
97-98 parts of epoxy vinyl resin, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor and 1-2 parts of curing agent, wherein the accelerating agent is cobalt liquid; the polymerization inhibitor is preferably p-benzoquinone liquid, and the curing agent is preferably methyl ethyl ketone peroxide.
The upper glass fiber mesh layer 3 and the lower glass fiber mesh layer 6 are made of glass fiber mesh cloth made of the same material, and are commercially available.
The upper glass fiber composite cloth layer 2 and the lower glass fiber composite cloth layer 7 are made of glass fiber composite cloth made of the same material, and are commercially available.
The sound insulation layer 5 is an oak board, the source of the sound insulation layer is commercially available, and the preferred density is 220kg/m3And the thickness is 2-3 mm.
The thickness of the 3D woven composite floor is 18mm-25mm, and more preferably 20mm soil is 0.3 mm.
Specifically, the thickness of the upper fireproof layer 1 is preferably 0.5-1mm, the thickness of the upper glass fiber composite cloth layer 2 is preferably 0.5-1mm, the thickness of the upper glass fiber mesh layer 3 is preferably 0.5-1mm, the thickness of the sound insulation layer 5 is preferably 2-3mm, the thickness of the lower glass fiber mesh layer 6 is preferably 0.5-1mm, the thickness of the lower glass fiber composite cloth layer 7 is preferably 0.5-1mm, and the thickness of the bottom fireproof layer 9 is preferably 0.5-1 mm. The thickness of the 3D woven PU core material layer 4 is preferably 11-15 mm. The thickness of the fireproof plate 10 is the sum of the thicknesses of the 3D woven PU core material layer 4 and the sound insulation layer 5.
The four sides of the 3D woven composite floor are also provided with Z-shaped mounting interfaces 9 which are mutually connected and assembled.
The invention also provides a manufacturing process of the 3D composite floor, which specifically comprises the following steps:
step one, preparing main material resin: according to the mass portion, 97-98 portions of epoxy vinyl resin, 1-1.5 portions of accelerating agent and 0.2-0.5 portion of polymerization inhibitor are added into a stirring barrel in sequence and stirred for 30-40 minutes to be fully mixed;
step two, preparing the bottom surface fire-proof layer 8: according to the mass portion, 95-97 portions of unsaturated polyester resin, 2-3 portions of foaming type flame retardant, 1-1.5 portions of accelerating agent, 0.2-0.5 portion of polymerization inhibitor, 1-2 portions of color paste and 1-2 portions of curing agent are added into a stirring barrel in sequence and stirred for 30-40 minutes, so that the unsaturated polyester resin, the color paste and the curing agent are fully mixed, and the mixed bottom surface fire-proof layer is sprayed or brushed on the surface of a mould in a rolling way;
sequentially laying the glass fiber composite cloth and the glass fiber gridding cloth on the bottom fire-proof layer to form a lower glass fiber composite cloth layer 7 and a lower glass fiber gridding cloth layer 6 respectively;
placing the oak board on the upper surface of the lower glass fiber mesh layer 6 to form a sound insulation layer 5;
step five, the density of the main core material is 35-45kg/m3Foaming PIR or PU material, controlling the thickness to be 11-15mm, structurally weaving the foaming material by using E glass fiber with the tensile strength of more than 1500mpa to form a 3D core material with a triangular non-deformation structure, and placing the 3D core material on the sound insulation layer 5 to form a 3D woven PU core material layer 4;
laying glass fiber mesh cloth and glass fiber composite cloth on the 3D woven PU core material layer 4 in sequence to form an upper glass fiber net interlayer 3 and an upper glass fiber composite cloth layer 2 respectively, laying a fireproof plate 10 between the upper glass fiber net interlayer 3 and a lower glass fiber net interlayer 6, tightly adhering the fireproof plate to the 3D woven PU core material layer 4, sealing and vacuumizing the laid material, and keeping the material in a leading-in state;
step seven, standing the main material resin prepared in the step one for 10min, weighing the main material resin into a clean plastic container according to the weight of 6kg per square meter of the product, adding a curing agent of methyl ethyl ketone peroxide, and uniformly mixing to obtain a resin adhesive;
step eight, introducing the resin adhesive prepared in the step seven into the mold in the step six in a vacuum state through a rubber inlet pipe, and curing for 24-26 hours to obtain a plate;
step nine, demolding the plate manufactured in the step eight in a mold, and placing the plate into a temperature control chamber for post-treatment, wherein the temperature of the temperature control chamber is controlled to be 50-60 ℃, and the constant temperature time is ensured to be more than 20 hours;
step ten, naturally cooling the board after the post-treatment in the step nine to room temperature, and then turning to CNC to process the periphery and the shape according to the drawing size;
step eleven, polishing one side of the non-mold surface of the plate qualified in the CNC process by using sand paper to be smooth and flat;
step twelve, preparation of the upper fireproof layer 1: according to the mass parts, sequentially adding 95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent into a stirring barrel, stirring for 30-40 minutes, fully mixing, and spraying the mixed upper fireproof layer 1 onto the polished smooth surface obtained in the step eleven to obtain the floor;
and thirteen, curing the floor obtained in the twelfth step for 24-26 hours, and operating once according to the ninth step to obtain the 3D composite floor.
