CN118003667A - Composite sandwich structure and preparation method thereof - Google Patents
Composite sandwich structure and preparation method thereof Download PDFInfo
- Publication number
- CN118003667A CN118003667A CN202410412341.3A CN202410412341A CN118003667A CN 118003667 A CN118003667 A CN 118003667A CN 202410412341 A CN202410412341 A CN 202410412341A CN 118003667 A CN118003667 A CN 118003667A
- Authority
- CN
- China
- Prior art keywords
- layer
- foaming
- data
- modeling
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 85
- 238000002360 preparation method Methods 0.000 title claims abstract description 8
- 238000005187 foaming Methods 0.000 claims abstract description 120
- 229920005989 resin Polymers 0.000 claims abstract description 71
- 239000011347 resin Substances 0.000 claims abstract description 71
- 239000000463 material Substances 0.000 claims abstract description 68
- 238000010438 heat treatment Methods 0.000 claims abstract description 20
- 238000005520 cutting process Methods 0.000 claims abstract description 12
- 239000000945 filler Substances 0.000 claims abstract description 12
- 238000001723 curing Methods 0.000 claims abstract description 10
- 238000004519 manufacturing process Methods 0.000 claims abstract description 9
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 239000000835 fiber Substances 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 21
- 239000011159 matrix material Substances 0.000 claims description 14
- 239000003822 epoxy resin Substances 0.000 claims description 9
- 239000004744 fabric Substances 0.000 claims description 9
- 229920000647 polyepoxide Polymers 0.000 claims description 9
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 6
- 239000004925 Acrylic resin Substances 0.000 claims description 6
- 229920000178 Acrylic resin Polymers 0.000 claims description 6
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 6
- 239000004917 carbon fiber Substances 0.000 claims description 6
- 229920001568 phenolic resin Polymers 0.000 claims description 6
- 239000005011 phenolic resin Substances 0.000 claims description 6
- 229920005749 polyurethane resin Polymers 0.000 claims description 6
- 229920001187 thermosetting polymer Polymers 0.000 claims description 6
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 6
- 229920002554 vinyl polymer Polymers 0.000 claims description 6
- 229920002748 Basalt fiber Polymers 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 239000004699 Ultra-high molecular weight polyethylene Substances 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 239000004760 aramid Substances 0.000 claims description 3
- 229920006231 aramid fiber Polymers 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- -1 polypropylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 229920000785 ultra high molecular weight polyethylene Polymers 0.000 claims description 3
- 238000012545 processing Methods 0.000 abstract description 15
- 239000010410 layer Substances 0.000 description 162
- 239000011162 core material Substances 0.000 description 26
- 239000006260 foam Substances 0.000 description 26
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 8
- 239000003063 flame retardant Substances 0.000 description 8
- 238000003801 milling Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 150000001336 alkenes Chemical class 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical class C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 238000007711 solidification Methods 0.000 description 4
- 230000008023 solidification Effects 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000011218 segmentation Effects 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Abstract
The application provides a composite sandwich structure and a preparation method thereof, which belong to the field of composite materials, and specifically comprise the steps of obtaining modeling data of a foaming layer and determining the theoretical minimum thickness of the foaming layer; determining the number of division layers of the foaming layer based on the modeling data and the theoretical minimum thickness; extracting median data of the modeling data layer by layer according to the number of division layers, and forming corresponding modeling contour data; cutting the composite material according to the data of the modeling data to form a composite material sheet, and correspondingly laying the composite material sheet in a product mould; mixing a physical foaming filler with a resin material, and preparing a film material sheet of a foaming layer according to modeling contour data; and sequentially attaching the film material sheets to the composite material sheets according to the sequence, closing the product mold, putting the product mold into heating equipment, foaming, heating and curing to prepare the composite sandwich structure. By the treatment scheme, the utilization rate of the material is improved, and the processing production period and the processing time are greatly shortened.
Description
Technical Field
The invention relates to the field of composite materials, in particular to a composite sandwich structure and a preparation method thereof.
Background
The composite material has higher specific strength, excellent mechanical property, fatigue property and stable chemical property, is an emerging material for replacing traditional metals, and has wide development prospect in the field of energy conservation and emission reduction. At present, the composite material is widely applied to the fields of wind power generation, sports and leisure, transportation, aerospace and the like, and the application requirements of the emerging industry are continuously emerging, so that the development is powerful.
