RU2790839C1 - Laminated composite material for ship floor covering, method for its manufacture and payol from such material - Google Patents

Abstract

FIELD: shipbuilding industry.

SUBSTANCE: invention relates to the shipbuilding industry and, in particular, to the design of a laminated multilayer composite material suitable for the manufacture of rigid ship decks, as well as to a method for manufacturing such a material and can be used, for example, in the design of a floorboard for an inflatable boat. Laminated multilayer material for ship flooring contains outer cladding, inner cladding and core connected by a polymer adhesive to form a single one-piece structure, located between the inner and outer claddings, while the inner and outer claddings contain a lamination layer, a glass veil layer and a glass mat layer sequentially located in the direction of the core, and the core contains three-dimensional elements of a gas-filled polymer located between two layers of fiberglass, passing in one direction, between which is located additional reinforcing layer of fiberglass that forms the ribs stiffness along the length of the indicated volumetric elements.

EFFECT: invention provides obtaining a lightweight composite material without loss of its rigidity, the working surface of which is hydrophobic and resistant to wear.

13 cl, 3 dwg

Description

The field of technology to which the invention belongs

The invention, in general, relates to the shipbuilding industry and, in particular, to the design of a laminated multilayer composite material suitable for the manufacture of rigid ship decks, as well as to a method for manufacturing such a material, and can be used, for example, in the design of a floorboard for an inflatable boat.

State of the art

In shipbuilding, a removable hard flooring installed on the bottom of an inflatable boat is commonly called a payol. In the installed position, the payol is sandwiched between the bottom of the boat and inflated inflatable sides and serves to give the hull of the inflatable boat longitudinal and transverse rigidity, as well as to form a solid surface under the feet of passengers. Most payols are made collapsible from sections installed across the axis of symmetry of the boat. It is customary to make sections of such floorboards from ship (bakelite) plywood or aluminum alloy.

From the description of the patent RU 169,992 U1, IPC B63B7/08, publ. 04/11/2017, it is known that the floor segments of an inflatable boat are made of waterproof multilayer plywood or aluminum alloy. However, these materials have a number of disadvantages. In particular, plywood flooring has a significant weight and, despite the claimed hydrophobic properties, in practice, over time, it is still subject to destruction due to prolonged contact with moisture. Aluminum payol also has a significant weight. In addition, the latter requires significant financial, labor and material costs associated with its production.

Composite materials are also used to make ship flooring. For example, from US 2014/069580 A1, IPC B32B38/10, B32B37/12, publ. 03/13/2014, the closest analogue of the invention is known, in particular, a floor covering in the form of a panel containing a substrate on which synthetic wood strips are fixed with silicone glue, evenly spaced with gaps filled with a curable silicone sealant. Although lighter than aluminum and bakelite plywood, the weight of such material still has the disadvantage of a large number of seams open on a surface directly subject to wear and precipitation. Over time, the impact of these factors can lead to damage, and then the destruction of such a coating.

Another common drawback of the listed known ship floor coverings is the possibility of slippery surface formation when moisture gets on them, which, in turn, can lead to inconvenience in using the flooring itself and even injury to passengers.

Thus, the technical problem associated with obtaining a rigid, but lightweight composite material with a hydrophobic and, if necessary, anti-slip working surface, suitable for the manufacture of rigid ship decking, seems to be an actual technical problem.

Disclosure of the essence of the invention

In accordance with the invention, this problem can be solved by manufacturing a laminated multilayer composite material containing an outer cladding, an inner cladding and a core located between the inner and outer claddings connected by a polymer adhesive to form a single one-piece structure. The invention is characterized in that the inner and outer facings contain a layer of lamination, a layer of glass veil and a layer of glass mat, located in series in the direction of the core, and the core contains three-dimensional elements of gas-filled polymer located between two layers of fiberglass, passing in one direction, between which there is an additional reinforcing layer of fiberglass , which forms stiffeners along the length of the specified volumetric elements.

In one embodiment, at least one stiffening rib can be formed between each two adjacent volumetric elements.

In one of the options, to interconnect all these layers and three-dimensional elements with the formation of a single one-piece structure, a polymer adhesive composition in the form of a polymer resin selected from the group: orthophthalic, isophthalic, epoxy, epoxyvinyl ether, vinyl ester and phenolic can be used.

In one of the options, the cross section of each volumetric element may have a shape selected from the group: triangular, rectangular and square.

In one of the options, the gas-filled polymer from which the volumetric elements are made can be polystyrene foam, polyurethane foam, polyethylene foam, or any other material with similar properties.