The present invention is described in further detail below with reference to specific examples, in which the starting materials are all commercially available.
Example 1
A fiber-reinforced 3D composite floor, as shown in fig. 1 and 2, comprising, in order from top to bottom:
the fireproof insulation board comprises an upper fireproof layer 1, an upper glass fiber composite cloth layer 2, an upper glass fiber net grid cloth layer 3, a 3D woven PU core material layer 4, a sound insulation layer 5, a lower glass fiber net grid cloth layer 6, a lower glass fiber composite cloth layer 7 and a bottom fireproof layer 8; the whole composite floor is infiltrated and reinforced by resin glue;
the four sides of the 3D woven composite floor are also provided with Z-shaped mounting interfaces 9 which are mutually connected and assembled,
and edge-sealing fireproof plates 10 are arranged around the 3D woven PU core material layer 4.
The manufacturing process of the fiber-reinforced 3D composite floor specifically comprises the following steps:
step one, preparing main material resin: adding 97 parts of epoxy vinyl resin, 1.5 parts of accelerating agent cobalt liquid and 0.2 part of polymerization inhibitor p-benzoquinone liquid into a 5-gallon stirring tank in sequence according to parts by mass under the conditions of 24 ℃ and relative humidity of less than 50% and stirring for 30 minutes to fully mix the epoxy vinyl resin, the accelerating agent cobalt liquid and the polymerization inhibitor p-benzoquinone liquid;
step two, preparing the bottom surface fire-proof layer 8: under the condition of 24 ℃ and relative humidity less than 50%, according to the mass portion, adding 95 portions of unsaturated polyester resin, 2 portions of foaming type flame retardant, 1.5 portions of accelerating agent cobalt liquid, 0.2 portion of polymerization inhibitor p-benzoquinone liquid, 1 portion of color paste and 1.5 portions of curing agent methyl ethyl ketone peroxide into a 5 gallon stirring barrel in sequence, stirring for 30 minutes, fully mixing, and spraying or rolling and brushing the mixed bottom surface fire-proof layer into a mould surface; the thickness of the bottom fire-proof layer 8 is 0.75 mm;
sequentially laying the glass fiber composite cloth and the glass fiber gridding cloth on the bottom fire-proof layer 8 to respectively form a lower glass fiber composite cloth layer 7 and a lower glass fiber gridding cloth layer 6; the thickness of the lower glass fiber composite cloth layer 7 is 0.75mm, and the thickness of the lower glass fiber grid cloth layer 6 is 0.75 mm;
fourthly, controlling the thickness of the oak board to be 3mm, and placing the oak board on the lower glass fiber mesh layer 6 to form a sound insulation layer 5;
step five, the density of the main core material is 40kg/m3Foaming a PIR material, controlling the thickness to be 13mm, structurally weaving the foaming material by using E glass fibers with the tensile strength of more than 1500mpa to form a 3D core material with a triangular non-deformation structure, and placing the 3D core material on a sound insulation layer 5 to form a 3D woven PU core material layer 4;
laying glass fiber mesh cloth and glass fiber composite cloth on the 3D woven PU core material layer 4 in sequence to form an upper glass fiber net interlayer 3 and an upper glass fiber composite cloth layer 2 respectively, laying a fireproof plate 10 between the upper glass fiber net interlayer 3 and a lower glass fiber net interlayer 6, tightly adhering the fireproof plate to the 3D woven PU core material layer 4, sealing and vacuumizing the laid material, and keeping the material in a leading-in state; the thickness of the upper glass fiber composite cloth layer 2 is 0.75mm, and the thickness of the upper glass fiber net interlayer 3 is 0.75 mm;
step seven, standing the main material resin prepared in the step one for 10min, weighing the main material resin into a clean plastic container according to the weight of 6kg per square meter of the product, adding 1.5 parts of curing agent methyl ethyl ketone peroxide, and uniformly mixing to obtain a resin adhesive;
step eight, introducing the resin adhesive prepared in the step seven into the step six in a relative vacuum state through an adhesive inlet pipe, and curing for 24 hours to obtain a plate;
step nine, demolding the board manufactured in the step eight in a mold, and placing the board in a temperature control chamber for post-treatment, wherein the temperature of the temperature control chamber is controlled at 50 ℃, and the constant temperature time is ensured to be more than 20 hours;
step ten, naturally cooling the board after the post-treatment in the step nine to room temperature, and then turning to CNC to process the periphery and the shape according to the drawing size;
step eleven, polishing one side of a non-mold surface of the plate qualified in the CNC process by using No. 80 and No. 120 abrasive paper to be smooth and flat;
step twelve, preparation of the upper fireproof layer 1: according to the mass parts, under the condition that the temperature is 24 ℃ and the relative humidity is less than 50%, sequentially adding 95 parts of unsaturated polyester resin, 2 parts of foaming type flame retardant, 1.5 parts of accelerating agent cobalt liquid, 0.2 part of polymerization inhibitor p-benzoquinone liquid, 1 part of color paste and 1.5 parts of curing agent methyl ethyl ketone peroxide into a 5 gallon stirring barrel to be stirred for 30 minutes, fully mixing the materials, and spraying the mixed upper fireproof layer 1 onto the polished smooth surface obtained in the step eleven to obtain the floor; the thickness of the upper fireproof layer 1 is 0.75 mm;
and thirteen, curing the floor in the step twelve for 24 hours, and operating once according to the step nine to obtain a finished product of the 3D composite floor.