Of the wide variety of composites, carbon fiber composites are the most representative. The volume ratio tensile strength of the carbon fiber composite material is about 10 times that of the traditional steel material in the fiber direction compared with the traditional steel material, namely the ultimate weight which can be born by the carbon fiber composite material with the same weight in the fiber direction is about 10 times that of the steel material. And the carbon fiber composite material has excellent designability, and the performance of the material can be flexibly utilized to the greatest extent.
For more efficient performance of materials, a sandwich structure or a hollow structure is usually used when designing the composite material, i.e. a composite material layer is adopted within a certain thickness range along the outer contour surface of the product, and the rest part adopts a core material or is directly hollow. The hollow structure is difficult in the actual manufacturing process, and the sandwich structure using the core material is easy to realize in a general regular shape, so that the sandwich structure using the core material is more common, the commonly used core material mainly comprises a foam core material and a honeycomb core material, and the foam core material is more common in the industry in consideration of various factors such as comprehensive cost performance.
The raw materials of the foam core material are generally in the form of a plate, and the foam core material needs to be combined and milled when in use, which brings about a series of problems as follows.
1. Size limitation problem: when the product size is larger than the plate size, the plates are required to be combined in advance, additional working procedures are added in the combination, and the bonding materials are likely to have weak joints in the material performance of the bonding positions, so that the deformation or the damage is easy to occur.
2. Material utilization problem: to make the profile of the foam core consistent with the actual requirements, the foam board is typically milled to ensure a net size. Milling belongs to material reduction processing, and the utilization rate of materials can be greatly reduced, and additional processing equipment and corresponding manpower and material resources are required to be input.
3. Suitability problem: the dimensional stability of the milled foam core material is higher, but the dimensional stability of the matched composite material layer is poorer. In order to achieve the best matching effect, the foam core material or the composite material layer may be reworked in the actual operation process.
4. Binding problem: the materials of the foam core materials and the resin of the composite materials commonly used in the industry are generally two materials, so that the problem of interface bonding exists, and the quality of interface bonding is also one of important factors for considering the performance of products. Even if an interface improving material is introduced between the composite layer and the foam core to optimize the properties in order to improve the interface properties, the material and additional process steps are also added.
5. Limited functionality: the common foam core material only ensures the mechanical properties of the foundation, and is difficult to meet for application in special scenes, such as flame retardant property, heat conducting property and the like. Meanwhile, the consumption of the functional foam core material is small, so that the functional foam core material is dynamically developed by few suppliers, and the application of the functional foam core material in some fields is greatly limited.
The above problems limit the popularization and use of the core material from different dimensions.
Disclosure of Invention
Therefore, in order to overcome the defects in the prior art, the invention provides a composite sandwich structure with improved material utilization rate and greatly shortened processing production period and processing time and a preparation method thereof.
In order to achieve the above object, the present invention provides a method for preparing a composite sandwich structure, wherein the composite sandwich structure has three layers from top to bottom, the upper layer and the lower layer are both composite material layers, and the middle layer is a foaming layer, comprising: acquiring modeling data of the foaming layer, and determining the theoretical minimum thickness of the foaming layer; determining the number of division layers of the foaming layer based on the modeling data and the theoretical minimum thickness; extracting median data of the modeling data layer by layer according to the number of the division layers, and forming corresponding modeling contour data; cutting the composite material according to the data of the modeling data to form a composite material sheet, and correspondingly laying the composite material sheet in a product mould; mixing a physical foaming filler with a resin material, and preparing a film material sheet of a foaming layer according to the modeling contour data; and sequentially attaching the film material sheets to the composite material sheets according to the sequence, closing the product mold, putting the product mold into heating equipment, foaming, heating and curing to prepare the composite sandwich structure.
In some embodiments, the determining the theoretical minimum thickness of the foamed layer comprises: when the thickness of the modeling data is judged to be uniform, setting the average thickness of the foaming layer as the calculated minimum thickness; when the thickness difference of the modeling data is judged to be large, setting the minimum thickness of the foaming layer as the calculated minimum thickness; and calculating the theoretical minimum thickness of the foaming layer according to the calculated minimum thickness, the foaming multiple of the resin material and the forming temperature.
