CN1268485C - 轻重量结构板 - Google Patents
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Abstract
一种纤维芯(24)材料，具有多个形成于其中用于减轻重量的孔(25)，该材料设置在金属外皮(22)之间并与它们相结合，从而形成具有与重量较重的钢板强度相当的结构层压板(20)。
Description
技术领域
本发明涉及层压结构板，更具体地说，涉及具有理想结构性能的轻重量层压板。
背景技术
人们采用很多方法在基本上不增加重量或材料成本的情况下改善面板的结构性能。在需要消声器和振动阻尼器的实际应用中，已经采用了具有实心聚合物芯的钢板复合物。但是，这些复合物有很多缺点，例如容易产生压痕，并在很多应用中不具备理想的刚度。在名称为STRUCTUAL PANEL WITH CRAFT PAPER CORE BETWEEN METALSKINS的美国专利5,985,457中，公开了一种结构面板，其具有层压板结构，并具有由居间纸层分开并结合到居间纸层上的金属外皮，其中该项专利在此被整个引入作为参考。此处描述的层压板具有较高的比刚度和抵抗压痕的性能。
在于1999年6月29日提交的、名称为CARGO VEHICLE WALL的同样未决的美国专利申请09/342,690中，描述了一种卡车拖车，它具有由金属外皮和纸形成的层压板制成的壁，其中该项专利在此被整个引入作为参考。这种卡车壁在减小重量和成本的同时提供了较好的结构性能。
在名称为IMPROVED STRUCTURAL PANEL AND METHOD OFMANUFACTURE的美国专利6,171,705中，公开了多种对金属/纸/金属层压板的改进，并包括对制造方法的改进，其中该项专利在此被整个引入作为参考。
尽管前述的金属/纸/金属层压板具有很多优点，本发明人发现在某些应用中需要一种重量减轻的创造性的面板，尤其是在制造大面积面板的情况中。本发明达到了这个目的。
发明内容
在一个方面，提供一种结构层压板，它具有第一和第二金属板外皮。在金属板外皮之间设置有一个纤维芯层，并结合到外皮上。纤维层中形成有多个孔，每个孔的面积为从约0.008平方英寸到约0.2平方英寸。在一个方面，纤维芯层浸透粘结树脂。在另一方面，在芯材料与外皮之间设置有粘结层。得到的层压板结构很结实而且重量较轻。
附图说明
图1是本发明层压板的透视剖切视图。
图2是图1所示纸层的俯视图。
图3是沿图2所示纸层中的线3-3剖开的截面图。
图4是图1中面板的俯视图(没有剖开)。
图5是图4所示面板沿线4-4剖开的截面图。
具体实施方式
现参照附图中的图1，所示面板20具有金属外皮22和居间纤维层24。层24具有多个开口或孔25。
在一种优选结构中，外皮22优选由镀锌钢制成，每个层22的厚度为约0.005英寸或更大，优选从0.005英寸到约0.030英寸，厚度更优选从约0.005英寸到约0.012英寸。在一个实施例中，居间纤维层24的厚度优选为约0.01英寸或更厚，并更优选从约0.01英寸到约0.05英寸。因此，在一个实施例中，面板20的全部厚度通常在约0.020英寸到约0.11英寸之间。
孔25可形成为大多数的几何形状，例如圆形、方形、三角形等等。孔25在单层24中的尺寸和形状可不相同或相同。优选的，每个孔25的面积为从约0.008平方英寸到约0.2平方英寸，更优选从约0.012平方英寸到约0.11平方英寸。层24中多个孔25的总面积(每个孔25的面积总和)取决于包括层24总面积的多个因素。最优选的，多个孔25的总面积大于层24总表面积(一侧的主表面)的约10％，但通常不大于层24总表面积(一侧的主表面)的50％。具有在上文描述附图中的图1时说明的尺寸、并具有刚刚描述的优选层厚和孔25面积的面板，其重量远远小于尺寸和刚度相当的单层钢板的重量。
下面将详细描述图1示出的各层。如前所述，金属外皮22通常是平的，并在每一侧具有平面表面。可用于形成外皮22的金属优选从下面的组中选出，所述组包括钢、铝、不锈钢和它们的组合。能以最低的成本在面板20所应用的特定环境中提供足够的结构和(如果需要的话)抗腐蚀性能的金属是最理想的。最优选的为镀锌钢板。
本领域普通技术人员可以理解，根据含碳量和其它元素的含量，钢分成多个等级。总的来说，这些等级都可以低碳钢、中碳钢和高碳钢来描述。此处优选采用低碳钢和低碳微合金高强度钢(HSLA)。用于本发明的最优选金属外皮为冷轧钢、镀锌钢、镀锡钢和不锈钢。理想的是，采用具有镀锌表面的单侧镀锌板构成外皮22的外表面，外皮的内表面是裸露的金属，以便用于粘结。在一个实施例中，优选采用不同的锌镀层，即，内表面上采用薄的锌镀层，外表面上采用厚的锌镀层。在一个实施例中，将表面上带有锌的镀锌钢冷轧到最终的厚度。
层24为纤维材料。尽管并不希望受任何理论的约束，我们相信层24的纤维性质有利于面板20的所需结构性能，包括抗抗剥离性。在本文中使用的术语“纤维”并没有在本发明的上下文中限制其范围，该术语用于指同类的纤维集合，其可为天然的或合成的，并能形成片状产品。