In one embodiment, the surface of the outer lining has an anti-slip texture. Moreover, the relief of the surface of the outer lining can be made in the form of corrugation such as lentil, rhombus, hemisphere, square, cone, duet, quintet or diagonal.

In one embodiment, the lamination layer of the inner and/or outer liner can be made from a woven material such as glass roving, or a nonwoven material such as powdered glass mat or emulsion glass mat, or long fiber glass mat, or a low plane material such as glass veil. .

According to the invention, said laminated multilayer composite material can be manufactured by a method comprising the steps of:

layers of the inner cladding, core and outer cladding of the manufactured material are placed in the mold in the following sequence: lamination layer, glass veil layer, glass mat layer, fiberglass layer, the first group of three-dimensional elements with a step that makes it possible to place an additional three-dimensional element between adjacent three-dimensional elements of the first group three-dimensional elements, a reinforcing layer of fiberglass, the second group of three-dimensional elements in the intervals between the three-dimensional elements of the first group of three-dimensional elements, a layer of fiberglass, a layer of glass mat, a layer of glass veil and an upper lamination layer, and all these layers located in the mold are impregnated with a polymer adhesive composition,

perform in the specified installation for a given time pressing the contents of the mold to polymerize;

after completion of polymerization, the resulting laminated multilayer composite material is removed from the mold.

In one of the variants of the method, before pressing, a perforated stencil is placed on the upper lamination layer, and the mold contents are pressed to form a surface relief of the outer lining according to the perforation of the stencil.

In one embodiment, after being removed from the mold, the resulting material is processed by mechanical flash removal.

In accordance with the invention, at least one of the floorboard sections for an inflatable boat can be made from said laminated multilayer composite material. Payol can also consist of just one section and be called single-section or one-piece.

In one of the options, the specified at least one section of the floorboard may have a plan shape selected from the group: triangular, rectangular, square, trapezoid.

In one of the options, the ends of the specified at least one section of the floorboard are closed with a lamination layer of the inner and/or outer lining, i.e. all surfaces of said floorboard section are laminated.

The technical result provided by the invention is the production of a composite material having a lower weight than that of similar fully glass composite materials without loss of rigidity, the working surface of which is hydrophobic and wear resistant. Additional technical results are the possibility of providing an anti-slip surface on such a material, as well as expanding the arsenal of technical means, in particular, materials suitable for the manufacture of rigid ship decking.

Brief description of the drawings

The invention is illustrated by the following drawings.

On FIG. 1 is a schematic sectional view of the structure of a laminated multilayer composite material according to a preferred embodiment of the invention;

On FIG. 2 is a schematic sectional view of the structure of a laminated multilayer composite material according to one embodiment of the invention;

On FIG. 3 schematically shows a press machine for manufacturing a laminated multilayer composite material according to one embodiment of the invention.

On FIG. 1-3 the following reference designations are affixed:

1 - laminated multilayer composite material;

2 - outer lining;

3 - inner lining;

4 - core;

5 - polymer adhesive composition;

6 - layer of lamination of the outer lining;

7 - a layer of glass veil of the outer cladding;

8 - a layer of glass mat of the outer cladding;

9 - layer of lamination of the inner lining;

10 - a layer of glass veil of the inner lining;

11 - a layer of glass mat of the inner lining;

12, 13 - fiberglass layers in the core;

14 - three-dimensional elements in the core;

15 - reinforcing layer of fiberglass in the core;

16 - core stiffener;

17 - working surface of the outer lining;

18 - corrugation of the working surface of the outer lining;

19 - outer surface of the inner lining;

20 - pressing unit;

21 - perforated stencil;

22 - mold;

23 - table;

24 - press.

Implementation of the invention

The invention can be successfully implemented in the form of a multilayer composite material 1 with laminated surfaces, as shown in FIG. 1. The design of the specified material includes a multilayer outer lining 2 and an inner lining 3, as well as a core 4 located between the said linings, which are interconnected with the help of a cured polymer adhesive composition 5 to form a single one-piece structure.

The outer cladding 2 contains a lamination layer 6 arranged in series in the direction of the core 4, which is the working surface of the material 1, a glass veil layer 7 and a glass mat layer 8. Similarly, the inner lining 3 comprises a lamination layer 9, a glass veil layer 10 and a glass mat layer 11 arranged in series in the direction of the core 4.

The core 4 contains three-dimensional elements 14 of gas-filled polymer located between two glass fabric layers 12,13, extending in the same direction, essentially parallel to each other. Between the volume elements 14 there is an additional reinforcing glass fabric layer 15, from which stiffening ribs 16 are formed along the length of the indicated volume elements 14. Preferably, only one stiffening rib 16 is formed between each two adjacent volume elements 14. However, the reinforcing layer 15 of fiberglass can also be placed with the formation of several such stiffeners between adjacent three-dimensional elements.