In some embodiments, the composite material is a prepreg formed by impregnating continuous fibers or fabrics with a resin matrix.
In some embodiments, the resin matrix is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, a thermoset polyurethane resin.
In some embodiments, the fabric is one or a combination of more of a woven fabric, a knitted fabric, a knit fabric, a nonwoven fabric.
In some embodiments, the continuous fibers are one or a combination of more of glass fibers, carbon fibers, basalt fibers, silicon carbide fibers, alumina fibers, aramid fibers, ultra-high molecular weight polyethylene fibers, ultra-high molecular weight polypropylene fibers.
In some embodiments, the extracting the median data of the modeling data layer by layer and forming the corresponding modeling profile data includes: extracting median data of the modeling data layer by layer to form a flattened shape of a median plane of the modeling of the layer, wherein the layer is an ith layer, i is any positive integer of 1-N, the number of division layers of the foaming layer is N, and the thickness of the nth layer is smaller than the theoretical minimum thickness; when i is less than N, setting the contour data of the flattened shape as the modeling contour data of the ith layer; when i=n, calculating a ratio S1 of the volume of the nth layer to the theoretical minimum thickness, and obtaining a projection area S2 of the flattened shape of the nth layer; the ratio S% of S1 to S2 is calculated, and the modeling contour data of the Nth layer is set as a shape contour with the projection area S2 reduced to S% in equal proportion.
In some embodiments, the product mold is clamped and placed into a heating device, and the heating and curing conditions are 80-180 ℃ for 30-180 min.
In some embodiments, the resin material is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, a thermosetting polyurethane resin.
The composite sandwich structure is prepared by the method.
Compared with the prior art, the invention has the advantages that: the problem that the traditional foaming core material is suitable for complex modeling and needs to be subjected to secondary splicing and a large amount of milling is effectively avoided, the utilization rate of the material is greatly improved, the suitability problem is not needed to be considered when the foaming material is adopted, and the processing production period and the processing time are greatly shortened.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and that other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a flow chart of a method of making a composite sandwich structure in an embodiment of the invention.
Detailed Description
Embodiments of the present application will be described in detail below with reference to the accompanying drawings.
Other advantages and effects of the present application will become apparent to those skilled in the art from the following disclosure, which describes the embodiments of the present application with reference to specific examples. It will be apparent that the described embodiments are only some, but not all, embodiments of the application. The application may be practiced or carried out in other embodiments that depart from the specific details, and the details of the present description may be modified or varied from the spirit and scope of the present application. It should be noted that the following embodiments and features in the embodiments may be combined with each other without conflict. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
It is to be noted that various aspects of the embodiments within the scope of the present application are described below. It should be apparent that the aspects described herein may be embodied in a wide variety of forms and that any specific structure and/or function described herein is merely illustrative. Based on the present disclosure, one skilled in the art will appreciate that one aspect described herein may be implemented independently of any other aspect, and that two or more of these aspects may be combined in various ways. For example, apparatus may be implemented and/or methods practiced using any number and aspects set forth herein. In addition, such apparatus may be implemented and/or such methods practiced using other structure and/or functionality in addition to one or more of the aspects set forth herein.
It should also be noted that the illustrations provided in the following embodiments merely illustrate the basic concept of the present application by way of illustration, and only the components related to the present application are shown in the drawings and are not drawn according to the number, shape and size of the components in actual implementation, and the form, number and proportion of the components in actual implementation may be arbitrarily changed, and the layout of the components may be more complicated.
In addition, in the following description, specific details are provided in order to provide a thorough understanding of the examples. However, it will be understood by those skilled in the art that the aspects may be practiced without these specific details.
As shown in fig. 1, the embodiment of the application provides a method for preparing a composite sandwich structure, which comprises three layers from top to bottom, wherein the upper layer and the lower layer are both composite material layers, and the middle layer is a foaming layer. The preparation method of the composite sandwich structure comprises the following steps:
and S1, acquiring modeling data of the foaming layer, and determining the theoretical minimum thickness of the foaming layer.