The experimental detection shows that: the composite floor obtained in the example 1 has the surface density of 10.0 kg/square meter, the fire resistance can reach EN45545-HL3, and the sound insulation effect is 32 dB.
In addition to the above embodiments, the present invention may have other embodiments. All technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.

Claims (10)

1. The 3D weaved composite floor is characterized by comprising the following components in sequence from top to bottom:
the upper fireproof layer, the upper glass fiber composite cloth layer, the upper glass fiber gridding cloth layer, the 3D knitted PU core material layer, the sound insulation layer, the lower glass fiber gridding cloth layer, the lower glass fiber composite cloth layer and the bottom fireproof layer; the whole composite floor is infiltrated and reinforced by resin glue;
fire-proof plates are arranged around the 3D woven PU core material layer;
the upper fireproof layer and the bottom fireproof layer comprise the following components in parts by mass:
95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent;
the 3D woven PU core material layer is made of a material with the density of 35-45kg/m3Foaming PIR or PU material by using glass fiber with tensile strength more than 1500mpaEThe structure is woven.
2. The 3D knitted composite floor according to claim 1, wherein the resin glue comprises the following components in parts by weight:
97-98 parts of epoxy vinyl resin, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor and 1-2 parts of curing agent.
3. A 3D woven composite floor according to claim 1 or 2, characterised in that said accelerator is cobalt liquid.
4. The 3D woven composite floor according to claim 1 or 2, wherein the polymerization inhibitor is p-benzoquinone liquid.
5. A 3D woven composite floor according to claim 1 or 2, wherein said curing agent is methyl ethyl ketone peroxide.
6. The 3D woven composite flooring according to claim 1, wherein said acoustical layer is an oak board.
7. The 3D knitted composite floor according to claim 1, wherein the upper fireproof layer is 0.5-1mm thick, the upper glass fiber composite cloth layer is 0.5-1mm thick, the upper glass fiber mesh cloth layer is 0.5-1mm thick, the sound insulation layer is 2-3mm thick, the lower glass fiber mesh cloth layer is 0.5-1mm thick, the lower glass fiber composite cloth layer is 0.5-1mm thick, and the bottom fireproof layer is 0.5-1mm thick.
8. The 3D woven composite floor according to claim 1, wherein the thickness of the 3D woven PU core layer is 11-15 mm.
9. A 3D woven composite floor according to claim 1, wherein said 3D woven composite floor is further provided with Z-shaped joints at four sides thereof, which are assembled with each other.