参照附图的图2、3和4，所示层24具有多个任意分布的开口或孔25。孔25也可以均匀阵列等形式分布。如前文所述，孔25可形成为大多数几何形状。优选的，每个孔25的面积为从约0.008平方英寸到约0.2平方英寸，更优选从约0.012平方英寸到约0.11平方英寸。最优选的，多个孔25的总面积大于层24总表面积(一侧的主表面)的10％，但通常不大于层24总表面积(一侧)的50％。孔25可用成型冲模切出或可在形成层24时形成。如在前述的未决美国专利申请中所描述的，这种结构尤其适用于制造载重卡车面板。
用于此处层24的最优选的纤维材料是纸，它是一种被认为是纤维板中比较独特的材料。象本领域普通技术人员可以理解的那样，纸实质上是纤维材料的缠结的或毡状的结构，其中纤维材料通过纸浆和水的稀释悬浮液形成相对较薄的片状。它主要由纤维素纤维组成。用于造纸的纸浆可通过机械研磨木材或其它植物物质、通过化学处理(亚硫酸盐、牛皮纸浆、或苏打)，还通过经化学处理的棉花、亚麻和大麻碎布、废物、麦杆等等来制备。
在本发明中，采用牛皮纸浆制法制造的纸是最优选的。本领域普通技术人员可以理解，采用牛皮纸浆制法(也可称为硫酸盐制浆法或碱法制浆)会产生较高物理强度和松密度的纸。一种优选的纸为Charleston，S.C.的Westvaco所出售的浸油牛皮纸。
同样，本领域普通技术人员可以理解，在造纸过程中，纸中纤维素纤维的平均对准多少是受“机器方向”控制的。我们相信，本发明中纸张在层压板中的取向是影响层压板的刚度和强度的因素。最优选的，层压板中牛皮纸的机器方向是一条平行于层压板弯曲中轴线的直线。
可用于此处的另一种纤维材料为塑料纤维纸。与纸不同，塑料纤维纸是形成片状的合成(即，合成聚合物)纤维类。例如，它可通过纺出非常细的纤维然后用热量和压力使它们结合在一起而由百分之百的高密度聚乙烯纤维制成。尼龙纸，例如型号为410的诺梅克，由耐高温的聚酰胺聚合物的短纤维(絮)和较小的粘结微粒(纤条体)制成，并形成片状产品。
在本发明的一个优选实施例中，层24设置为浸树脂纤维材料。最优选的，将该纸用树脂浸透然后使其干燥。用于此处最优选的纸为浸酚醛树脂牛皮纸。在某些应用中，聚酯树脂浸渍也是适用的。用树脂浸渍纸的方法对本领域普通技术人员来说是熟知的。实质上，优选的浸树脂纸通过在液体酚醛树脂中浸渍基质纸幅而形成。通常，将饱和浸透纸层层叠在一起从而形成单层的半固化浸透纸。其它浸渍方法包括将层24浸渍在树脂浴槽中，或在纸上涂覆和涂抹树脂。尽管在特定应用中，层24的树脂含量超出下面说明的范围可能是适当的或需要的，但在本发明的一个优选实施例中，树脂构成浸树脂层24重量的约15％到约45％。在浸渍过程中孔25基本上没有树脂；即，在浸渍过程中孔25中部不填充树脂。
尽管在某些应用中，热塑性树脂是容许的，但在大多数情况下，优选用热固性树脂浸透纸层24。如前所述，在采用热固性树脂的情况中，在形成面板20之前通常使树脂固化到B状态，但在下文描述的层压操作(控制热量和压力)之前，也可使浸透树脂完全固化。在采用酚醛树脂的情况下，在层压之前使树脂固化到B状态。然后，当用压力使外皮22和浸透纸芯24层压在一起时，使树脂完全固化。在某些应用中，可能需要在树脂中加入例如固化剂、填料等的多种标准添加剂。
现参照附图中的图5(不论有无纤维层24的浸透树脂)，在某些应用中需要使用粘结层26使外皮22结合到纤维芯24上。多种粘结剂可适用于特定应用中，包括环氧树脂、酚醛塑料、异氰酸酯、聚氨酯和热熔物。用于该目的的一种特别优选的粘结剂为AshlandChemical以“Arofene1166”出售的丁腈酚醛树脂粘结剂。粘结剂可采用多种方法直接施加到层24或金属外皮22或两者之上。同样，孔25不填充树脂。优选采用例如复合氧化物或磷酸锌的转化涂层来预处理钢，从而提高结合完整性和抗腐蚀性能。
形成复合板20的一种方法是通过使用加热的压模机(未示出)。将多个金属/纤维/金属层压板层叠起来(优选从5到20)后，使压模机靠近以便向叠层施加压力。根据外皮22和层24的厚度、用于浸透居间层的树脂类型，和在居间层与金属外皮之间所采用的粘结剂的类型(如果有的话)，时间、温度和压力有很大的不同。最优选的，所采用的温度应足够使酚醛树脂完全固化，并确保粘结层(如果有的话)的结合。在模压的叠层冷却后，将其从压模机上去除，然后将各个面板分离。
尽管此处示出并描述了本发明的特定实施例，显然可以理解的是，本发明不局限于此，因为受本申请内容的启发，特别是本领域普通技术人员可对本发明作出多种修改。因此，可以理解，通过附加的权利要求，本发明包括落入本发明真正精神和范围内的任何的这种修改。
Claims (14)
1.一种结构层压板，包括：
第一和第二金属板外皮，每个所述外皮的厚度至少为0.005英寸；
设置在所述金属板外皮之间的纤维芯；
所述纤维芯结合到所述金属外皮上；和
所述纤维芯具有多个形成在其中的孔，每个所述孔的面积为从0.008平方英寸到0.2平方英寸。