The modeling data may be data composed of dimensional data or theoretical design data carrying foam modeling parameters. The modeling data may vary from foam layer to foam layer. In some embodiments, for a foam layer with a relatively uniform thickness, determining an average thickness value H1 of the foam layer as a calculated minimum thickness, and taking H1 as a basis for subsequent calculation; for the foaming layers with complex shapes and large thickness differences, determining the minimum thickness value H2 of the foaming layers as the calculated minimum thickness, and taking H2 as the calculation basis. And then calculating the theoretical thickness h of the foaming resin film according to the foaming multiple of the foaming material.
And S2, determining the number of division layers of the foaming layer based on the modeling data and the theoretical minimum thickness.
Based on the modeling data and the theoretical minimum thickness, the number of divided layers of the foam layer is determined. For example, when the foam molding is based on the average thickness H1 as a calculation basis, the number of layers of the foam layer is determined to be 1.
When the foaming modeling takes the minimum thickness H2 as a calculation basis, the foaming layer modeling can be divided into a plurality of layers N along the bottom surface or the top surface by taking the H2 as a unit thickness, the thickness of the last layer is usually not more than H2, and the number of division layers of the foaming layer is determined to be N. More often, the thickness of the last layer is less than H2.
And step S3, extracting median data of the modeling data layer by layer according to the number of the segmentation layers, and forming corresponding modeling contour data.
And extracting median data of the modeling data layer by layer according to the number of the division layers, and forming corresponding modeling contour data. When the number of layers of the foaming layer is 1, the shape of the foaming layer is selected from the flattened shape of the middle position surface in the shape of the foaming layer as the shape of the foaming resin film.
When the total number of the divided layers of the foaming layers is N, the flattened shape of the median plane in each layer of molding can be selected as the shape of the foaming resin film of the corresponding layer. In one embodiment, when the total number of the divided layers of the foaming layers is N, from the 1 st layer to the N-1 st layer, the flattened shape of the middle position surface in each layer of molding is selected as the shape of the foaming resin film of the corresponding layer; for the nth layer (i.e., the last layer having a thickness not greater than H2), an additional calculation of the ratio S1 of the volume of the nth layer to the minimum thickness H2 is required. And taking the projection area S2 of the nth layer, and calculating the ratio s% of the S1 to the S2. The shape of the N-th layer foamed resin film is a shape profile in which the S2 ratio is reduced to S%.
And S4, cutting the composite material according to the data of the modeling data to form a composite material sheet, and correspondingly laying the composite material sheet in a product die.
Cutting the composite material according to the data of the modeling data to form a composite material sheet, and correspondingly laying the composite material sheet in a product die. And laying a composite material, wherein the composite material can be prepared by taking a prepreg formed by impregnating continuous fibers or fabrics with a resin matrix as a raw material. Based on a layering drawing of a product to be prepared, a numerical control cutting machine is used for cutting composite material sheets with various shapes and angles, and the composite material sheets are sequentially paved in an upper die cavity and a lower die cavity of a product die. The composite sheet placed at this time is used to form the final composite layer. Step S4 is not set with a fixed order between other steps, as long as it is later than step S1 and earlier than step S6.
And S5, mixing the physical foaming filler with a resin material, and preparing a film material sheet of the foaming layer according to the modeling contour data.
The process parameters of the coating equipment can be set based on the theoretical minimum thickness h obtained by calculation in the step S1, and then the physical foaming filler and the resin material needing foaming are mixed to prepare a foaming resin film; then, based on the molding contour data, the foamed resin film is prepared into a film web of the foamed layer. The physical foaming filler and the resin material can be mixed, and the film material sheet of the foaming layer can be prepared by one-step molding based on the theoretical minimum thickness h and the molding contour data obtained in the step S1.
And S6, sequentially attaching the film material sheets on the composite material sheets according to the sequence, closing the product mold, putting the product mold into heating equipment, foaming, heating and curing to prepare the composite sandwich structure.
And (5) paving the film material sheet prepared in the step (S5) on the corresponding upper and lower die composite material layers according to the design positions and rules. And then, after the upper die and the lower die are assembled, putting the upper die and the lower die into heating equipment for foaming and heating curing, and obtaining the composite sandwich structure.
The method effectively avoids the problems that the traditional foam core material is suitable for complex modeling and needs to be subjected to secondary splicing and a large amount of milling, greatly improves the utilization rate of materials, and greatly shortens the processing production period and the processing time due to the adoption of the foam material without considering the suitability.
