RU2494874C1 - Method of producing composite laminar material (versions) - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to production of glued laminates. Proposed method consists in gluing together consecutive layer. Glue or adhesive is applied on first layer surface for, at least, one next layer to be glued thereon and coated by second surface layer. Pressure is applied to the latter and layers of glue or adhesive are dried unless their polymerisation. Mesh of web of fiber glass is applied on the first surface layer after application of glue or adhesive. Inner layer is composed of placing the ring- or cylinder-shape bamboo fragments on said web or mesh the fragments. Then, layer of glue or adhesive is applied thereon and covered by another mesh or wed of fiber glass for attachment of second surface layer.

EFFECT: higher efficiency.

4 cl, 7 dwg

Description

The invention relates to the production of glued laminated structures and can be used for the manufacture of small-sized wall materials, small-sized prefabricated structures, elements of building structures and the structures themselves, as well as elements of floor and roof coverings, false and false ceilings, carpentry and furniture panels.

The invention contemplates a method for producing a composite laminate or a layered structure, in which the term “composite” is understood to mean the so-called composite material or composite — an artificially created inhomogeneous solid material consisting of two or more components, different in physical and chemical properties, which remain separate by macroscopic level in the finish structure. The mechanical behavior of the composite is determined by the ratio of the properties of the reinforcing elements and the matrix (only in the value of the binder in the composite material), as well as the strength of the bond between them. The effectiveness and efficiency of the material depend on the correct choice of the starting components and the technology of their combination, designed to provide a strong bond between the components while maintaining their original characteristics.

In today's market for composite materials, there is a need for lightweight, durable warm panels containing environmentally friendly materials that facilitate the rapid construction of structures for any purpose, including buildings, furniture, floors, for example. In this regard, panels made of natural bamboo are considered as an alternative to industrial wood. Manufacturers quickly appreciated the hardness of bamboo (Brinnell index - 4.5-4.8), resistance to moisture and point loads. Bamboo is not a tree, but a fast-growing tall herbaceous plant with a small thickness, a hollow stem. If we compare the strength of two rods of the same cross section of wood and bamboo, we can make sure that bamboo is approximately two times more durable and flexible. For a long time, these features were used in the manufacture of various products. The use of bamboo as a wood substitute reduces the weight of solid wood and wood-based composite materials by about 40%, reaching a density of up to 250 kg / m3, and can significantly reduce the internal stress in such laminated materials, which often leads to deformation of the panels in violation of manufacturing technology or when exposed to stress and atmospheric conditions.

A known method of manufacturing a composite laminate, which consists in sequentially gluing the layers one on top of another by applying glue or adhesive to the first surface layer, applying the next at least one layer on it, which is the inner layer on which the glue or adhesive layer is applied and is closed on top the second surface layer with the application of pressure over the entire surface of the latter and drying of the layers of glue or adhesive prior to their polymerization (AU 2011213905, Е04С 2/10, Е04С 2/24, publ. 22.03.12).

This decision was made as a prototype for all declared facilities.

The disadvantage of the prototype, like all known solutions related to the manufacture of layered composites, is that it is initially laid out that the layers to be bonded must be prepared both in terms of area size and thickness (for example, by milling) so that all layers were pre-calibrated for flatness and thickness. In this case, a panel of a given thickness equal to the sum of the thicknesses of the layers to be glued (plus the thickness of the adhesive coat) is made by simply superimposing one another with sizing. In this regard, in panels where bamboo is used, its fragments are processed and a plate or panel is made from it, in which flatness conditions are observed and its thickness is maintained. Such layers or plates are used as veneer for the exterior of the composite, or a plate is pressed from fragments of bamboo to embed it as an inner layer in the composite. In any case, well-known methods for producing composites with the inclusion of bamboo always imply the presence of preparatory operations for the layers, which will then be glued together. An example of this is a parquet board with a surface layer of bamboo veneer or a panel with an internal filler in the form of compressed bamboo chips.

When using the technology of known methods, it is not possible to achieve a decrease in the weight of the composite with an increase in the layers in it while increasing the strength of the bearing capacity of such a layered material.