2.如权利要求1所述的结构层压板，其中所述金属板从包括冷轧钢、镀锌钢、镀锡钢和不锈钢的组中选出。
3.如权利要求1所述的结构层压板，其中所述纤维芯粘结地结合到所述金属外皮上。
4.如权利要求1所述的结构层压板，其中每个所述外皮的厚度为从0.005英寸到0.030英寸。
5.如权利要求1所述的结构层压板，其中所述纤维芯用树脂浸透，并且所述孔没有树脂。
6.如权利要求1所述的结构层压板，其中所述纤维芯的厚度至少为0.01英寸。
7.如权利要求1所述的结构层压板，其中所述纤维芯的厚度为从0.01英寸到0.05英寸。
8.如权利要求1所述的结构层压板，其中所述纤维芯为纸。
9.如权利要求1所述的结构层压板，其中所述纤维芯为合成聚合物。
10.如权利要求1所述的结构层压板，其中所述纤维芯为粘结地相互结合的多个纤维网。
11.如权利要求1所述的结构层压板，其中所述金属外皮为用转化涂层进行过预处理的钢，从而提高结合完整性和抗腐蚀性能。
12.如权利要求1所述的结构层压板，其中所述金属外皮由低碳微合金高强度钢制成。
13.如权利要求1所述的结构层压板，其中纤维芯具有一个主表面，并且孔的总面积大于所述主表面面积的10％。
14.如权利要求13所述的结构层压板，其中孔的总面积为所述主表面面积的50％或更少。
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| US09/841,339 US6546694B2 (en) | 2001-04-24 | 2001-04-24 | Light-weight structural panel |
| US09/841,339 | 2001-04-24 |
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| US20040242095A1 (en) * | 2003-05-27 | 2004-12-02 | Amit Prakash | Composites reinforced by wire net or mesh for lightweight, strength and stiffness |
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2001
- 2001-04-24 US US09/841,339 patent/US6546694B2/en not_active Expired - Fee Related
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2002
- 2002-04-19 KR KR10-2003-7013754A patent/KR20030090772A/ko not_active Application Discontinuation
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- 2002-04-19 CA CA 2445196 patent/CA2445196A1/en not_active Abandoned
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- 2002-04-19 DE DE60210301T patent/DE60210301D1/de not_active Expired - Fee Related
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Also Published As
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| US20020152716A1 (en) | 2002-10-24 |
| WO2002085617A1 (en) | 2002-10-31 |
| DE60210301D1 (de) | 2006-05-18 |
| US6546694B2 (en) | 2003-04-15 |
| KR20030090772A (ko) | 2003-11-28 |
| EP1401648B1 (en) | 2006-03-29 |
| CA2445196A1 (en) | 2002-10-31 |
| JP2004527401A (ja) | 2004-09-09 |
| MXPA03009637A (es) | 2004-06-30 |
| BR0209071A (pt) | 2004-09-28 |
| EP1401648A1 (en) | 2004-03-31 |
| ATE321655T1 (de) | 2006-04-15 |
| CN1505561A (zh) | 2004-06-16 |
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