In some embodiments, determining the theoretical minimum thickness of the foamed layer comprises:
When the thickness of the modeling data is judged to be uniform, setting the average thickness of the foaming layer as the calculated minimum thickness; when the thickness difference of the modeling data is judged to be large, setting the minimum thickness of the foaming layer as the calculated minimum thickness;
And calculating the theoretical minimum thickness of the foaming layer according to the calculated minimum thickness, the foaming multiple of the resin material and the forming temperature.
According to the method, the foaming multiplying power of the resin material under different conditions is considered, and the accuracy of the finally obtained composite sandwich structure is further improved.
In some embodiments, the composite material is a prepreg formed by impregnating continuous fibers or fabrics with a resin matrix.
In some embodiments, in order to improve the bonding property of the foaming layer and the composite material layer, the resin material and the resin matrix can be made of the same system and the same general type of resin material, so that a series of hidden dangers caused by interface bonding can be effectively avoided. The resin material to be used for foaming may be the same resin (resin matrix) as the upper and lower layers of the composite material, may be the same type of resin, or may be different types of resin as long as a predetermined interfacial bonding property is satisfied.
In some embodiments, the resin matrix is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, a thermoset polyurethane resin.
In some embodiments, the continuous fibers are one or more combinations of glass fibers, carbon fibers, basalt fibers, silicon carbide fibers, alumina fibers, aramid fibers, ultra-high molecular weight polyethylene fibers, ultra-high molecular weight polypropylene fibers, and the fabric is one or more combinations of woven, knit, nonwoven.
In some embodiments, extracting median data of the modeling data layer by layer and forming corresponding modeling profile data includes: extracting median data of modeling data layer by layer to form a flattened shape of a median plane of the modeling of the layer, wherein the layer is an ith layer, i is any positive integer from 1 to N, the number of segmentation layers of the foaming layer is N, and the thickness of the nth layer is smaller than the theoretical minimum thickness; when i is less than N, setting the contour data of the flattened shape as the modeling contour data of the ith layer; when i=n, calculating a ratio S1 of the volume of the nth layer to the theoretical minimum thickness, and obtaining a projection area S2 of the flattened shape of the nth layer; the ratio S% of S1 to S2 is calculated, and the modeling contour data of the Nth layer is set as a shape contour with the projection area S2 reduced to S% in equal proportion.
In some embodiments, the product mold is clamped and placed into a heating device, and the heating and curing conditions are 80-180 ℃ for 30-180 min.
In some embodiments, the resin material is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, a thermosetting polyurethane resin.
The composite sandwich structure is prepared by the method.
Example 1
A sandwich panel with flame retardant requirements is prepared. The modeling data of the plate are as follows: the product is arc, and crooked along length direction, projection length 2200mm, projection width 500mm, total thickness is 18mm, and wherein the combined material layer thickness is 3mm, and upper and lower both sides are 1.5mm respectively. The method comprises the following specific steps:
1. and acquiring modeling data of the foaming layer, and determining the theoretical minimum thickness of the foaming layer. The product belongs to the type that the thickness of the foaming layer is relatively uniform, so that the average thickness of the foaming layer is 15mm as a calculation basis, and the foaming multiple of the selected foaming material is 30 times, namely the theoretical thickness of the single-layer foaming resin film is 0.5mm.
2. Based on the flame retardant property requirement of the product, the flame retardant resin ST007-A (the component is the mixture of epoxy resin and flame retardant filler) can be selected as a matrix material, and the resin component of the corresponding foaming resin layer is also selected from the same type of resin material.
3. The foaming particles of olefin are used as foaming agent, the physical foaming filler is mixed with the resin material, and the film material sheet of the foaming layer is prepared according to the modeling contour data. Mixing with matrix resin according to the ratio of 1:1, setting coating technological parameters, and preparing the foaming resin film with the thickness of 0.5 mm. The foaming particles of the physical foaming filler can be selected from olefin foaming materials.
4. And extracting median data of the modeling data layer by layer according to the number of the division layers, and forming corresponding modeling contour data. The product is a product with a uniform foaming layer thickness, and only one layer of foaming resin film is needed. And intercepting the middle plane of the foaming layer of the product by three-dimensional CAD design software, specifically a space cambered surface. The arc surface was developed on a plane by design software to obtain the outline of the foamed resin film, specifically a rectangle of 500mm×2750mm for the product.
