CN1370113A - 改进的结构板材和其制造方法 - Google Patents

改进的结构板材和其制造方法 Download PDF

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CN1370113A
CN1370113A CN00811657A CN00811657A CN1370113A CN 1370113 A CN1370113 A CN 1370113A CN 00811657 A CN00811657 A CN 00811657A CN 00811657 A CN00811657 A CN 00811657A CN 1370113 A CN1370113 A CN 1370113A
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laminated plate
epidermis
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CN1270886C (zh
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戴维·达西·克利福德
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ArcelorMittal Dofasco Inc
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Abstract

纤维芯材料被设置在金属表皮之间并与之接触,以形成结构叠层板。它具有与重量更大的钢板相当的强度。

Description

改进的结构板材和其制造方法
本申请是美国专利申请No.8/947,030以及No.09/342,690的继续申请。前者于1997年10月8日提出，名称为“在金属表层之间夹入牛皮纸芯的结构板材”，并要求美国临时申请No.60/038,816的利益；而后者于1999年6月29日申请，名称为“载重汽车壁”。
技术领域
本发明涉及夹层的结构板材，特别涉及具有理想结构特性的重量轻的叠层板材。
发明背景
薄钢板广泛地用于制造板材。要求的结构特性，诸如刚度等取决于特定用途是不同的。在要求较高刚度时，钢板的厚度一般增加。但是增加钢板的厚度，不仅使得板材的较重，而且较昂贵。
在过去采取了各种方法在不明显增加重量或材料成本之下以改进板材的结构特性。例如，具有固体聚合物芯的复合薄钢板被用在需要隔音和缓冲振动的用途中。但是聚合物芯产品的特定刚度不理想。
在本文全文参引的，标题为“在金属表皮之间夹入牛皮纸芯的结构板材”，1997年10月8日注册的待审美国专利申请No.08/947,030中，公开的结构板材是具有金属表皮的夹层结构，所述金属表面由插入纸层分开并与之结合。公开的夹层具有很高的刚度。
在本文全文参引的，标题为“载重汽车壁”的，1999年6月29日注册的在审美国专利申请No.09/342,690中，公开具有金属表皮和纸叠层板的壁的卡车拖车。所述卡车壁提供优良的结构特性，同时还使得重量和成本最低。
本发明概述
在一方面，提供一种结构叠层板，它具有第一和第二金属薄板表皮。每个金属薄板的厚度至少约为0.005英寸。在金属薄板表皮之间形成纤维芯层并结合到所述表皮上。在一方面，纤维芯层用粘合剂树脂浸渍，所述树脂将芯层直接结合到表皮上。在另一方面，粘合剂层位于芯层和表皮之间，将芯结合到表皮。与类似厚度和强度的单一钢的薄板比较，产生的夹层结构重量极轻。
在一方面，纤维芯是纸并且金属表皮是具有耐腐蚀性的镀锌钢板。
在另一方面，纤维芯层具有在所述金属表皮之间延伸的多个通道。这些横向通道用粘合剂填充，产生进一步将表皮结合到芯的粘合剂桥。
在本发明的另一方面，提供形成结构用叠层板的方法。所述方法包括步骤：将纤维芯材料置于两个金属表皮之间，向所述三层叠层板施加压力，促进在芯和金属表皮之间的结合。在一方面，制备几个三层叠层板，然后一个将它们一个在另一个上重叠，然后加压同时将各层结合。
在本发明另一方面，本发明提供非平面的叠层板和制造这种非平面的叠层板的方法。所述方法包括步骤：将纤维芯置于金属表皮之间，提供一种将所述芯结合到所述表皮的装置，用金属成型技术将所述叠层板形成为非平面的产品。在一方面，使用的所述金属成型技术是模压技术。在一方面，在模压加工前、或后或在当中，向所述叠层板加热。