To interconnect all of the above structural elements of the material 1, a polymer resin selected from the group: orthophthalic, isophthalic, epoxy, epoxy vinyl ether, vinyl ester and phenolic can be used as a curable polymer adhesive composition 5.

Volumetric elements 14 are preferably a hexahedron in the form of a parallelepiped or a pentahedron in the form of a triangular prism. Thus, the cross section of each volumetric element 14 may have a shape selected from the group: triangular, rectangular and square. The gas-filled polymeric material from which the three-dimensional elements 14 are made can be expanded polystyrene, polyurethane foam, polyethylene foam or any other material with similar properties.

If necessary, the laminated surface 17 of the outer lining 2 may have a relief that prevents various objects or shoe soles from sliding on it. For example, the relief of the specified surface can be made in the form of corrugations such as lentil, rhombus, hemisphere, square, cone, duet, quintet or diagonal. On FIG. 2 shows a variant of the laminated composite material 1, the working surface of which is provided with hemispherical embossment 18, obtained by pressing, as explained later.

The lamination layers 6,9 can be made of a woven material such as glass roving or a nonwoven material such as powdered glass mat or emulsion glass mat or long fiber glass mat or a low plane material such as glass veil.

Said laminated multilayer composite material 1 can be produced using a press machine 20 illustrated in FIG. 3 in a manner comprising the following steps.

In the first step, the layers of inner lining 3, core 4 and outer lining 2 are placed in the mold 22 in a predetermined sequence.

In particular, first layers of the inner lining 3 are placed one above the other: starting with the lamination layer 9, then the glass veil layer 10, and then the glass mat layer 11.

Following the indicated layers of the inner lining 3, the core layers 4 are placed in the mold 22. First, the first (lower) layer 13 of fiberglass is placed. Then the first group of spaced volumetric elements 14 is placed with a step that makes it possible to place an additional volumetric element 14 between adjacent volumetric elements 14 of the first group of volumetric elements 14. groups of volumetric elements 14 are pressed in the direction of the inner lining 3 so that the specified reinforcing layer 15 of fiberglass follows essentially the shape of these gaps. Preferably, the reinforcing layer 15 of glass fabric is placed so that in the indicated intervals it is in contact with the side faces of the volumetric elements 14 and the bottom layer 13 of glass fabric. Then the second group of volumetric elements 14 is placed in the gaps between the volumetric elements 14 of the first group of volumetric elements 14, ensuring the contact of the volumetric elements 14 of the second group of volumetric elements 14 with the reinforcing layer 15 of fiberglass, but without contact with the volumetric elements 14 of the first group of volumetric elements 14. At the end place the second (top) layer 12 of fiberglass. Thus, between the two groups of three-dimensional elements 14, there is a reinforcing layer 15 of fiberglass separating them, forming stiffening ribs 16. Said stiffening ribs 16 run along the length of said three-dimensional elements 14. One or more stiffening ribs 16 are formed between each two adjacent three-dimensional elements 14.

Following the indicated layers of the core 4 in the mold 22, the layers of the outer lining 2 are placed: they start with the layer 8 of the glass mat, then the layer 7 of the glass veil and then the top layer 6 of the lamination.

All these layers and elements of the manufactured material 1, placed in the mold 22, are impregnated or coated with a polymer adhesive composition 5 before or during laying.

Next, the mold 22 with the content, i.e. with the layers and elements of the manufactured material 1 located therein, is placed on the table 23 of the pressing unit 20. Alternatively, the filling of the mold 22 can initially be performed when the latter is located on the specified table 23.

At the next step, using the press 24, the contents of the mold 22 are pressed for a specified time required for the polymerization (curing) of the polymer adhesive composition 5.

In the next step, after polymerization is completed, the resulting laminated multilayer composite material 1 is removed from the mold 22.

If necessary, in the next step, the resulting laminated multilayer composite material 1 is mechanically processed by removing excess fiberglass or cured adhesive at the edges of the product, the so-called. burr.

Alternatively, before the pressing step, a perforated stencil 21 is placed (shown by arrows) on the upper lamination layer 6, whereupon the aforementioned step of pressing the contents of the mold 22 is carried out to form a surface relief of the outer lining 2 according to the perforation on the stencil 21. After the pressing is completed, the perforated stencil is removed 21 and follow the next steps as above.

Said pressing unit 20 may be a hot or cold pressing unit.