5. And laying a composite material layer, cutting the composite material sheet according to the design requirement of the composite sandwich structure, and sequentially laying the composite material sheet in an upper die cavity and a lower die cavity of a product die respectively.
6. Cutting the foaming resin film in the step 3 according to the modeling contour data obtained in the step 4 to obtain a film material sheet.
7. And (3) attaching the film material sheet cut in the step (6) to a composite material sheet of a lower die cavity.
8. And (3) after the upper die and the lower die are clamped, placing the die into hot pressing equipment for foaming and heating solidification. The corresponding curing condition of the product is 150 ℃ and 120min.
9. And after the heating and solidification are completed, naturally cooling to room temperature, and then removing the pressure and opening the die to obtain the product.
This embodiment effectively solves the problem of the size limitation of the conventional foam core, typically 2500mm in the largest dimension of the foam core. Meanwhile, the core material of the product is arc-shaped, the flat plate is processed into arc-shaped, a series of processing means of heating and milling are needed, and the material cost and the processing cost are increased at the same time. Finally, compared with the traditional foaming material without any flame retardant performance, the foaming layer of the product has a certain flame retardant property due to the adoption of the flame retardant resin as the matrix material of the foaming resin film, thereby endowing the product with a new function and effectively improving the competitiveness of the product.
Example two
Preparing a composite material tool for a robot, wherein a product is of a sandwich structure, and modeling data of the composite material tool are as follows: the projection width is 450mm and the projection length is 1200mm. The upper side and the lower side of the composite material layer are respectively 2mm, the foaming layer is shaped into a special shape, the maximum thickness is 24mm, and the minimum thickness is 5mm. The method has no functional requirement and comprises the following specific steps:
1. And acquiring modeling data of the foaming layer, and determining the theoretical minimum thickness of the foaming layer. The foaming layer of the product belongs to the types with complex modeling and large thickness difference, the minimum thickness of 5mm is selected as the theoretical thickness of the foaming resin film, and the foaming multiple of the selected foaming material is 20 times, namely the theoretical thickness of the single-layer foaming resin film is 0.25mm.
2. The foaming resin film resin material is selected, the product has no additional functional requirement, and the product adopts general epoxy resin ST001 (the components are epoxy resin and toughening filler) as a matrix material, so that the mechanical property and the technological property are excellent. The resin component of the foaming resin layer is also made of the same type of resin material.
3. The foaming particles of olefins are used as foaming agent. And mixing the physical foaming filler with the resin material, and preparing the film material sheet of the foaming layer according to the modeling contour data. Specifically, a foamed resin film having a thickness of 0.25mm was prepared by mixing with a matrix resin in a ratio of 1:0.8 and setting the coating process parameters. The foaming particles of the physical foaming filler can be selected from olefin foaming materials.
4. And extracting median data of the modeling data layer by layer according to the number of the division layers, and forming corresponding modeling contour data. The product belongs to a foaming layer structure with complex modeling. The thickness of 5mm is used as a division unit, the foaming layer is divided into 5 independent foaming layer models along the upper end face through three-dimensional CAD design software, and the 1 st layer of 5mm, the 2 nd layer of 5mm, the 3 rd layer of 5mm, the 4 th layer of 5mm and the 5 th layer of 4mm are arranged downwards from the upper end face in sequence.
And modeling the 1 st layer of foaming resin film, cutting off the middle plane of the 1 st layer of foaming layer of the product by three-dimensional CAD design software, and then expanding the cambered surface to a plane by the design software so as to obtain the contour of the 1 st layer of foaming resin film.
This step is repeated to sequentially obtain the profiles of the foamed resin films of the 2 nd to 4 th layers.
The 5 th layer foaming resin film is molded, the volume of the 5 th layer foaming layer is grabbed through three-dimensional CAD design software, the actual measurement is 2400mm, the S1 is calculated to be 480 mm 2, the projection area S2 of the 5 th layer is obtained through the three-dimensional CAD design software to be 620mm 2, and the s% is calculated to be 77%. The middle plane of the 5 th foaming layer of the product is cut through three-dimensional CAD design software, then the cambered surface is unfolded to a plane through the design software, and the contour is scaled to be 77% of the original contour, so that the contour of the 5 th foaming resin film is obtained.
