CN1906024A - 改进的结构夹层板构件 - Google Patents

改进的结构夹层板构件 Download PDF

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CN1906024A
CN1906024A CNA2004800404279A CN200480040427A CN1906024A CN 1906024 A CN1906024 A CN 1906024A CN A2004800404279 A CNA2004800404279 A CN A2004800404279A CN 200480040427 A CN200480040427 A CN 200480040427A CN 1906024 A CN1906024 A CN 1906024A
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Abstract

提供了一种结构夹层板构件，其具有至少一个夹层以提高抗冲击和/或爆炸性。夹层可为实心或穿孔金属板、金属网、硬质陶瓷或高抗拉强度布。夹层可被起皱。

Description

改进的结构夹层板构件
本发明涉及结构夹层板构件，其包括两个外板和塑料或聚合物材料芯，芯以足够的强度粘合到外板上，非常有助于构件的结构强度。
结构夹层板构件描述在US5778813和US6050208中，本文引入这些文献作为参考，它们包括与中间弹性体芯例如非泡沫聚氨酯粘合到一起的外金属板如钢板。这些夹层板系统可用于多种建筑形式中以代替加强钢板、成形钢板、钢筋混凝土或复合钢筋混凝土结构，并大大简化得到的结构，在节省重量的同时提高强度和结构性能(例如劲度、减震特性)。这些结构夹层板构件的更多发展描述在WO01/32414中，本文也引入作为参考。如本文所述，可在芯层中引入泡沫形式以减轻重量和可加入横向金属侧板提高劲度。
根据WO01/32414的教导，泡沫形式可为空心或实心的。空心泡沫产生较大的重量减轻，因此是有利的。该文献中描述的泡沫不限于由轻质泡沫材料制成，而且还可由其它材料如木或钢箱制成。
国际专利申请WO02/078948为包括空心泡沫的观念的进一步发展，并描述了易于制造和组装的形式，尤其是描述了由铆在一起的块制成的空心细长形式。
US5778813和US6050208中描述的结构夹层板构件的基本形式具有优异的耐火性能，甚至不用结构防火。与具有在爆炸或爆破荷载事件中可能被破坏或打爆脱离板的外部防火结构的加强钢板不同，提供耐火性的结构夹层板构件的弹性体芯在内部，并保持完整和功能。
根据US5778813和US6050208的结构夹层板构件还提供比常规镀钢板大的对冲击威胁的防护。例如，试验证实，3-30-3结构夹层板构件(3mm软钢-30mm聚氨酯-3mm软钢)提供比类似重量的常规加强钢板大70％的对7.62mm口径子弹的防护。但是，仍需要进一步改进以满足标准如US National Institute of Justice标准NIJ 0108.01。
用来抵抗射弹的盔甲的现有形式通常包括硬质板如陶瓷板和高抗拉强度布如Kevlar(TM)或Spectra(TM)的层的组合，但是，这些配置制造昂贵，很重，且在物品的正常使用中易损坏板。
本发明的一个目的是提供耐爆炸和抗射弹性能提高的结构夹层板构件。
根据本发明，提供：一种结构夹层板构件，包括：第一和第二外板；以足够的强度粘合到所述外板上的塑料或聚合物材料的芯，以转移外板之间的剪切力；和在芯内的至少一个夹层，所述夹层通常平行于外板且具有比芯材料高的抗拉强度。
在芯内提供夹层或内衬提供了板构件耐爆破性和/或抗射弹性相当大的提高，远远大于仅仅加入外加材料所能预料到的。夹层应采用的具体形式取决于要防护的威胁。
对于爆炸防护，优选与外层尺寸相似的附加金属例如钢或铝层。这确保即使一个外层被弹片穿透或被爆炸力完全剥去，也能保留具有充分强度和耐火性能的夹层结构。实心金属板还提供对射弹的额外防护。
为了只增加耐冲击性和保护作用，可使用较轻质的层如金属(例如钢)网或高抗拉强度布，如Kevlar(TM)或Spectra(TM)。这种层阻碍或限制了任何穿透外金属层的射弹和捕获任何由于射弹冲击产生的外金属层或芯层的碎片。还可使用陶瓷片提供冲击和/或爆炸防护。