The mold 22 and the perforated stencil 21 are made of an “inert” material that is resistant to the operating temperature and pressure of the pressing unit 20 and does not chemically react with the curable polymer adhesive composition 5. For example, such a material can be one of the following: metals and their alloys, wood, plywood, chipboard (chipboard), fibreboard (hardboard), plastic materials, in particular polypropylene or polyethylene terephthalate (PET).

The obtained laminated multilayer composite material 1 is suitable for the manufacture of a solid floorboard for an inflatable boat or at least one of its sections.

The final shape of at least one floorboard section depends essentially on the geometry of the mold 22 and may preferably have a plan shape selected from the group: triangular, rectangular, square, trapezoid.

The ends of the specified at least one section of the floorboard can be laminated with a layer of lamination of the inner 3 and/or outer 2 cladding. To do this, the placement of the layers of material 1 in the mold 22 includes wrapping the ends of the floorboard section with at least one of the indicated layers 6,9 of lamination. In this case, at least one of these lamination layers 6.9 close the ends of the floorboard section with overlapping (i.e., overlapping) of the outer surface 17 of the outer lining 2 or the outer surface 19 of the inner lining 3, respectively.

It should be understood that the dimensions and ratios of all structural layers and elements of the laminated multilayer composite material presented in the drawings are shown schematically and serve only to facilitate understanding of the essence of the invention. For the implementation of the invention, these dimensions and ratios may differ from those shown in the drawings.

The conducted patent research confirmed the world novelty and inventive step of the invention.

Testing of a prototype laminated multilayer composite material for ship flooring confirmed the industrial applicability of the invention and its compliance with the claimed technical results.

Claims (16)

1. A laminated multilayer composite material for ship flooring, containing an outer cladding, an inner cladding and a core located between the inner and outer claddings, connected by a polymer adhesive to form a single integral structure, characterized in that the inner and outer claddings contain cores arranged in series in the direction a lamination layer, a layer of glass veil and a layer of glass mat, and the core contains three-dimensional elements of gas-filled polymer located between two layers of glass fabric, passing in one direction, between which there is an additional reinforcing layer of glass fabric, forming stiffening ribs along the length of these three-dimensional elements. 2. The material according to claim 1, characterized in that at least one stiffening rib is formed between each two adjacent volumetric elements. 3. The material according to claim 1, characterized in that the polymer adhesive composition is a polymer resin selected from the group: orthophthalic, isophthalic, epoxy, epoxy vinyl ester, vinyl ester and phenolic. 4. The material according to claim 1, characterized in that the cross section of each volumetric element has a shape selected from the group: triangular, rectangular and square. 5. The material according to claim 1, characterized in that the gas-filled polymer is expanded polystyrene, polyurethane foam or polyethylene foam. 6. The material according to claim 1, characterized in that the surface of the outer lining contains corrugation such as lentil, rhombus, hemisphere, square, cone, duet, quintet or diagonal. 7. The material according to claim 1, characterized in that the lamination layer of the inner and/or outer lining is made of a material selected from the group: roving fiberglass, powdered glass mat, emulsion glass mat, long-fiber glass mat, glass veil. 8. A method for manufacturing a laminated multilayer composite material for ship flooring according to any one of the preceding claims, comprising the steps of: the mold is sequentially placed: a lamination layer, a layer of glass veil, a layer of glass mat, a layer of fiberglass, the first group of volumetric elements with a step that makes it possible to place an additional volumetric element between adjacent volumetric elements of the first group of volumetric elements, a reinforcing layer of fiberglass, the second group of volumetric elements in between the volumetric elements of the first group of volumetric elements, a layer of fiberglass, a layer of glass mat, a layer of glass veil and an upper lamination layer that forms the working surface of the material, and all these layers located in the mold are impregnated with a polymer adhesive composition, perform within a predetermined time the pressing of the contents of the mold to polymerize; after completion of polymerization, the resulting laminated multilayer composite material is removed from the mold. 9. The method according to claim 8, characterized in that before the pressing step, a perforated stencil is placed on the upper lamination layer, and the pressing of the mold contents is performed with the formation of a surface relief of the outer lining according to the perforation of the stencil. 10. The method according to claim 8, characterized in that after being removed from the mold, the resulting material is processed by mechanical removal of flash. 11. Floorboard for an inflatable boat, containing at least one section, characterized in that said at least one section of the floorboard is made of a laminated multilayer composite material according to any one of paragraphs. 1-7. 12. The floorboard according to claim 11, characterized in that said at least one section of the floorboard has a plan shape selected from the group: triangular, rectangular, square, trapezoidal. 13. The floorboard according to claim 11, characterized in that the ends of said at least one section of the floorboard are laminated.

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