附图简要说明
图1是本发明叠层板的剖视图；
图2是本发明的叠层板的剖视图，示出粘合剂通道的使用；
图3是将各层结合成本发明叠层板的压力机示意图；
图4是本发明非平面叠层板的剖视图；和
图5是形成图4的非平面叠层板的模压机示意图。
优选实施例的详细说明
见图1，板材20具有金属表皮22和插入的纤维芯24。应理解，板材20基本上是三层叠层板结构，它具有不同的三层，它们共同形成一个功能单元。如下详细说明的，这个功能单元的性能比单个的元素要优越。
上面提到的在1997年10月8日注册的申请号No.08/947,030的美国专利申请中，完全地说明了纸形成所述纤维芯的板材20的一种优选结构。
见图1，在一个优选结构中，表皮22最好是由镀锌钢板制造，每层表皮22具有约0.005英寸或更高的厚度，在0.005-0.03英寸更好，在0.005-0.012最好。在一个实施例中，插入的纤维层24最好具有约0.01英寸或更高的厚度，在约0.01-0.05英寸更好。因此，在一个实施例中板材20的整个厚度一般为约0.020-0.110英寸。具有图1说明的尺寸和上述优选层厚度的板材的重量一般约为类似尺寸和刚度的单一钢板的重量的40-70％。
下面详细说明图1示出的各层。如所陈述的，金属表皮22一般是扁平的在两侧具有平表面。用作制造表皮22的金属最好选择自钢、铝、铜合金和它们的各种组合构成的组。以最低的价格在板材20使用的特定环境提供足够结构特性和耐腐蚀(如果要求)性能的金属是最理想的。最好是镀锌薄钢板。
如本领域技术人员所知，根据钢所含的碳和其他元素的量，钢有许多品种。广义地说，这些品种可以被称为低碳钢、中碳钢和高碳钢。在此最好是用低碳钢和高强度低碳合金钢(HSLA)。在本发明中使用的金属表皮最好是冷轧钢板，镀锌薄钢板，镀锡钢板和不锈钢板。用单一侧面镀锌钢板作为表皮22的外表面，而表皮内表面是用于粘合的裸露金属是理想的。在一个实施例中，可取地使用不同的镀锌层，即在内表面是较薄的镀锌层，在外表面是较厚的镀锌层。在一个实施例，镀锌钢板是冷轧钢板，其表面上的锌达到最终的厚度。
层24是纤维材料。虽然不希望拘泥于理论，但一般认为，层24的纤维特性有助于形成板材20的理想的结构特性，包括抗分层性能。在本文中使用的术语“纤维”，不限于本发明的上下文的范围，用于表示能够形成薄层制品的天然或合成的基本均质的纤维集合。
在此用作层24的最优选的纤维材料是纸，它被认为在纤维薄层当中是独特的。本领域技术人员理解，纸本质上是通过纸浆和水的稀释悬浮液形成为较薄层的纤维材料的一种垫或毡的结构。它基本由纤维素纤维构成。制造纸的纸浆能够通过机械地研磨木材或其他植物材料，化学处理(亚硫酸盐、牛皮纸或苏打)，以及化学处理棉花、亚麻和大麻布，废料和麦秸等制备。
在本发明中，最好是使用牛皮纸工艺形成的纸。本领域技术人员应理解，牛皮纸工艺(也称为硫酸盐制浆或碱法制浆)形成高机械强度和高膨胀的纸。南卡罗南纳州Charleston的Westvaco出售一种较好的浸透牛皮纸(油纸)。
另外，本领域技术人员理解，在纸中的纤维素纤维的一般取向在一定程度上是由生产纸时的“机器方向”控制。在本发明中，认为叠层板中的纸的取向是影响叠层板的刚度和强度的一个因素。最好的叠层板是，牛皮纸的机器方向是平行于叠层板的弯曲的中性轴线的直线。
在此使用的纤维材料的另一种是塑料纤维纸。与纸不同的是，塑料纤维树纸是构成薄板的合成(即合成聚合物)纤维的集合。例如，通过纺很细的纤维然后用热和压力将它们结合，能够用100％的高密度聚乙烯纤维制造它。尼龙纸，如Nomex 410型，用耐高温聚酰胺聚合物的短纤维(絮状物质)和较小的粘合剂颗粒(纤条体)制造，以形成薄层制品。
在本发明的一个优选实施例中，将层24形成为浸渍树脂的纤维材料。当层24是牛皮纸时，所述纸用树脂浸渍然后干燥。在此最好使用浸渍酚醛树脂的牛皮纸。在一些应用中也可以浸渍聚酯树脂。纸中浸渍树脂的方法是本领域技术人员了解的。主要是，通过在液体树脂酚醛中浸入基层纸幅以形成优选的树脂浸渍纸。一般，饱和的浸渍纸一层一层地叠置在一起形成单独一层半熟化的浸渍纸。在1997年10月22日公布的加拿大专利No.2,203,200中公开一种生产树脂浸渍纸的方法。其他的浸渍方法包括在纸上涂覆和分布树脂。虽然它对特定应用是适用或理想的，但是它超出层24的树脂含量的下述范围，在本发明的优选实施例中，树脂构成树脂浸渍层24重量的约15-45％。