优选夹层被弄皱或成波状。这增加了射弹接合更多夹层并处于更有利冲击角度的机会。
可提供多个夹层以进一步提高耐冲击或爆炸性。如果提供多个起皱或波状的夹层，则不同层中的皱纹和/或波纹可具有不同的方向和/或偏移。
可按照需要为结构夹层板构件要投入的具体应用选择本发明结构夹层板构件外板的材料、尺寸和一般性质，通常可如US5778813和US6050208中所述。通常使用厚度为0.5-20mm的钢或不锈钢，并在需要轻质时使用铝。同样，塑料或聚合物芯可为任何合适的材料，例如弹性体如聚氨酯，如US5778813和US6050208中所述。
另外，本发明提供制造结构夹层板构件的方法，包括步骤：提供处于隔开关系的第一和第二外板，至少一个夹层位于其间，并与所述外金属板的每一个隔开；注入未固化的塑料或聚合物材料以填充在所述外板和所述夹层任何一侧之间限定的空间；使所述塑料或聚合物材料固化从而以足够的强度粘合所述外板到一起以转移其间的剪切力；其中所述夹层具有比固化塑料或聚合物材料高的抗拉强度。
在夹层完全或明显不渗透未固化塑料或聚合物材料时，可从板的两侧同时或分两个阶段进行芯的注入。
在插入到外金属板之间的空腔前可用塑料或聚合物材料涂敷或浸渍夹层，以提供额外的刚性，从而在注入过程中夹层能保持它的形状和位置，例如在夹层为高抗拉强度布时，和/或促进到芯材料的粘合。如果与芯材料不相同，则涂敷或浸渍夹层的塑料或聚合物材料应与芯材料相容。
下面将参照示例性实施方案和附图描述本发明，其中：
图1为根据本发明第一种实施方案的结构夹层板构件的横截面图；
图2为根据本发明第二种实施方案的结构夹层板构件的横截面图；
图3为根据本发明第三种实施方案的结构夹层板构件的横截面图；
图4为根据本发明第四种实施方案的结构夹层板构件的横截面图；
图5为根据本发明第五种实施方案的结构夹层板构件的横截面图；和
图6为根据本发明第六种实施方案的结构夹层板构件的横截面图；
在各个图中，相同的部件用相同的参考数字表示。
图1中所示的结构夹层板构件包括上和下外板(面板)11、12，它们可为钢或铝，并具有例如在0.5-20mm范围内的厚度。大于或等于3mm的厚度在许多应用中是有利的。在面板11、12之间围绕它们的外圆周焊接边板形成封闭的空腔。在面板11、12之间的空腔中为塑料或聚合物材料优选密实热固性材料如聚氨酯弹性体的芯13。该芯可具有在15-200mm范围内的厚度；在本申请中，50mm是合适的。芯13以足够的强度粘合到面板11、12上，并具有充分的机械性能以转移使用时两个面板之间预期的剪切力。芯13和面板11、12之间的粘合强度应大于3MPa，优选6MPa，芯材料的弹性模量应大于200MPa，优选大于250MPa，尤其是如果预期在使用中暴露于高温时。对于低载荷应用，如地板镶板，在典型的使用和占用载荷为大约1.4kPa-7.2kPa时，粘合强度可更低，例如大约0.5MPa。利用芯层，结构夹层板构件具有板厚度大很多且显著补充加固的加强钢板的强度和载荷承受能力。当然，板不需要是平的，而是可采取其预定用途所需的任何形式。
为了提高材料的抗冲击射弹性，在芯13中提供高抗拉强度布的夹层14。如所示，夹层14位于芯13的中间，但这是可变化的，只要合理数量的芯材料保留在夹层的任何一侧即可。夹层应具有高抗拉强度，例如，类似于钢的抗拉强度，和其它性质，如高的弹性模量和高的粘-弹性，以帮助抵抗射弹，这是已知的。可使用几层布或网提供所需的强度。夹层可在整个夹层板上延伸，或可位于需要防护的那些区域。夹层的厚度不需要是均匀的，同样，在需要最大防护时，可提供附加材料。
合适的材料包括由聚对亚苯基对苯酰胺(芳族聚酰胺)产生的分子链制成的纤维，优选如E.I.Du Pont de Nemours and Company以商标名Kevlar(TM)出售的。合适的等级包括Kevlar 29、Kevlar KM2、Kevlar 129和Kevlar 49。另外合适的为由超高分子量聚乙烯制成的纤维，优选如Honeywell Performance Fibers以商标名Spectra(TM)出售的。其它合适的材料包括对-芳族聚酰胺纤维，优选如Teijin Limited以商标名Technora(TM)和Twaron(TM)出售的。
当需要轻质时，芯可包括如WO 01/32414中所述的轻质形式。优选地，形式由如2003年3月18日提交的尚待批准英国专利申请0306195.9中描述的耐火材料制成。利用2003年11月14日提交的题目为“INPROVED STRUCTURAL SANDWICH PLATE MEMBERSWITH FORMS”的英国专利申请0326608.7(代理参考号N90171)中所述的非镶嵌形状制成的形式可获得特别的优点。如本文所述，形式可由硬质材料制成以提高耐冲击性和碎片捕获。本文全文引入这些文献作为参考。
为了制造结构夹层板构件10，在下面板11的圆周周围焊接边板，然后在得到的敞开空腔内放置夹层14和固定它到适当位置的垫片。在这个阶段，可将芯的任何预制段以及可能需要的任何剪切板或其它配件放在适当位置。然后，焊接上面板12到边板上形成封闭的空腔，并注入塑料或聚合物材料形成芯13。然后使注入的材料固化，磨掉注入步骤中使用的注入口并和排气孔一起密封。这些步骤可在工厂条件下原地或装置外进行，完成的板被输送到装置点。
为了改善形成夹层的布的处理，可在插入到空腔前用塑料或聚合物材料涂敷或浸渍布以便更硬。浸渍或涂敷材料可与用于形成芯材料的相同，但如果不同，应彼此相容，例如很好地粘合到芯材料上。芯和布夹层14之间的粘合强度应不小于芯和面板11&12之间的粘合强度。在一些情况下，必需化学处理布以确保充分粘合到芯13上。
如果布是致密的，尤其是如果提供几层的话，则它不容易被未固化的芯材料渗透，因此可从板的两侧同时或依次进行芯材料的注入。
本发明的第二种实施方案示于图2。根据本发明第二种实施方案的结构夹层板构件20类似于第一种实施方案，但在夹层性质上不同，如下面所述。
在第二种实施方案中，夹层15包括金属如钢、不锈钢或铝板，形成多层结构夹层板构件。金属板通常由与外板相同的材料形成，但不必需这样。金属板15的厚度取决于所需的冲击或爆炸防护数量和所要求的残余结构强度。在许多情况下，用作夹层的金属板将具有与外金属板之一相同的厚度，但可在此基础上变化±50％。
按与第一种实施方案相同的一般方式制造第二种实施方案，只是通常不需要金属板的浸渍或涂敷。而是按与面板相同的方式清洗和/或预处理金属板以为芯13提供相等的粘合强度。金属板15可简单地被定位焊或胶合到支撑上以在注入过程中保持它到合适的位置。
图3图示了本发明的第三种实施方案，其与第二种实施方案不同在于夹层16被穿孔。穿孔提供了重量减轻，通过机械互锁增强到芯的粘合，并允许未固化的芯材料在整个空腔内自由流动。合适的穿孔板可具有大小在3-20mm范围内的孔的规则图案，其密度以孔的总面积与板总平面面积的比表示，在0.25-0.5的范围内。这种板可广泛地得到。可进行孔图案、大小和密度的变化以增强抗冲击和爆破性。穿孔板可由硬陶瓷材料和金属制成。
作为穿孔板的替代，可使用金属网。这图示在图4中，其显示了本发明的第四种实施方案。网不仅提供了与第三种实施方案相同的优点，而且还具有相对于面板变化的夹层取向，这提供了更大的抗冲击性，尤其对于在45和90°之间射击到板的子弹。展开的钢丝网如英格兰哈特尔普尔的Expanded Metal Company Limited制造的钢丝网No.1292适用于本发明。其具有30.48mm×12.70mm的网目尺寸(中心-中心)、4.75mm的绞合线宽度和2.5mm的厚度，和25％的总开阔面积。可作为要抵抗的冲击威胁和所需阻力水平的函数选择网目尺寸、绞合线宽度和厚度和总开阔面积。
图5显示了第一种实施方案的另一变形，其中夹层18具有Z字形转弯的起皱形式。对于大多数射弹，这种布置使射弹接触的夹层材料量最大，并确保垂直冲击外层的射弹能以锐角射到夹层上，提高了夹层的有效穿透强度。如果夹层为高抗拉强度布，则通过在合适形状的模具内用热固性材料浸渍布实现Z字形转弯形状。在为金属或金属网层时，可通过滚轧成形或压制施加Z字形转弯形状。
如图6所示，作为Z字形转弯形状的替代方案，夹层可具有波状皱纹。这具有类似效果，并能以简单的方式实现。图6还图示了多个(在这种情况下为2个)夹层19a、19b的使用，它们可彼此偏置(如所示)或彼此垂直定向。还可使用波状夹层或在两个方向上起皱的层。
应认识到，上述描述不打算是限制性的，其它改变和变化落在由附加权利要求限定的本发明的范围内。

Claims (18)

1.一种结构夹层板构件，包括：
第一和第二外板；
以足够的强度粘合到所述外板上的塑料或聚合物材料的芯，以转移外板之间的剪切力；和
在芯内的至少一个夹层，所述夹层通常平行于外板且具有比芯材料高的抗拉强度。
2.根据权利要求1的结构夹层板构件，其中所述夹层包括金属层如钢、不锈钢或铝层。
3.根据权利要求2的结构夹层板构件，其中所述夹层的厚度在所述外板之一的厚度的50％-150％范围内。
4.根据权利要求1的结构夹层板构件，其中所述夹层包括金属(如钢、不锈钢或铝)网。
5.根据权利要求4的结构夹层板构件，其中所述金属网由多孔金属板形成。
6.根据权利要求1的结构夹层板构件，其中所述夹层包括高抗拉强度布。
7.根据权利要求1的结构夹层板构件，其中所述夹层包括硬陶瓷板。
8.根据前述权利要求任意一项的结构夹层板构件，其中所述夹层被起皱或成波状或形成波形。
9.根据前述权利要求任意一项的结构夹层板构件，包括多个夹层。
10.根据前述权利要求任意一项的结构夹层板构件，其中所述夹层被穿孔。
11.根据前述权利要求任意一项的结构夹层板构件，其中所述夹层不在所述板构件的整个区域上延伸。
12.根据前述权利要求任意一项的结构夹层板构件，其中所述外板由金属制成。
13.根据前述权利要求任意一项的结构夹层板构件，其中所述外板具有大于或等于3mm的厚度。
14.根据前述权利要求任意一项的结构夹层板构件，其中所述芯由密实材料制成。
15.根据前述权利要求任意一项的结构夹层板构件，其中所述芯具有大于或等于15mm的厚度。
16.一种制造结构夹层板构件的方法，包括步骤：
提供处于隔开关系的第一和第二外板，至少一个夹层位于其间，并与所述外金属板的每一个隔开；
注入未固化的塑料或聚合物材料以填充在所述外板和所述夹层任何一侧之间限定的空间；
使所述塑料或聚合物材料固化从而以足够的强度粘合所述外板到一起以转移其间的剪切力；
其中所述夹层具有比固化塑料或聚合物材料高的抗拉强度。
17.根据权利要求16的方法，其中从板的两侧同时或分成两个阶段进行所述注入步骤。
18.根据权利要求16或17的方法，包括在插入到外金属板之间的空腔之前用塑料或聚合物材料涂敷或浸渍夹层的附加步骤。
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