In the known practice, one can rely on an attempt to lighten the weight of a three-layer composite composed of outer layers and a reinforced inner layer placed between them, made of a set of bamboo parts in the form of cylinders or cardboard or plastic, layers of sheet material in the form of bamboo panels are placed between the layers of the inner filler , plywood, cardboard or paper, and between the layers of sheet material and the honeycomb cells in the form of bamboo cylinders there is a reinforcing mesh of fiberglass or plastic or metal and layers of glue or adhesive are bonded that bind the sheet material with bamboo, cardboard or plastic cylinders (RU No. 103548, Е04С 2/00, published on 04/20/2011). However, in such a panel fragments of bamboo in a layered composite are used as a filler of the space between two surface layers, which are entrusted with the function of forming a predetermined panel thickness and investment by weight of this product. In this regard, bamboo cylinders are used as a filler and a shaper of a honeycomb structure. With this design and in order to comply with the requirements for controlling the thickness of the product and the flatness of the upper surface layer with respect to the lower one, it is strictly necessary to fulfill the condition that the bamboo cylinders must be of the same height while the surface on which they are laid must also be aligned. If these conditions can be fulfilled to a sufficient degree of complexity for a three-layer structure, then with increasing layers of the honeycomb layer, the leveling process becomes complex and becomes directly dependent on the size of the bamboo cylinders. The task of constant monitoring of the flatness of the position of each subsequent layer in the known patent is solved by the use of reinforcing meshes, including plastic and metal. This indicates that these grids are rigid and do not change their spatial shape. Due to this and due to the maintenance between the layers of glue, the surface to be aligned is aligned with the laid out layer. But the introduction of metal grids affects the weight of the product and does not allow the finished product to be cut and customized at the place of application. In addition, the presence of panels in the internal structure as load-bearing elements between fillers increases the weight of the product.

The present invention is aimed at achieving a technical result, which consists in simplifying the manufacture of composites with bamboo fragments while providing reduced weight while increasing the number of inner layers in the composite laminate with respect to the prototype.

The specified technical result for the first embodiment is achieved by the fact that in the method of manufacturing a composite layered material, which consists in sequentially gluing layers on top of each other by applying glue or adhesive to the first surface layer, applying the next at least one layer, which is the inner layer on which a layer of glue or adhesive is applied and closed from above with a second surface layer by applying pressure over the entire surface of the latter and drying the layers of glue or adhesive before polymerization, after applying a layer of glue or adhesive, a grid or fiberglass cloth is laid on the first surface layer, the inner layer is formed by laying out fragments of bamboo in the form of rings or cylinders, obtained transversely by cutting the bamboo stem, on a grid or fiberglass cloth, or , plates or chips from the walls of bamboo, obtained by cutting the bamboo stem along the walls and across the stem, and then apply a layer of glue or adhesive and cover on top with another mesh or fiberglass for attaching the second guide surface layer.

The specified technical result for the second embodiment is achieved by the fact that in the method of manufacturing a composite layered material, which consists in sequentially gluing layers on top of each other by applying glue or adhesive to the first surface layer, applying the next at least one layer, which is the inner layer on which a layer of glue or adhesive is applied and closed from above with a second surface layer by applying pressure over the entire surface of the latter and drying the layers of glue or adhesive ziva before their polymerization, characterized in that after applying a layer of glue or adhesive to the first surface layer, a mesh or fiberglass cloth is laid, the inner layer is formed by laying on a mesh or fiberglass cloth in the form of a first layer of bamboo fragments in the form of rings or cylinders, obtained transversely by cutting the bamboo stalk, or in the form of plates or chips from the walls of bamboo, obtained by cutting the bamboo stalk along the walls and across the stalk, and then apply a layer of glue or adhesive and cover another mesh on top or a fiberglass cloth onto which a layer of glue or adhesive is applied and at least one next layer of said bamboo fragments is formed, which, after applying a layer of glue or adhesive, is closed on top with another mesh or fiberglass for subsequent bonding of the second surface layer.

The specified technical result for the third embodiment is achieved by the fact that in the method of manufacturing a composite layered material, which consists in sequentially gluing layers one on top of another by applying glue or adhesive to the first surface layer, applying at least one layer on it, which is the inner layer, onto which a layer of glue or adhesive is applied and closed from above with a second surface layer with pressure applied over the entire surface of the latter and drying the layers of glue or adhesive to their polymerization, characterized in that the surface layers use a grid or a fiberglass cloth, and the inner layer is formed by laying out fragments of bamboo in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of, plates or wood chips on a grid or fiberglass cloth from bamboo walls, obtained by cutting the bamboo stem along the walls and across the stem, followed by applying a layer of glue or adhesive to these fragments to attach the second surface layer.