10. The manufacturing process of the 3D composite floor board as claimed in claim 1, specifically comprising the steps of:
step one, preparing main material resin: according to the mass portion, 97-98 portions of epoxy vinyl resin, 1-1.5 portions of accelerating agent and 0.2-0.5 portion of polymerization inhibitor are added into a stirring barrel in sequence and stirred for 30-40 minutes to be fully mixed;
step two, preparing a bottom fireproof layer: according to the mass portion, 95-97 portions of unsaturated polyester resin, 2-3 portions of foaming type flame retardant, 1-1.5 portions of accelerating agent, 0.2-0.5 portion of polymerization inhibitor, 1-2 portions of color paste and 1-2 portions of curing agent are added into a stirring barrel in sequence and stirred for 30-40 minutes, so that the unsaturated polyester resin, the color paste and the curing agent are fully mixed, and the mixed bottom surface fire-proof layer is sprayed or brushed on the surface of a mould in a rolling way;
sequentially laying the glass fiber composite cloth and the glass fiber gridding cloth on the bottom fire-proof layer to respectively form a lower glass fiber composite cloth layer and a lower glass fiber gridding cloth layer;
placing the oak board on the upper surface of the lower glass fiber gridding cloth layer to form a sound insulation layer;
step five, the density of the main core material is 35-45kg/m3Foaming PIR or PU material, controlling the thickness to be 11-15mm, structurally weaving the foaming material by using E glass fiber with the tensile strength of more than 1500mpa to form a 3D core material with a triangular non-deformation structure, and placing the 3D core material on a sound insulation layer to form a 3D woven PU core material layer;
laying glass fiber mesh cloth and glass fiber composite cloth on the 3D knitted PU core material layer in sequence to form an upper glass fiber net interlayer and an upper glass fiber composite cloth layer respectively, laying the fireproof plate between the upper glass fiber net interlayer and the lower glass fiber net interlayer, tightly adhering the fireproof plate to the 3D knitted PU core material layer, sealing and vacuumizing the laid material, and keeping the material in a guiding state;
step seven, standing the main material resin prepared in the step one for 10min, weighing the main material resin into a clean plastic container according to the weight of 6kg per square meter of the product, adding a curing agent of methyl ethyl ketone peroxide, and uniformly mixing to obtain a resin adhesive;
step eight, introducing the resin adhesive prepared in the step seven into the mold in the step six in a vacuum state through a rubber inlet pipe, and curing for 24-26 hours to obtain a plate;
step nine, demolding the plate manufactured in the step eight in a mold, and placing the plate into a temperature control chamber for post-treatment, wherein the temperature of the temperature control chamber is controlled to be 50-60 ℃, and the constant temperature time is ensured to be more than 20 hours;
step ten, naturally cooling the board after the post-treatment in the step nine to room temperature, and then turning to CNC to process the periphery and the shape;
step eleven, polishing one side of the non-mold surface of the plate qualified in the CNC process by using sand paper to be smooth and flat;
step twelve, preparation of the upper fireproof layer: according to the mass parts, sequentially adding 95-97 parts of unsaturated polyester resin, 2-3 parts of foaming type flame retardant, 1-1.5 parts of accelerating agent, 0.2-0.5 part of polymerization inhibitor, 1-2 parts of color paste and 1-2 parts of curing agent into a stirring barrel, stirring for 30-40 minutes, fully mixing, and spraying the mixed upper fireproof layer on the polished smooth surface obtained in the step eleven to obtain the floor;
and thirteen, curing the floor obtained in the twelfth step for 24-26 hours, and operating once according to the ninth step to obtain the 3D composite floor.
CN202111207310.7A 2021-10-18 2021-10-18 3D woven composite floor and manufacturing process thereof Active CN113858728B (en)

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JPH11227081A (en) * 1998-02-17 1999-08-24 Ibiden Co Ltd Fire resistant composite floor material
JP2005178167A (en) * 2003-12-19 2005-07-07 Bridgestone Corp Composite panel
CN102900163A (en) * 2012-11-07 2013-01-30 山东联创节能新材料股份有限公司 High-strength PU compound A-level fireproof heat-insulating pate and preparation method thereof
CN103950233A (en) * 2014-01-03 2014-07-30 唐山轨道客车有限责任公司 Floor for high-speed train
CN104989074A (en) * 2015-07-21 2015-10-21 江苏锐升新材料有限公司 PVC composite floor board with fireproof flame-retardant structure and manufacturing process of PVC composite floor board
CN108909126A (en) * 2018-07-25 2018-11-30 嘉兴领科材料技术有限公司 A kind of rail traffic vehicles composite floor board
CN108943923A (en) * 2018-05-29 2018-12-07 嘉兴领科材料技术有限公司 One kind making fire-retardant rail traffic vehicles interior trim floor based on foam process
CN112576003A (en) * 2020-12-10 2021-03-30 江苏佳运晟汇新材料有限公司 Magnesium oxide composite floor and manufacturing process thereof

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11227081A (en) * 1998-02-17 1999-08-24 Ibiden Co Ltd Fire resistant composite floor material
JP2005178167A (en) * 2003-12-19 2005-07-07 Bridgestone Corp Composite panel
CN102900163A (en) * 2012-11-07 2013-01-30 山东联创节能新材料股份有限公司 High-strength PU compound A-level fireproof heat-insulating pate and preparation method thereof
CN103950233A (en) * 2014-01-03 2014-07-30 唐山轨道客车有限责任公司 Floor for high-speed train
CN104989074A (en) * 2015-07-21 2015-10-21 江苏锐升新材料有限公司 PVC composite floor board with fireproof flame-retardant structure and manufacturing process of PVC composite floor board
CN108943923A (en) * 2018-05-29 2018-12-07 嘉兴领科材料技术有限公司 One kind making fire-retardant rail traffic vehicles interior trim floor based on foam process
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CN112576003A (en) * 2020-12-10 2021-03-30 江苏佳运晟汇新材料有限公司 Magnesium oxide composite floor and manufacturing process thereof

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