5. And laying a composite material layer, cutting the composite material sheet according to the design requirement of the composite sandwich structure, and sequentially laying the composite material sheet in an upper die cavity and a lower die cavity of a product die respectively.
6. Cutting the foaming resin film in the step 3 according to the modeling contour data obtained in the step 4 to obtain a film material sheet.
7. And (3) attaching the film material sheet cut in the step (6) to a composite material sheet in a product mold, for example, attaching the 1 st layer to the 3 rd layer to the composite material sheet of an upper mold cavity of the product mold, and attaching the 4 th layer to the 5 th layer to the composite material sheet of a lower mold cavity of the product mold.
8. After the upper die and the lower die are assembled, the upper die and the lower die are locked by a locking mechanism to apply pressure, and the dies are placed into a drying room to be foamed and heated for solidification. The corresponding curing condition of the product is 130 ℃ and 210min.
9. And after the heating and solidification are completed, naturally cooling to room temperature, removing the fastening device, and opening the die to obtain the product.
The embodiment effectively avoids the problems that the traditional foam core material is suitable for complex modeling and needs to be spliced and a large amount of milling processing, greatly improves the utilization rate of materials and shortens the processing time. Meanwhile, the product has complex modeling, so that the matched size is more, the consistency is difficult to ensure when the composite material layer is laid manually, and the foam core material is required to be processed for the second time. The foaming material is adopted without considering the suitability problem, so that the processing production period is greatly shortened.
The foregoing is merely illustrative of the present application, and the present application is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the scope of the present application should be included in the present application.
Claims (10)
1. The preparation method of the composite sandwich structure is characterized in that the composite sandwich structure comprises three layers from top to bottom, wherein the upper layer and the lower layer are both composite material layers, and the middle layer is a foaming layer, and the preparation method comprises the following steps:
acquiring modeling data of the foaming layer, and determining the theoretical minimum thickness of the foaming layer;
Determining the number of division layers of the foaming layer based on the modeling data and the theoretical minimum thickness;
Extracting median data of the modeling data layer by layer according to the number of the division layers, and forming corresponding modeling contour data;
Cutting the composite material according to the data of the modeling data to form a composite material sheet, and correspondingly laying the composite material sheet in a product mould;
mixing a physical foaming filler with a resin material, and preparing a film material sheet of a foaming layer according to the modeling contour data;
and sequentially attaching the film material sheets to the composite material sheets according to the sequence, closing the product mold, putting the product mold into heating equipment, foaming, heating and curing to prepare the composite sandwich structure.
2. The method of claim 1, wherein said determining a theoretical minimum thickness of said foamed layer comprises:
When the thickness of the modeling data is judged to be uniform, setting the average thickness of the foaming layer as the calculated minimum thickness; when the thickness difference of the modeling data is judged to be large, setting the minimum thickness of the foaming layer as the calculated minimum thickness;
and calculating the theoretical minimum thickness of the foaming layer according to the calculated minimum thickness, the foaming multiple of the resin material and the forming temperature.
3. The method of manufacturing according to claim 1, wherein the composite material is a prepreg formed by impregnating continuous fibers or fabrics with a resin matrix.
4. The method according to claim 3, wherein the resin matrix is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, or a thermosetting polyurethane resin.
5. A method of making according to claim 3 wherein the fabric is one or a combination of more of a woven, knit, nonwoven.
6. The method of claim 3, wherein the continuous fibers are one or more of glass fibers, carbon fibers, basalt fibers, silicon carbide fibers, alumina fibers, aramid fibers, ultra-high molecular weight polyethylene fibers, ultra-high molecular weight polypropylene fibers.
7. The method of claim 1, wherein the extracting the median data of the modeling data layer by layer and forming the corresponding modeling profile data comprises:
extracting median data of the modeling data layer by layer to form a flattened shape of a median plane of the modeling of the layer, wherein the layer is an ith layer, i is any positive integer of 1-N, the number of division layers of the foaming layer is N, and the thickness of the nth layer is smaller than the theoretical minimum thickness;
When i is less than N, setting the contour data of the flattened shape as the modeling contour data of the ith layer;
When i=n, calculating a ratio S1 of the volume of the nth layer to the theoretical minimum thickness, and obtaining a projection area S2 of the flattened shape of the nth layer; the ratio S% of S1 to S2 is calculated, and the modeling contour data of the Nth layer is set as a shape contour with the projection area S2 reduced to S% in equal proportion.