在大多数情况中，对于在浸渍纸层24中使用来说热固性树脂较好，但是在一些应用中，也可以采用热塑性树脂。在热固性树脂的情况，如所述的，树脂一般是在形成板材20之前被固化到半溶阶段(Bstage)，但是也可以在下述的层压加工(控制的加热和压力)前完全固化浸渍的纸。在酚醛树脂的情况，树脂在层压前固化到半溶阶段。然后在用压力机将浸渍的纸芯24和表皮22层压在一起时完全固化。在树脂中包括几种标准添加剂，如固化剂、填充剂等，在一些应用中是适当的。
在纤维层24的树脂浸渍或不浸渍情况下，使用粘结剂层将表皮22结合到纤维芯24是所希望的或要求的。在特定应用中可以使用包括环氧类、酚醛类、异氰酸盐类、聚氨基甲酸酯类和热熔体类的数种粘合剂。这种用途的一种特别好的粘合剂是Ashland化学公司出售的“Arofene 1166”腈酚醛。所述粘合剂可以用任何方法直接施加到层24或金属表皮22，或两者都施加。用络合氧化物或磷酸锌转化涂层对所述薄钢板进行预处理，以改进结合的整体性和耐腐蚀。
在另一个实施例中，见图2，叠层板30’的纤维层24具有穿过其中的多个孔26。如在上述美国专利申请08/947,030更完全说明的，在一些应用中，孔26形成粘结剂桥。
见图3，此图示出用压力机28将表皮22和层24组装的一个方法。压力机28包括用液压等通过通常方式彼此上下运动的压板30。压板30最好是可加热的，以使得热和压力都能够施加到叠层板上以固化树脂并结合粘合剂。更具体地说，在图3中，两个金属/纤维/金属板材32和34彼此重叠。如上所述，在层24中的酚醛树脂在压力加工前处于固化的半溶阶段，并且在加压加工时加热的压板30完成酚醛树脂的固化。应理解，虽然在图中示出的一个单独层24，但是通常有几层纤维层材料彼此重叠，以将层24形成到适当的厚度。在一些应用中，在形成层24的每层之间放置一层粘合剂。
见图3，在几层金属/纤维/金属叠层板被重叠后(最好是5-20层)，压力机闭合以便向重叠层施加压力。根据表皮22和层24的厚度，浸渍中心层使用的树脂类型，以及在中心层和表皮之间使用的粘合剂(如果有的话)的类型，时间、温度和压力是不同的。最好是，使用的温度足以完全固化酚醛树脂，并且确保粘合剂层(如果有的话)结合。对于酚醛树脂浸渍的纸，在25-400psi低压下，温度300-350度F较好；压力在25-100psi更好。为了形成牢固结合的叠层板用这些优选的温度和压力所需的时间一般为15-60分钟。即，热和压力一般在这个范围的时间施加。在加压的重叠层冷器后，从压力机取下，然后分开各层板材。
在一些应用中，可以向层24加入胶粘剂以提高耐水性和加强纤维之间的结合。也可以向层24加入阻燃剂，如基于结合溴、氯、锑、硼和磷的组合。
见图4，下面说明本发明形成非平面的叠层板构件的方法。应理解，在一些应用中，本发明的叠层板材可以代替不是平板的金属部分。因此，在本发明一个实施例，提供了非平面的叠层板36。本文中的术语“非平面”的含义是除了扁平板层(如在金属成型加工前的叠层板)外的几何形状。为了说明的目的，示出的非平面的叠层板36是一种具有结合在纤维芯层40的相反侧的金属表皮38的帽形部分。各层和将它们组装成适合于在金属成型加工中起毛坯作用的三层板的装置，与图1和2所述的相同。
在图5中示出简单的模压机42具有阳模(44)和阴模(46)组件。平面的金属/纤维/金属毛坯被置于模的阴半模上。然后通过将压力机42闭合，用压力机的阳模部分形成非平面叠层板36。在一些情况，各层(金属/纤维/金属)在叠层板的状态被预先组装并当作一块毛坯使用。在其他情况，也可以形成未结合的或部分结合的层(即金属/纤维/金属)的叠层，然后同时结合或随后结合在一起，并在它们被压制时成形(加热或不加热)。也可以用具有足够粘合强度的粘合剂将各层部分地结合在一起，然后在油漆烘干循环中完全结合所述叠层板。
虽然说明了本发明的特定实施例，但是应理解，本发明不限于这些，本领域技术人员能够根据这些公开形成各种不同的实施方式。因此，权利要求包括在本发明范围内的各种方案。

Claims (21)

1.一种结构叠层板，其特征在于，包括：
第一和第二金属薄板表皮，每个所述表皮的厚度至少约0.005英寸；
夹在所述金属薄板表皮之间的纤维芯层；并且
所述纤维芯结合到所述金属薄板表皮。
2.根据权利要求1的结构叠层板，其特征在于，所述金属薄板选择自冷轧钢、镀锌钢、镀锡钢和不锈钢组成的组。
3.根据权利要求1的结构叠层板，其特征在于，所述纤维芯通过粘结结合到所述金属薄板表皮上。
4.根据权利要求1的结构叠层板，其特征在于，每个所述表皮具有0.005-0.030英寸的厚度。
5.根据权利要求1的结构叠层板，其特征在于，所述纤维芯是用树脂浸渍的。
6.根据权利要求1的结构叠层板，其特征在于，所述纤维芯的厚度至少约为0.01英寸。
7.根据权利要求1的结构叠层板，其特征在于，所述纤维芯的厚度约为0.01-0.05英寸。
8.根据权利要求1的结构叠层板，其特征在于，所述叠层板是一种结构板材。
9.根据权利要求1的结构叠层板，其特征在于，还包括在所述纤维芯和每个所述表皮之间的粘合剂层。
10.根据权利要求1的结构叠层板，其特征在于，所述纤维芯是纸。
11.根据权利要求1的结构叠层板，其特征在于，所述纤维芯是合成聚合物。
12.根据权利要求1的结构叠层板，其特征在于，还包括穿过所述纤维芯和在所述金属表皮之间延伸的多个通道。
13.根据权利要求12的结构叠层板，其特征在于，所述通道中填充粘合剂，以在所述金属表皮之间形成粘合剂桥。
14.根据权利要求1的结构叠层板，其特征在于，所述金属表皮是在其表面上已经冷轧有锌的镀锌钢板。
15.根据权利要求1的结构叠层板，其特征在于，所述纤维芯是彼此粘结结合的多层纤维网。
16.根据权利要求1的结构叠层板，其特征在于，所述叠层板是非平面的。
17.根据权利要求1的结构叠层板，其特征在于，所述金属表皮是已经经过转化涂层预处理的钢，以加强结合的整体性和防腐性能。
18.根据权利要求1的结构叠层板，其特征在于，所述金属表皮是由高强度低碳合金钢制造的。
19.根据权利要求1的结构叠层板，其特征在于，还包括在所述纤维芯中的阻燃剂。
20.一种形成结构叠层板的方法，包括步骤：
形成第一和第二金属薄板表皮，每个所述表皮的厚度至少约0.005英寸；
形成纤维芯；以及
将所述纤维芯粘结结合到所述表皮，使得所述纤维芯位于所述表皮之间。
21.一种形成非平面叠层板的方法，包括步骤：
形成第一和第二金属薄板表皮，每个所述表皮的厚度至少约0.005英寸；
形成纤维芯；
将所述纤维芯置于所述表皮之间并与表皮接触，从而生成叠层板结构；以及
金属成型所述叠层板结构，以形成所述非平面叠层板。
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US6696164B2 (en) 2004-02-24
BR0013233A (pt) 2002-04-23
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US20020086172A1 (en) 2002-07-04
US6949295B2 (en) 2005-09-27

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