The specified technical result for the fourth embodiment is achieved by the fact that in the method of manufacturing a composite layered material, which consists in sequentially gluing layers one on top of another by applying glue or adhesive to the first surface layer, applying the first inner layer onto it, onto which the glue layer is applied or adhesive and lay on top of the second inner layer, on which a layer of glue and adhesive is applied for at least one next inner layer until the parallelepip block is formed a uniform or cubic form on which a layer of glue or adhesive is applied to attach the second surface layer by applying pressure over the entire surface of the latter and drying the layers of glue or adhesive before polymerization, characterized in that a surface or a fiberglass cloth is used as surface layers, between each surface layer and adjacent inner layer and between each adjacent inner layers place a mesh or fiberglass cloth with glue or abrasive, and each inner layer is formed by the layout grid or cloth of fiberglass bamboo pieces in the form of rings or cylinders, cross-cutting of the obtained bamboo stem, or in the form of plates or walls of bamboo chips obtained cutting of bamboo stem along the walls and transverse stem.

These features are significant and are interconnected with the formation of a stable set of essential features sufficient to obtain the desired technical result.

The present invention is illustrated by specific examples of execution, which, however, are not the only possible, but clearly demonstrate the ability to achieve the desired technical result.

Figure 1 - the first example of the method;

figure 2 - composite material obtained by the method of figure 1;

figure 3 is a second example of the method;

figure 4 - composite material obtained by the method of figure 3;

5 is a third example of the method;

6 is a composite material obtained by the method of figure 5;

7 is an example of a composite material.

According to the present invention, methods for manufacturing layered composite materials that can be used for the manufacture of panels or structural elements for a wide range of purposes are discussed. A feature of the composite material is its reduced weight with high strength characteristics and high bearing capacity, which is due to the fact that natural bamboo is used as the starting material, which fills the cavity of the panel in the form of fragments (individual parts in the form of rings, cylinders, plates of walls). Fragments of bamboo can withstand high loads both along the fiber and across the fiber.

A method of manufacturing a composite laminate consists in sequentially gluing layers on top of each other by applying glue or adhesive 2 (in the form of a layer) to the first surface layer 1, applying the next at least one layer, which is the inner layer onto which the adhesive layer is applied or adhesive 2 and closed on top of the second surface layer 3 with the application of pressure P over the entire surface of the latter and drying the layers of glue or adhesive until they polymerize. In this part, the method repeats the known techniques used in the manufacture of laminated panels, as is the case in the prototype.

In the method according to the present invention, a fiberglass mesh or web is used as surface layers, and the inner layer is formed by laying out bamboo fragments 4 in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of, plates or wood chips on a grid or fiberglass cloth from bamboo walls, obtained by cutting the bamboo stem along the walls and across the stem, followed by applying a layer of glue or adhesive to these fragments to attach the second surface layer.

Thus, a new panel is obtained by placing and securing between two layers of a flexible mesh or fabric made of fiberglass. Flatness is formed by applying the required pressure (from the press) to the entire surface of the formed panel, as a result of which the upper located mesh or web is adjacent in parts of bamboo fragments either under pressure or by sagging. Thus, all fragments of bamboo have adhesion to two layers of mesh or canvas. Such a panel is the basis for the formation of decorative panels, that is, equipped with outer layers that adhere to the layers of mesh or fabric in places of contact with them (cavities that do not come into contact with them are filled with glue or adhesive and form areas of high adhesive content, creating drying the support under the outer decorative layers).

In the method according to the present invention, in order to obtain a panel with external decorative or reinforcing layers 5, after applying a layer of glue or adhesive, a fiberglass mesh or web is laid on the first surface layer, the inner layer is formed by laying out fragments of bamboo in the form of rings or cylinders on a grid or fiberglass cloth obtained transversely by cutting a bamboo stalk, or in the form of plates or chips from the walls of bamboo, obtained by cutting a bamboo stalk along the walls and across the stalk, and then apply a layer glue or adhesive and cover on top with another mesh or fiberglass for subsequent attachment of the second surface layer.

Obtained by the described method, the composite layered material has a multilayer structure and in the example shown in figure 2, consists of three layers: two outer layers 4, which are surface and reinforcing, and one inner layer, made in the form of a cellular honeycomb structure of bamboo fragments in the form of rings or cylinders 1 obtained transversely by cutting a bamboo stalk, or in the form of plates 2 or chips from bamboo walls, obtained by cutting a bamboo stalk along the walls and across the stalk. For this example of execution and for all subsequent examples of execution, regardless of the number of layers for reinforcing the honeycomb cellular structure, a fiberglass mesh or fiberglass web was used. The honeycomb cellular structure is laid on a grid or web on which a layer of glue or adhesive is applied, and on top is covered with another grid or cloth, on the side of which facing the honeycomb structure a layer of glue or adhesive is also applied. Thus, in the example of FIG. 2, outer layers 4 made of fiberglass mesh or fiberglass fabric are also reinforcement layers.

As glue or adhesive, adhesives are used, which are usually used in the manufacture of parquet boards or gluing veneers on furniture surfaces. Due to the variety of such products, this type of adhesive or adhesive is not specified in the framework of this application. More details on such adhesives and adhesives are described in the article “Adhesives for all cases” (http://eurostil.su/klei_na_vse_sluchai).

Such a composite material is a panel of a given size, whose internal structure, made of bamboo fragments, determines the mechanical properties of this product. The panel accepts loads well in directions that coincide both with the direction of the bamboo fiber and across these fibers, and this one is just the loads transverse to the panel, which allows such a panel to be considered as a building sheet laminate with high bearing capacity. Such a panel has a reduced weight, which is determined, in fact, by the weight of the bamboo itself (bamboo has a low density of about 500 kg / m3, the weight of the fiberglass mesh is 135 grams per square meter, and the weight of the fiberglass cloth is 473 grams per square meter). Since a fiberglass mesh or cloth, having flexibility before interacting with glue or a binder, is practically not affected by aggressive media and does not have elasticity, monolithization of the entire layered structure takes place after the adhesive dries or the polymerisation of the adhesive.

The mechanical properties, that is, the bearing capacity of a panel of composite material, can be multiplied by an almost small increase in weight by increasing the number of layers of the honeycomb structure. To form two layers, a panel is first formed, as described with reference to the product of FIG. 2, and then a second layer is formed. In the second layer, a mesh or web covering the bamboo fragments in the first layer is covered with a layer of glue or adhesive. Then the bamboo fragments are laid on a mesh or cloth covering the bamboo fragments in the first layer, and on top they are covered with an additional mesh or cloth, the back of which also carries a layer of glue or adhesive. Similarly, you can increase the number of layers. After compaction under the press and polymerization of the binder components, a panel with two or more inner layers becomes a monolithic structure.

In such multilayer panels, layers with bamboo fragments can be located in the same direction as their fibers, or in one layer bamboo fragments can be located in the direction of their fibers, different from the direction of the fibers of bamboo fragments in another layer or other layers (Fig. 7). Moreover, in the inner layer, at least part of the bamboo fragments can be located with the direction of their fibers different from the direction of the fibers of the other part of bamboo fragments in this layer (an example is not shown illustratively).

With an increase in the number of similar layers described with reference to the example in FIG. 1, it can be achieved that the material takes the form of a composite block in the form of a parallelepiped or cube (FIG. 6). Such blocks are convenient, because I then allow using a saw to saw it into separate panels in any direction of the block. To form the block, the first basic three-layer fragment is formed: the honeycomb cellular structure of bamboo fragments is laid on a fiberglass mesh or cloth and covered with the same other mesh or cloth on top, and in each next layer, bamboo fragments are laid on a mesh or cloth covering the bamboo fragments in the previous layer, and on top cover with an additional mesh or canvas to form a composite block. Illustratively, this method is shown in Fig.5. Each operation of this method repeats the operation of the method of figure 1. Naturally, the bonding of nets or webs with fragments of bamboo is carried out by means of glue or adhesive, which are applied in layers to a net or canvas.

A feature of the use of a flexible mesh or a flexible non-woven fabric made of fiberglass is that during the polymerization of glue or adhesive, the mesh is laid on a layer of bamboo fragments and levels the irregularities of the honeycomb structure.

The use of a mesh or nonwoven fabric made of fiberglass allows for air permeability of a separate three-layer panel, as well as a multilayer panel and a building block of such layers. This allows you to get a ventilated structure on the one hand, and a noise and sound insulating structure on the other hand. Noise and sound insulation is ensured by the fact that sound waves. Dropping into the internal structure of the panel, they fall into a large number of chambers or cavities and are crushed and quenched. There is no resonance effect in such a panel.

In cellular honeycomb structures, parts of it can be used as fragments of bamboo in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of plates or wood chips from bamboo walls obtained by cutting a bamboo stem along the walls and across the stem. Moreover, variations in the location of these fragments in cellular cellular structures are diverse. For example, in the second inner layer, bamboo fragments in the form of rings or cylinders may be offset with respect to bamboo fragments in the form of rings or cylinders in the first inner layer. In the inner layer fragments of bamboo in the form of rings or cylinders can be located adjacent to each other by walls or are located relative to each other with a gap between the walls. Or in the inner layer at least part of the bamboo fragments in the form of rings or cylinders are located adjacent to each other by the walls.

An embodiment is possible, according to which the middle layer can be made of bamboo cylinders on the principle of "one in another", i.e. small small less. The same cylinder or ring of bamboo, but of a smaller diameter, is inserted into a cylinder or ring made of bamboo. This option allows cylinders (rings) of large bamboo diameter to more easily "select" the volume of products. And to increase strength, a small one is inserted inside such a cylinder. In this embodiment, the arrangement of the cylinders in the middle layer can be either ordered or chaotic.

The proposed design of the building and finishing composite material makes it possible to obtain panels of any thickness and structure with low weight, while the design is sufficiently rigid to be used as load-bearing plates that protect the interior from temperature fluctuations and external noise, and thereby increase heat and sound insulation.

It will be apparent to one skilled in the art that various modifications and changes are possible in the present invention. Accordingly, it is intended that the present invention covers the modifications and variations as well as their equivalents without departing from the spirit and scope of the invention disclosed in the appended claims.

Claims (4)

1. A method of manufacturing a composite layered material, which consists in sequentially gluing layers one on top of another by applying glue or adhesive to the first surface layer, applying the next at least one layer, which is the inner layer onto which the adhesive or adhesive layer is applied, and close on top of the second surface layer with the application of pressure over the entire surface of the last and drying of the layers of glue or adhesive before they polymerize, characterized in that after applying a layer of glue or adhesive, and the first surface layer is laid on a mesh or fiberglass cloth, the inner layer is formed by laying out fragments of bamboo in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of plates or wood chips from bamboo walls obtained by cutting a bamboo stem on a grid or fiberglass cloth along the walls and across the stem, and then apply a layer of glue or adhesive and cover on top with another mesh or fiberglass for subsequent attachment of the second surface layer. 2. A method of manufacturing a composite laminate, which consists in sequentially bonding the layers one on top of another by applying glue or adhesive to the first surface layer, applying the next at least one layer on it, which is the inner layer onto which the glue or adhesive layer is applied and is closed on top of the second surface layer with the application of pressure over the entire surface of the last and drying of the layers of glue or adhesive before they polymerize, characterized in that after applying a layer of glue or adhesive, and the first surface layer is laid with a fiberglass mesh or cloth, the inner layer is formed by laying on a fiberglass mesh or cloth in the form of a first layer of bamboo fragments in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of plates or wood chips from bamboo walls obtained by cutting the bamboo stem along the walls and across the stem, and then apply a layer of glue or adhesive and cover it with another mesh or fiberglass cloth on top of which a layer of glue or adhesive is applied and form of at least one further layer of said bamboo fragments which after applying a layer of glue or adhesive sealed on top of another net or web of glass fibers for the subsequent attachment of the second surface layer. 3. A method of manufacturing a composite laminate, which consists in sequentially gluing layers one on top of another by applying glue or adhesive to the first surface layer, applying at least one layer on it, which is the inner layer onto which the glue or adhesive layer is applied and is closed on top the second surface layer with the application of pressure over the entire surface of the latter and drying the layers of glue or adhesive prior to their polymerization, characterized in that as the surface layers use a mesh of sludge fiberglass cloth, and the inner layer is formed by laying out fragments of bamboo on a grid or fiberglass cloth in the form of rings or cylinders obtained transversely by cutting a bamboo stalk, or in the form of plates or wood chips from bamboo walls, obtained by cutting a bamboo stalk along the walls and across the stalk with subsequent application to these fragments of a layer of glue or adhesive to attach the second surface layer. 4. A method of manufacturing a composite laminate, which consists in sequentially gluing layers one on top of another by applying glue or adhesive to the first surface layer, applying a first inner layer onto it, onto which a layer of glue or adhesive is applied, and spreading a second inner layer on top of which apply a layer of glue and adhesive for at least one subsequent inner layer until a parallelepiped or cubic block is formed, onto which a layer of glue or adhesive is applied for attaching w of the surface layer with the application of pressure over the entire surface of the latter and drying of the layers of glue or adhesive prior to their polymerization, characterized in that the surface layers use a mesh or fiberglass cloth between each surface layer and adjacent inner layer and between each adjacent the inner layers are placed with a fiberglass mesh or cloth with glue or abrasive, and each inner layer is formed by laying out fragments on a grid or fiberglass cloth comrade of bamboo in the form of rings or cylinders obtained transversely by cutting a bamboo stem, or in the form of plates or chips from bamboo walls, obtained by cutting a bamboo stem along the walls and across the stem.

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