8. The method according to claim 1, wherein the product mold is clamped in a heating device, and the heating and curing conditions are 80 ℃ to 180 ℃ for 30min to 180min.
9. The method according to claim 1, wherein the resin material is an epoxy resin, a phenolic resin, a vinyl resin, an acrylic resin, a thermosetting polyurethane resin.
10. A composite sandwich structure, characterized in that it is produced by the method according to any one of claims 1-9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410412341.3A CN118003667B (en) | 2024-04-08 | 2024-04-08 | Composite sandwich structure and preparation method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410412341.3A CN118003667B (en) | 2024-04-08 | 2024-04-08 | Composite sandwich structure and preparation method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN118003667A true CN118003667A (en) | 2024-05-10 |
| CN118003667B CN118003667B (en) | 2024-06-04 |
Family
ID=90954802
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202410412341.3A Active CN118003667B (en) | 2024-04-08 | 2024-04-08 | Composite sandwich structure and preparation method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN118003667B (en) |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009285957A (en) * | 2008-05-28 | 2009-12-10 | Nippon Steel Composite Co Ltd | Manufacturing method for foamed core sandwich panel |
| CN107215039A (en) * | 2017-06-07 | 2017-09-29 | 国电联合动力技术有限公司 | A kind of core filled composite material and preparation method thereof |
-
2024
- 2024-04-08 CN CN202410412341.3A patent/CN118003667B/en active Active
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009285957A (en) * | 2008-05-28 | 2009-12-10 | Nippon Steel Composite Co Ltd | Manufacturing method for foamed core sandwich panel |
| CN107215039A (en) * | 2017-06-07 | 2017-09-29 | 国电联合动力技术有限公司 | A kind of core filled composite material and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| CN118003667B (en) | 2024-06-04 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP5971409B2 (en) | Manufacturing method of fiber reinforced composite material molded article | |
| CN112677362B (en) | Preforming body for forming grid reinforced foam sandwich composite material and forming method thereof | |
| CN101663155A (en) | Method for a complex part of a composite material with long fibers and heat-curable matrix | |
| CN102105296A (en) | Device and method for the manufacture of three dimensional beam type elements in composite material | |
| JP2008246981A (en) | Manufacturing method of fiber-reinforced composite material | |
| CN105946327B (en) | A kind of reversible twill three-dimensional structural glass fabric and the method for preparing composite | |
| CN113400677B (en) | Auxiliary die and preparation method of grid structure reinforced foam sandwich composite material | |
| CN110103488A (en) | A kind of continuous mould pressing manufacturing process of fan blade thermoplastic composite spar cap | |
| CN101758923A (en) | Composite material box-shaped rib and manufacturing method thereof | |
| CN106273989A (en) | The shaped device of a kind of fiber reinforced thermolplastic composite material plate and forming method thereof | |
| CN103568447B (en) | Device laminated into type and prepare the method for thermosetting polymer based composites | |
| CN111941875A (en) | Forming method of carbon fiber composite material for vehicle | |
| Eichenhofer et al. | Analysis of processing conditions for a novel 3D-composite production technique | |
| CN106739245A (en) | Electronic product casing and its manufacture method | |
| CN118003667B (en) | Composite sandwich structure and preparation method thereof | |
| JP2018507128A5 (en) | ||
| CN105383142A (en) | Motor train unit aramid fiber honeycomb in-built part forming process | |
| CN102248685A (en) | Forming method of glass fiber reinforced plastic (GFRP) | |
| CN114801251B (en) | Integrated forming method of universal aircraft carbon fiber prepreg corrugated wallboard | |
| CN109353034A (en) | Thermoplasticity is punched hot pressing die and its application method certainly | |
| AU2021103814A4 (en) | Method for improving interlaminar strength effect of z-pin reinforced composite | |
| CN101637974A (en) | Sizing device of composite profile | |
| GB2560703A (en) | Moulding method | |
| CN104157974B (en) | The curvature that is used for the honeycomb sandwich layer of antenna house is determined method | |
| EP3592540B1 (en) | Moulding method |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |