WO2021128407A1

WO2021128407A1 - Honeycomb core sandwich composite panel and manufacturing method therefor, and device

Info

Publication number: WO2021128407A1
Application number: PCT/CN2019/130277
Authority: WO
Inventors: 朱华平
Original assignee: 江苏奇一科技有限公司
Priority date: 2019-12-26
Filing date: 2019-12-31
Publication date: 2021-07-01
Also published as: CN111098559A

Abstract

The present invention provides a honeycomb core sandwich composite panel, comprising a honeycomb core material formed by a plurality of units arranged in rows; the units are hexagonal cylinders formed around by side walls, the side walls each comprise a support layer and an adhesion layer, and upper and lower surfaces of the honeycomb core material are respectively provided with panels, the panels each comprise a main body layer and an interface layer, the interface layers being layers respectively connected to the upper and the lower surfaces of the honeycomb core material, the main body layers being provided on the interface layers, the main body layers being made of a continuous fiber-reinforced thermoplastic material, and the interface layers being made of the continuous fiber-reinforced thermoplastic material or a thermoplastic resin film. The manufacturing method of the present invention is simple, better mechanical properties can be obtained by using fewer materials, and production costs are reduced. The honeycomb core sandwich composite panel manufactured by means of a thermal composite process has excellent mechanical properties, effectively improving the compressive strength and bending strength, and further improving the stability of the production process.

Description

Honeycomb core sandwich composite board and preparation method and equipment thereof

Technical field

The invention belongs to the technical field of honeycomb structures, and in particular relates to a honeycomb core sandwich composite board and a preparation method and equipment thereof.

Background technique

The honeycomb core sandwich composite panel made of light and high-strength materials as the upper and lower panels and the low-density honeycomb core material as the intermediate through the hot-pressing composite process has light weight, high stiffness/mass ratio and strength/mass ratio and The advantages of high compressive strength, etc., are widely used in many fields requiring light weight, such as aramid honeycombs and aluminum honeycombs on airplanes, thermoplastic PP honeycombs in the transportation field, paper honeycombs in the packaging industry, and lightweight components in the photovoltaic industry. Backing board, etc.

Known honeycombs produced by the existing honeycomb production technology mainly include tubular honeycombs and semi-closed folded honeycombs. The tubular honeycomb mainly adopts a segmented or discontinuous production process. It is the first commercialized thermoplastic honeycomb. In addition to the most commonly used polypropylene (PP), it also uses polycarbonate (PC). And polyetherimide (PEI), etc., its mechanical properties largely depend on the density and pipe diameter of the honeycomb core. Tubus Bauer, Plascore, Induplast and Newcourt are all manufacturers of tubular honeycombs. In recent years, such core materials have been combined with glass fiber reinforced polypropylene skins and used in automobile spare tire covers.

In addition, the extruded core tube is a hexagonal honeycomb core material, such as the honeycomb core material produced by Induplast and Newcourt. The extruded block is very long, but the plane size of the core is only 150mm×150mm. Therefore, it is necessary to combine multiple The blocks are glued together and cut to the required thickness with a saw or hot steel wire. The entire production process is less automated and the cost is relatively high.

Hexcel has developed a complex process for the production of PP and PET honeycombs, called Cecore. Each honeycomb unit is formed independently by the movement and bonding of tools. Based on this development, Hexcel launched a The thermoplastic honeycomb made of non-woven fabric is called HexWeb EM. Versacore recently proposed that the traditional automated processes and applications of thermoplastic materials have been formed. In 2002, Versacore/Thermostack equipment was launched on the market. Both processes can continuously and automatically produce thermoplastic honeycomb cores, thereby reducing costs. However, in the production of honeycomb cores with small apertures, the production speed is limited because the ribbons need to be welded one by one with tools.

Recently, Sodesa has developed a continuous extrusion process of honeycomb core. After the material is melted, it is pressed into a strip with regular wavy patterns through a mold, and the desired honeycomb shape is formed after expansion. The formed product is called Hexacore. Wacotech has developed an excellent technology to form a thermoplastic honeycomb through continuous film "weaving", but because the mold needs to be moved vertically out of the formed honeycomb, the production speed is limited and the internal structure of the material is not ideal.

The manufacturing process of the semi-closed folded honeycomb is as follows: first, the adhesive is applied on the surface of the flat paper to form glue lines, and then the glue lines are staggered by multi-layer stacking, and finally the formed block is cut and stretched to form six Edge honeycomb core. The size and thickness of the honeycomb hexagons made of unimpregnated low-cost paper are usually more than 10 mm, because the smaller the internal hexagon size, the more time-consuming and low production efficiency for the traditional production process. , These paper honeycombs are mainly used for component packaging and filling.

Another production process of traditional honeycomb is corrugated. This process is not commonly used because of its high cost. This is because it requires manual operations (folding and bonding of corrugated paper) and is difficult to cut, but if cheap corrugated paper is used, A slightly heavier but more economical honeycomb core can be produced by this method. The cell size of standard corrugated cardboard is 5mm, and the size of the cell is related to the surface quality. Therefore, the current paper honeycomb application is usually achieved by manually using a laminated corrugated cardboard. . This kind of sandwich structure board, which is reinforced by glass fiber or natural fiber felt and core layer is honeycomb paper, is used for sun visor, hard top, parcel rack, spare tire cover and trunk floor.

The amount of raw materials required to produce honeycomb cores is small. If appropriate raw material types (such as paper, PP film) and efficient production methods are combined, a very economical sandwich material can be provided for automotive parts. However, the high cost of the production process limits its application in the automotive and furniture industries.

Most of the honeycomb production process technologies are non-continuous production processes, and now more advanced continuous production processes have emerged one after another. For example, patent numbers CN101084108B and CN105835484A disclose continuous production processes, but there are still areas that need to be improved, as follows :

According to the technical solution disclosed in the patent number CN101084108B in the "forming and folding process", after folding, each honeycomb hexagon is still in a separated state of two semi-hexagons, so it is folded to 90 degrees. During the (vertical) process, the proper lateral pressure cannot be obtained, which affects the fusion bonding strength of the individual hexagonal honeycombs and the adjacent vertical sides between each hexagonal honeycomb, and ultimately affects the compressive performance of the honeycomb core. In addition, it will affect the process stability of the downstream thermal compounding process, especially when the ratio of the thickness of the honeycomb to the side length of the hexagon or the size of the inscribed circle of the hexagon is greater. At the same time, the low connection strength will also cause the honeycomb core material to spread or detach during the secondary processing and conveying process, thereby affecting the positioning accuracy of the secondary processing. In addition, the molding die is complicated, and it is impossible to efficiently and quickly change the honeycomb cores of different thickness sizes.

The continuous production process disclosed in the patent number CN105835484A is to cut the whole body, and then stack it in a staggered position. The error is large. The irregular hexagonal structure is formed to reduce the overall strength, and due to its specific forming process, the honeycomb core material is The top or bottom of the 50% or 100% honeycomb hexagon is sealed. The material will shrink when heated during processing. The top material in the middle will shrink and dent due to lack of support. It cannot form a bond with other materials and cannot increase the contact area. , Resulting in excess material usage.

The patent numbers of the American BRADFORD company are US8303744B2, US8663523B2, and US9550336B2 propose a continuous structure consisting of multiple semi-hexagons connected by extrusion molding or film hot pressing, and cut them, and then fold them into honeycomb core materials; The design feature also does not involve a structure connected by a plurality of semi-hexagons after cutting, bonding of the side walls of adjacent semi-hexagonal units after folding, or other effective solutions. The honeycomb core material made according to its technological process cannot obtain the required mechanical properties, especially the compressive strength. This index is not only an important performance index involved in the application of honeycomb core sandwich composite panels, but also a key technical parameter that directly affects the stability of the hot-pressing composite process.

The compressive strength and the ratio of the flexural strength to the area weight of the honeycomb core sandwich composite panel are the main technical performance indicators for the application of the product. At present, the equipment for producing sandwich composite panels with thermoplastic material as the skin layer and honeycomb core material as the middle layer or sandwich layer in a continuous process mainly includes double-sided steel belt type thermal composite process equipment and double-sided high temperature resistant Teflon belt type thermal equipment. There are two major types of composite process equipment. These two types adopt the same process design principle, mainly including upper and lower contact heat conduction heating devices, one or more sets of hot-pressing composite rollers, and upper and lower contact cooling devices. The configured steel belt or high temperature resistant Teflon belt is responsible for the continuous conveying and cooling process of the product and the separation from the product after the product. By integrating heating, pressurizing, cooling, conveying and separation, a honeycomb core sandwich composite panel with a continuous process flow is realized Production. The above two production process equipment use the same heating process design, that is, the configured heating device respectively heats the honeycomb core sandwich composite board and the lower panel, and passes through the heat transfer path from the outside to the inside of the panel. Using the mixed heat transfer method of heat conduction and heat convection, the inner layer surface of the upper and lower panels and the upper and lower surfaces of the honeycomb core material are connected to the surface layer to reach the set heat melting temperature, and immediately go through the continuous heat pressing and cooling process. Then obtain the desired honeycomb core sandwich composite board.

Therefore, the present invention combines materials and heat transfer technology principles to further improve and optimize the structure of the honeycomb core material and the material, heat transfer and thermal composite process characteristics of the upper and lower panels and the honeycomb core material connection interface, and are designed and manufactured for compression resistance. The honeycomb core sandwich composite panel with better strength and bending strength provides an effective solution.

Summary of the invention

In order to achieve the above objective, the present invention provides a honeycomb core sandwich composite panel, which includes a honeycomb core material composed of a plurality of cells arranged in rows. The cells are hexagonal cylinders surrounded by sidewalls, and the sidewalls include supports. Layer and adhesion layer, support layer and adhesion layer are made of different materials, the melting point of the adhesion layer is lower than the softening point of the support layer, wherein the horizontally adjacent units are connected by the horizontally arranged connecting walls, and the longitudinally adjacent ones Adjacent side walls of the unit are bonded or bonded to each other through an adhesive layer; the upper and lower surfaces of the honeycomb core material are respectively provided with panels, and the panels include a main body layer and an interface layer, and the interface layer is respectively connected to the honeycomb core. The layer connecting the upper and lower surfaces of the core material, the main body layer is arranged on the interface layer, the main body layer is made of continuous fiber reinforced thermoplastic material, and the interface layer is made of continuous fiber reinforced thermoplastic material or thermal Made of plastic resin film.

Further, the melting point of the thermoplastic resin of the main body layer of the panel is higher than the melting point of the thermoplastic resin of the interface layer of the panel, and the melting point of the interface layer of the panel is the same as or compatible with the melting point of the support layer of the unit.

Further, the side wall of the unit has a three-layer structure, wherein there is an adhesion layer on each side of the support layer.

Further, the six side walls of the unit and the connecting wall are respectively provided with at least one reinforcing rib or reinforcing rib parallel to the element line.

Further, the reinforcing ribs or reinforcing ribs are staggered or aligned on the adjacent or corresponding side walls and the connecting wall of the unit.

Further, the interface layer of the panel is made of a thermoplastic resin film, and the thickness of the film layer is 0.01-0.5 mm.

Further, the main body layer and the interface layer of the panel are made of the same material, and the fiber content of the main body layer of the panel to the interface layer of the panel is from high to low; wherein, the fiber content of each layer of the main body layer The weight ratio of the corresponding thermoplastic resin is 30-80%, and the weight ratio of the fiber content of each layer constituting the interface layer to the corresponding thermoplastic resin is 20-40%.

Further, the main body layer and the interface layer of the panel are made of different materials, the main body layer of the panel is made of high-performance continuous fiber reinforced thermoplastic material, and the interface layer of the panel has lower mechanical properties than the main body. Layer of continuous fiber reinforced thermoplastic material or thermoplastic resin film.

Further, the main body layer of the panel is made of at least one layer of continuous fiber reinforced thermoplastic material with different material properties, and the main body layer of the panel is made of a continuous fiber reinforced thermoplastic sheet with higher performance. The material is the outer layer and the continuous fiber-reinforced thermoplastic sheet with lower performance is used as the adjacent inner layer, or the continuous fiber-reinforced thermoplastic sheet with higher performance and the continuous fiber-reinforced thermoplastic sheet with lower performance are used as the adjacent inner layer. The sheet is manufactured with a design of alternating high and low layers.

Further, the panel further includes a decoration layer, the decoration layer and the interface layer are disposed on both sides of the main body layer opposite to the interface layer, and the decoration layer is a thermoplastic resin film with appearance decoration characteristics.

The present invention also provides a preparation method of the honeycomb core sandwich composite panel. The preparation method is used to manufacture the honeycomb core sandwich composite panel according to any one of the above, and comprises the following steps:

S1: The thermoplastic resin film is formed into a longitudinally continuous and transversely connected semi-hexagonal structure through a heating compression molding process or a heating vacuum suction molding process, and the semi-hexagonal structure includes semi-hexagonal shapes distributed at intervals Unit part and adjacent connecting part;

S2: Adopt heating press bonding or ultrasonic heating welding process to align the connecting parts of the two connected semi-hexagonal structures to form a piece of hexagons that are continuous in the longitudinal direction and connected in the transverse direction. Core board of column structure;

S3: Cut the core plates of the multiple connected hexagonal column structures that have been connected into one body at upper and lower intervals to form upper and lower intervals and partially connected incisions. The hexagonal column structure is not cut when cutting. The core plate is completely cut off, but the connecting edge is retained at the cut;

S4: Take the incision as the folding position and the connecting edge of the incision as the folding axis of rotation. The core plate with the incision is rotated by plus or minus 90 degrees in the direction of the incision to fold the core plate, and heat it The adhesive layer in the hot-melt state forms a honeycomb core material in which the side walls of adjacent units are attached to each other;

S5: Laminate the upper and lower surfaces of the honeycomb core material to the panel, so that the interface layer of the panel and the upper and lower surfaces of the honeycomb core material are heated to the set hot melt temperature, and the interface layer of the panel forms the hot melt connection layer and the honeycomb core The upper and lower surfaces of the material are hot-pressed and composited, and then cooled to form a honeycomb core sandwich composite board.

Further, the thermoplastic resin film for preparing the unit includes a support layer and an adhesion layer. The support layer and the adhesion layer are made of different materials. The melting point of the adhesion layer is lower than the softening point of the support layer. In step S2, two sheets are used. The outer side of the core board formed by a plurality of longitudinally continuous and transversely connected semi-hexagonal structures is an adhesion layer. In step S4, the sidewall adhesion layers of the units connected side by side after being folded are heat-melt connected by heating, wherein the heating temperature Between the melting point of the adhesion layer and the softening point of the support layer.

Further, the thermoplastic resin film for preparing the unit has a single-layer structure. In step S1, the single-layer thermoplastic resin film is used as the supporting layer, and a thermal compounding process is used to thermally compound one layer on each side of the supporting layer. The thermoplastic resin film is used as the adhesion layer, and the melting point of the adhesion layer is lower than the softening point of the support layer; in step S4, heating makes the adhesion layer on the sidewalls of the units connected side by side after folding heat-melt connection, wherein the heating temperature is the melting point of the adhesion layer And the softening point of the thermoplastic resin film as the support layer.

Further, the panel is a single structure, and the S5 includes the following steps:

S51: Using extrusion molding or hot pressing to form a hot-melt connection film, the thickness of the hot-melt connection film is 0.01-0.5mm;

S52: Using at least one layer of continuous fiber reinforced thermoplastic material in the panel as the main layer, and bonding a layer of hot-melt connection film on the inner surface of the panel to form an interface layer;

S53: Heat the interface layer between the upper and lower surfaces of the honeycomb core material and the panel to the desired melting point temperature, and heat-press the interface layer of the panel and the upper and lower surfaces of the honeycomb core material Composite, and then cooled and formed into a honeycomb core sandwich composite board.

Further, the S1 further includes forming the thermoplastic resin film into a semi-hexagonal structure containing reinforcing ribs or reinforcing flutes through a heating compression molding process or a heating vacuum suction molding process, and the semi-hexagonal structure containing the reinforcing ribs or reinforcing flutes is formed into the thermoplastic resin film. The polygonal structure includes semi-hexagonal unit parts and adjacent connecting parts distributed at intervals, and the reinforcing ribs or reinforcing flute structures are distributed on the semi-hexagonal unit parts and the adjacent connecting parts.

Further, the preparation method further includes, S6: preliminarily hot pressing and bonding the decorative layer during the preparation process of the panel, or second hot pressing and bonding the decorative layer to the upper and lower surfaces of the honeycomb core sandwich composite panel formed by cooling , The decorative layer is a thermoplastic resin film with decorative appearance.

The present invention also provides a device for implementing any one of the above-mentioned preparation methods for the honeycomb core sandwich composite panel, including:

A first conveyor belt device for continuous conveying between the various processes from the thermoplastic resin film to the honeycomb core material;

A thermoforming device for thermoforming a thermoplastic resin film. The thermoforming device includes an upper and a lower forming mold. The two layers of thermoplastic resin film pass through the upper and lower forming molds respectively, and undergo a heating compression molding process or The heating and vacuum suction molding process forms two pieces of longitudinally continuous and horizontally connected semi-hexagonal structures, the semi-hexagonal structure includes spaced apart semi-hexagonal unit parts and adjacent connecting parts; two pieces Vertically continuous, horizontally, a plurality of connected semi-hexagonal structures enter the meshing place of the upper and lower pressing synthetic molds, and press the two rollers through the set gap between the upper and lower pressing synthetic molds. The connecting part of the semi-hexagonal structure forms a longitudinally continuous core plate with a plurality of connected hexagonal column structures in the transverse direction;

A first cooling device for cooling the core plate of the hexagonal cylindrical structure formed by pressing;

An incision device for cutting a core plate of a hexagonal column structure formed by pressing a plurality of connected semi-hexagonal structures in a longitudinal direction and a transverse direction. The incision device is continuous in the longitudinal direction of two pieces and has a plurality of transversely. The connected semi-hexagonal structure is pressed into an integrated core board to cut upper and lower intervals to form upper and lower intervals and partly connected incisions;

An indexing roller device for folding the core board cut by the slitting device. The indexing roller device folds the core board with the slit to form a continuous unit that is connected side by side and connected side by side. Provide the pushing and squeezing force required when connecting the side walls;

A hot-melting device for heating and melting the core plate folded by the indexing roller device, the hot-melting device heats the units connected side by side after being folded, so that the adjacent side walls between the units are heat-melt connected;

The equipment also includes:

A second conveyor belt device for continuous conveying between the honeycomb core material and the honeycomb core sandwich composite board;

A heating device for heating the upper and lower surfaces of the honeycomb core material and the panel. The heating device includes an upper and lower contact type heat conduction heating device for heating the upper and lower surfaces of the honeycomb core material and the interface of the panel. The layer is heated to the set temperature;

At least one set of hot-pressing composite rollers for hot-pressing and pressing the upper and lower surfaces of the honeycomb core material and the interface layer of the panel to form a honeycomb core sandwich composite board;

A second cooling device for cooling the honeycomb core sandwich composite board hot-pressed and composited by the hot-pressing composite roller, and the second cooling device includes an upper and a lower contact type cooling device.

Further, the indexing pair-roller device includes a set of rollers with indexing teeth.

Further, the equipment also includes a belt press for cooperating with the indexing roller device to squeeze adjacent units after the cutting, folding, and heating processes to achieve bonding of the side walls of the honeycomb core material. Device.

Further, the equipment also includes a plasma emission device for polarity treatment on the upper and lower surfaces of the honeycomb core material and the inner surface of the panel.

By adopting the above technical solution, the present invention achieves the beneficial effects that the preparation method is simple, the use of less materials is used to obtain better mechanical properties, and the production cost is reduced. The honeycomb core sandwich composite panel prepared by the thermal composite process has excellent mechanical properties, effectively improves the compressive strength and bending strength, and further improves the stability of the production process. In addition, the surface of the honeycomb core sandwich composite board is laminated with a thermoplastic resin film with appearance decoration characteristics to make the product more beautiful.

Description of the drawings

FIG. 1 is a schematic diagram of the structure of a honeycomb core material according to an embodiment of the present invention;

Figure 1a is a structural schematic diagram of a honeycomb core material provided with reinforcing ribs or reinforcing ribs on the side wall of an embodiment of the present invention;

2 is a schematic diagram of the side wall structure when the unit side wall of the embodiment of the present invention has two layers;

3 is a schematic flow chart of a method for preparing a honeycomb core sandwich composite panel using a two-layer structure of thermoplastic resin film according to an embodiment of the present invention;

4 is a schematic diagram of forming a core board during the preparation process of the honeycomb core sandwich composite board according to the embodiment of the present invention;

4a is a schematic diagram of a structural design of a core board containing ribs or ribs formed during the preparation of the honeycomb core sandwich composite board of the embodiment of the present invention;

4b is a schematic diagram of another structural design of a core board containing ribs or ribs formed during the preparation of the honeycomb core sandwich composite board of the embodiment of the present invention;

5 is a schematic flow chart of a method for preparing a honeycomb core sandwich composite panel using a panel with a monomer structure according to an embodiment of the present invention;

Fig. 6 is a schematic diagram of the preparation equipment of the honeycomb core material according to the embodiment of the present invention;

Figure 6a is a schematic structural diagram of an indexing roller device in a honeycomb core material preparation equipment according to an embodiment of the present invention;

Fig. 7 is a schematic structural diagram of a continuous fiber reinforced unidirectional sheet according to an embodiment of the present invention;

FIG. 8 is a schematic structural diagram of a panel according to an embodiment of the present invention;

Figure 8a is a schematic structural view of a panel containing a decorative layer according to an embodiment of the present invention;

Figure 9 is a schematic structural view of a honeycomb core sandwich composite panel according to an embodiment of the present invention;

Figure 9a is a schematic diagram of the force applied to the honeycomb core sandwich composite panel of the embodiment of the present invention during thermal compounding;

Fig. 10 is a schematic diagram of a preparation equipment of a honeycomb core sandwich composite panel according to an embodiment of the present invention.

Figure 10a is a schematic diagram of another preparation equipment for honeycomb core sandwich composite panels according to an embodiment of the present invention

Among them, 1 unit, 2 side walls, 21 adjacent side walls, 211 support layer, 212 adhesion layer, 3 connection wall, 4 semi-hexagonal unit part, 4a, 4b semi-hexagonal unit containing reinforcing ribs or reinforcing flutes Part, 5 connecting parts, 5a, 5b containing ribs or ribs or ribs, 6a, 6b ribs or ribs, 61 first conveyor belt device, 62 thermoforming device, 63 slitting device, 64 indexing roller Device, 641 roller, 65 hot melt device, 66 extrusion device, 67 pressing device, 68 first cooling device, 69 honeycomb core material, 69a honeycomb core material upper and lower surfaces, 70 decoration layer, 71 main body layer, 72 interface Layer, 72a inner layer of interface layer, 73 panel, 73a rolled panel, 74 thermoplastic resin, 75 continuous fiber, 76 continuous fiber reinforced unidirectional sheet, 79 heating device, 80 hot pressing composite roll, 81 second Cooling device, 82 second conveyor belt device, 83 plasma emission device.

Detailed ways

The present invention will be further explained by specific embodiments below. The following examples are preferred embodiments of the present invention, but the embodiments of the present invention are not limited by the following examples.

Example 1

As shown in Figure 1, the honeycomb core material includes a plurality of cells 1 arranged in rows. The cell 1 is a column surrounded by side walls 2. The adjacent cells 1 are connected by a connecting wall 3 arranged in the longitudinal direction. Adjacent units 1 are attached to or adhered to each other through adjacent side walls 21. In this embodiment, the unit 1 is a hexagonal column, but it should be understood that the cross-sectional shape of the unit in the honeycomb core material can be selected as required, for example, it can be a polygon, preferably an even-numbered polygon.

As shown in FIG. 2, the side wall 2 of the unit 1 has a two-layer structure, including a support layer 211 and an adhesion layer 212. The inner layer is the support layer 211 and the outer layer is the adhesion layer 212. Of course, those skilled in the art should understand that, The present invention has no particular limitation on the number and distribution of the side walls 2, as long as it is ensured that the adjacent side walls 21 of the longitudinally adjacent units 1 can be thermally connected by the adhesion layer 212, for example, the side walls of the unit 1 of the present invention 2 can also be a three-layer structure, in which there is a layer of adhesion layer 212 on each side of the support layer 211.

In this embodiment, the support layer 211 and the adhesion layer 212 in the side wall 2 of the unit 1 are made of different materials, wherein the support layer 211 is made of polypropylene material, and the adhesion layer 212 is made of ethylene with a vinyl acetate (VA) content of 28. Vinyl acetate copolymer (EVA) material, in which the softening point of the support layer 211 is 130°C, and the melting point of the adhesion layer 212 is 60°C. When the adjacent side walls 21 of the longitudinally adjacent units 1 are connected by heat, the heating The temperature is controlled between 80 and 100°C to make the adhesion layer 212 in a molten state to achieve hot melt connection. At the same time, the heat received by the support layer 211 is lower than the softening point, and has mechanical properties at room temperature, so that the support layer 211 is Adjacent units 1 can provide the required supporting force when they are folded and bonded, so as to achieve a higher bonding strength of adjacent side walls 21 while effectively maintaining the geometry of the unit, and greatly improve the compression resistance of the honeycomb core 69 strength. The adhesion layer is made of materials with a melting point temperature of 40-80°C, and the support layer is made of materials with a softening point temperature of 150-160°C.

Wherein, the adhesion layer 212 is made of ethylene copolymer, such as EVA (ethylene-vinyl acetate copolymer), EAA (ethylene-acrylate copolymer), EMA (ethylene-maleic anhydride-acrylate copolymer); support layer 211 is made of polymer materials that can be cast, such as PP (polypropylene), PA (polyamide), PC (polycarbonate), PET (polyethylene terephthalate), etc. The support layer can also use modified resin materials such as fiber reinforced thermoplastic resin materials, which are suitable for the present invention, but are not limited to the fiber modified reinforced thermoplastic resin materials described herein, such as LFT (long fiber thermoplastics) and LFT-D And other fiber-reinforced thermoplastic resins; suitable reinforcing fibers include, but are not limited to, those stated here, such as glass fibers, carbon fibers, etc.; suitable fiber-reinforced thermoplastic resins, but not limited to those stated here, such as Polypropylene resin PP, polyester resin PET, nylon resin PA6 or PA66, PC resin, PEEK resin, PPS resin, etc. Using the mechanical properties of fiber-reinforced thermoplastic resin, the compressive strength of the honeycomb core material is improved without replacing the main thermoplastic resin and without affecting the hot-melt connection characteristics of the interface between the upper and lower surfaces of the panel and the honeycomb core material.

As shown in Figures 4 to 4b, in Figure 4, the upper and lower half-hexagonal unit structures that make up the core plate include half-hexagonal unit parts 4 and adjacent connecting parts 5; in Figure 4a, the upper and lower half-hexagonal unit structures include half-hexagonal unit parts 4 and adjacent connecting parts 5; The lower half-hexagonal unit structure includes a half-hexagonal unit portion 4a containing ribs or ribs and an adjacent connecting portion 5a containing ribs or ribs. The side walls 2 and connecting walls 3 of the unit 1 can be The six side walls 2 and the connecting wall 3 of the unit 1 may be respectively provided with at least one reinforcing rib or reinforcing rib 6a parallel to the element line. In Figure 4b, the upper and lower half-hexagonal unit structure includes a semi-hexagonal unit portion 4b containing ribs or ribs and an adjacent connecting portion 5b containing ribs or ribs. The adjacent or Corresponding side walls 2 and connecting walls 3 can be aligned or staggered with stiffeners or ribs 6b. Each side wall 2 and connecting wall 3 of the unit 1 can also be equipped with the same number or different numbers of stiffeners or reinforcements. Leng 6b. As shown in Fig. 1a, the side wall of the honeycomb core material is provided with reinforcing ribs or reinforcing ribs 6a, 6b. It can be seen that at least one reinforcing rib or reinforcing rib 6a, 6b is provided on the six side walls 2 of the unit 1 and the connecting wall 3 arranged transversely, and the adjacent or corresponding side walls 2 or the connecting wall 3 can be The aligning arrangement can also be staggered with stiffening ribs or stiffening ribs 6a, 6b, and the number can be the same or different. It should be understood that the geometric shapes of the reinforcing ribs or reinforcing flutes 6a, 6b include semicircular, arc, angular, and sinusoidal waveforms, but are not limited to those described here. The side wall 2 and the connecting wall 3 of the unit 1 are provided with reinforcing ribs or reinforcing ribs 6a, 6b, which can improve the compression resistance of the honeycomb core 69 without increasing the thickness of the hexagonal film layer. strength.

As shown in Figure 7, the continuous fiber reinforced unidirectional sheet 76 (UD-Tape for short) is made of multiple continuous fibers 75 and thermoplastic resin 74 arranged in a single direction through a hot melt process. The equipment running direction is defined as the 0 degree direction, and the continuous fiber reinforced unidirectional sheet 76 laid perpendicular to this is defined as the 90 degree direction. A member made of two layers of continuous fiber reinforced unidirectional sheets 76 according to a 0/90 degree layup design. Among them, the fiber length direction of the continuous fiber reinforced unidirectional sheet 76 is consistent with the operating direction of the process equipment, which is defined as the 0 degree layup, and the vertical stack is defined as the 90 degree layup. According to the required mechanical properties, the main body layer 71 may be composed of at least one layer of continuous fiber reinforced unidirectional sheet 76. Moreover, in accordance with the definition of the ply angle, the main layer 71 of the designed panel 73 can be a set of 0/90 degree ply designs, or multiple sets of 0/90 degree ply designs, or as required The mechanical properties of the direction require a ply design between 0 and 90 degrees. The continuous fiber reinforced thermoplastic material is manufactured from at least one layer of continuous fiber reinforced unidirectional sheet 76 according to the above-mentioned method.

As shown in Figs. 8 to 8a, the panel 73 of the honeycomb core sandwich composite panel is made by the main body layer 71 and the interface layer 72 through the superimposed layer design through the heating composite process. Among them, the main layer 71 is the outer layer of the panel 73, which is made of continuous fiber reinforced thermoplastic material with higher mechanical properties and melting point, and the interface layer 72 is the inner layer of the panel 73, which is reinforced by continuous fiber with a lower melting point. It is made of thermoplastic material or thermoplastic resin film. The panel 73 includes at least one layer of continuous fiber-reinforced thermoplastic sheet 76. The melting point of the thermoplastic resin of the main body layer 71 is higher than the melting point of the thermoplastic resin of the interface layer 72. The interface layer The melting point of 72 is the same as or compatible with the melting point of the supporting layer 211. The panel 73 also includes a decoration layer 70, which is made of a thermoplastic resin film material, and can be one layer or multiple layers. The use of the decorative layer 70 with appearance decoration features or fire and scalding can make the honeycomb core sandwich composite panel more beautiful. Thermoplastic resin film materials include, but are not limited to those stated here, such as: polycarbonate, polyvinyl chloride, polymethyl methacrylate, polyethylene terephthalate, polyphenylene ether, polyphenylene sulfide , Polyetheretherketone and so on. As shown in Figure 9, the honeycomb core sandwich composite panel includes a honeycomb core 69 and a panel 73. The interface layers 72 of the upper and lower panels 73 are respectively thermally fused to the upper and lower surfaces 69a of the honeycomb core to form a honeycomb core sandwich composite panel. .

The main body layer 71 of the panel 73 is made of at least one layer of continuous fiber reinforced thermoplastic material with different material properties. The main body layer 71 of the panel 73 is made of a continuous fiber reinforced thermoplastic sheet with higher performance. Layer and a continuous fiber reinforced thermoplastic sheet with lower performance as the adjacent inner layer, or a continuous fiber reinforced thermoplastic sheet with higher performance and a continuous fiber reinforced thermoplastic sheet with lower performance are used as the adjacent inner layer. It is designed and manufactured with alternating high and low layers.

The inner layer of the upper and lower panels of the honeycomb core sandwich composite panel made by the thermal compounding process, that is, the interface layer 72 contacting the upper and lower surfaces of the honeycomb core material, can be passed by a thermoplastic resin with a lower melting point. Extrusion film process or bonding a film made of a thermoplastic resin with a lower melting point to the main body layer 71 of the panel, which is used as a hot melt adhesion between the upper and lower surfaces of the panel and the honeycomb core material. For the bonding layer, the melting point of the thermoplastic resin of the interface layer 72 is lower than the melting point of the thermoplastic resin of the main body layer 71, and the suitable thickness of the thermoplastic resin ranges from 0.01 to 0.5 mm. The low melting point thermoplastic resin material combination that meets the characteristics of this design includes, but is not limited to the ones stated here, such as continuous fiber reinforced PP as the main layer 71 and POE (ethylene octene copolymer), Vistamaxx ExonMobil's propylene octene copolymer), EAA (ethylene acrylate copolymer), EMA (ethylene acrylate maleic anhydride terpolymer), EVA (ethylene vinyl acetate copolymer) are panels composed of the interface layer 72 73; Or a panel 73 composed of continuous fiber reinforced PA6 as the main layer 71 and modified PP as the interface layer 72, where the modified PP is a graft of PP-g-MAH maleic anhydride, PP-g-GMA (former Glycidyl acrylate) grafts, monomers with polar anhydride or epoxy functional groups can form covalent bonds with nylon and have high bonding strength; or use continuous fiber reinforced PET as the main layer 71 and modified PP It is the panel 73 of the interface layer 72. The low-melting hot-melt adhesive layer and the upper and lower surfaces of the honeycomb core material are thermally composite bonded in advance through the thermal composite process, and the continuous process of the honeycomb core sandwich composite panel is completed according to the thermal composite process equipment design. The material design feature of the panel designed according to the material and heat transfer technology is the hot-melt adhesive layer with low resin melting point from the outside to the inside, and the corresponding melting point temperature is from high to low, showing the characteristics of stepwise decrease, achieving less The heat meets the design requirements of the hot melting and hot pressing process of the upper and lower panels and the honeycomb core material in the thermal composite process, reduces the inertia of the heat transfer in the heating process, and improves the heating and pressurizing process of the honeycomb core material in the thermal composite process The bearing pressure along the parallel direction of the six-sided cylinder cylinder in the process, that is, the compressive strength required for the hot-compression bonding of the thermal composite process. This data is not only an important indicator to measure the technical reliability of the thermal composite process of the honeycomb core sandwich composite panel , It also directly affects the compressive strength and flexural strength of the honeycomb core sandwich composite finished board.

Each layer of the upper and lower panels 73 of the honeycomb core sandwich composite panel made by the thermal composite process can be a continuous fiber reinforced thermoplastic sheet made of continuous fibers 75 of the same material, but the fiber content of each adjacent layer is used There is a differentiated design. Its characteristic is that the fiber content from the outer layer to the inner layer is from high to low, and the thermal conductivity and mechanical properties of the corresponding layer are also from high to low. According to the principle of material mechanics, the outer main layer 71 of the honeycomb core sandwich panel structure adopts a relatively high content of continuous fibers and continuous fiber reinforced thermoplastic material with high mechanical properties, which can effectively improve the bending strength of the honeycomb core sandwich composite panel. At the same time, the relatively high heat transfer efficiency is used to achieve the hot-melting process temperature of the connection interface between the upper and lower panels and the honeycomb core material with less heat. The innermost interface layer 72 adopts continuous fiber reinforced thermoplastic material with less continuous fiber content, that is, a higher content of thermoplastic resin can improve the bonding strength between the interface layer 72 and the honeycomb core material 69. Suitable continuous fibers include, but are not limited to, those made from inorganic mineral materials such as carbon fiber, glass fiber, basalt fiber, etc. The thermal conductivity coefficient is higher than that of the composite thermoplastic resin, and the fiber content accounts for The volume percentage of the continuous fiber reinforced thermoplastic sheet is in the range of 30-60%. The weight ratio of the fiber content of each layer of the main body layer 71 to the corresponding thermoplastic resin is 30-80%, and the weight ratio of the fiber content of the interface layer 72 to the corresponding thermoplastic resin is 20-40%. The main body layer and the interface layer of the same material are used, but the continuous fiber content is differentiated in design, forming a panel 73 from the main body layer 71 to the interface layer 72 corresponding to the continuous fiber content from high to low. Among them, the main body layer 71 is a high fiber content layer, and the interface layer 72 is a lower fiber content layer. According to the mechanical performance requirements required by the product design, the structure of the panel 73 can be a combination of at least one continuous fiber reinforced thermoplastic material with a large continuous fiber content and a continuous fiber reinforced thermoplastic material with a small continuous fiber content. This design can meet the design requirements of the hot melting and hot pressing process of the upper and lower panels 73 and the honeycomb core material 69 in the thermal compounding process with less heat, reduce the inertia of the heat energy transfer in the heating process, and improve the honeycomb core material 69 The bearing pressure along the parallel direction of the hexahedral cylinder during the heating and pressurizing process of the thermal composite process, that is, the compressive strength required for the thermal compression of the thermal composite process. At the same time, the main layer with higher mechanical properties optimizes the mechanical structure design of the honeycomb core sandwich composite panel.

The layers of the upper and lower panels 73 of the honeycomb core sandwich composite panel made by the thermal composite process can be continuous fiber reinforced thermoplastic sheets made of continuous fibers 75 of different materials. It is characterized by the fiber content from the outer layer to the inner layer and the performance of the composite continuous fiber reinforced thermoplastic sheet from high to low, and the thermal conductivity and mechanical properties of the corresponding layer are also from high to low. The material and ply structure design feature is the use of high-performance continuous fiber reinforced thermoplastic materials, such as continuous carbon fiber reinforced thermoplastic materials, which have better heat transfer and mechanical properties, and are used for the outer main layer 71 of the panel. The inner interface layer 72 is made of a continuous fiber-reinforced thermoplastic material with lower mechanical properties than the adjacent outer layer, such as a glass fiber-reinforced thermoplastic material layer or a thermoplastic resin film layer. The mechanical properties of each layer corresponding to the outside are from low to high, showing a step-up state. Suitable high-performance fiber materials include, but are not limited to, the combination of carbon fiber and glass fiber, the combination of high-strength and high-modulus glass fiber and low-performance glass fiber, and other continuous thermoplastic materials suitable for reinforcement. Fibers are designed and combined according to the difference in mechanical properties between each other. Use high-performance continuous fibers, such as carbon fiber reinforced thermoplastic materials, which have better mechanical properties, such as high modulus and high tensile strength materials as the main layer 71 of the panel 73, and the thermoplastics are engineering plastics or special engineering plastics. , Such as PA6, PA66, PET, PC, PPS, PPO, PPSU, PEEK, PEKK, etc., while the interface layer 72 uses more economical fibers such as glass fiber reinforced thermoplastic material layer, the thermoplastic is a general-purpose plastic, such as PP, PE , PVC, etc. There is a layer of bonding transition layer between continuous fiber 75 and thermoplastic resin 74. The main function of this layer is to bond two continuous fiber-reinforced thermoplastic materials together to form a whole. Because economical thermoplastics are all poly Olefin materials, so it has a good bond with polyolefin materials, high-strength and high-modulus continuous fiber reinforced thermoplastic materials have polar functional groups, such as amide bonds, ester bonds, ether-ketone bonds, such polar functional groups It has good bonding performance with acid anhydride, epoxy bond, or ester bond, so the over-bonding layer is a film made of EMA (ethylene acrylic acid maleic anhydride copolymer) and ethylene acrylic acid glycidyl ester copolymer. Continuous fibers 75 of different performance materials are used to form a panel with a structural design from the outside to the inside, and the corresponding mechanical properties are presented from high to low. Among them, the main body layer 71 uses a high-performance continuous carbon fiber reinforced thermoplastic material, and the interface layer 72 uses a more economical continuous fiber reinforced thermoplastic material. According to the mechanical performance requirements required by the product design, the structure of the panel 73 can be a combination of at least one layer of high-performance continuous carbon fiber reinforced thermoplastic material and a more economical continuous fiber reinforced thermoplastic material. The design feature is to use the excellent heat transfer characteristics of the carbon fiber of the continuous carbon fiber reinforced thermoplastic material layer as the main layer 71 of the panel 73, which can effectively reduce the heat of the panel 73 and the upper and lower surfaces 69a of the honeycomb core material during the thermal composite process. The heat required for the melting process and the reduction of the inertia of the heat energy transfer in the heating process increase the bearing pressure of the honeycomb core material 69 along the parallel direction of its hexahedral cylinder during the heating and pressing process of the thermal composite process, that is, thermal composite The compressive strength required for process hot pressing. At the same time, according to the principle of material mechanics, the honeycomb core sandwich composite panel is designed with a "continuously increasing" layer structure design of the middle layer in the thickness direction of the honeycomb core material from the inner to the outer layer, which has more optimized material mechanics. Characteristic, its mechanical performance presents the characteristic of increasing steps, which realizes that the honeycomb core sandwich composite panel with better mechanical properties can be made with less materials and more economical methods.

Example 2

As shown in Figures 3 and 5, a two-layered thermoplastic resin film is used to prepare a honeycomb core sandwich composite panel. The thermoplastic resin film includes a support layer 211 and an adhesion layer 212 made of different materials. The adhesion layer 212 The melting point is lower than the softening point of the support layer 211. The supporting layer 211 is made of polyethylene terephthalate (PET), and the adhesive layer 212 is made of EMA. The EMA is obtained from ethylene and methyl acrylate as raw materials, oxygen or peroxide as initiators, and high-pressure heating polymerization. The softening temperature of the supporting layer 211 is 160°C, the melting point of the bonding layer 212 is selected to be 80°C, and the heating temperature is controlled at 100 to 150°C. The preparation method includes the following steps:

S1: Pass the two layers of thermoplastic resin film through the upper and lower forming molds at the same time, and form two semi-hexagonal structures separated from the upper and the lower through the heating compression molding process or the heating vacuum suction molding process, and the semi-hexagonal structure It includes semi-hexagonal unit parts 4 and adjacent connecting parts 5 distributed at intervals.

S2: Use heating and pressing or ultrasonic heating welding process to align and fit the connecting parts of multiple connected semi-hexagonal structures to form a piece of hexagonal columns that are continuous in the longitudinal direction and connected in the transverse direction. For the core board of the body structure, the outer side of the core board is the adhesion layer 212, and the inner side is the support layer 211.

S3: Cut the core plates of the multiple connected hexagonal column structures that have been connected into one body at upper and lower intervals to form upper and lower intervals and partially connected incisions. The hexagonal column structure is not cut during cutting. The core plate is completely cut off, but the connecting edge is retained at the incision. The cutting method can be carried out according to actual needs by using methods known in the prior art to achieve the production requirements of honeycomb core materials 69 of different thicknesses, for example, Cut in one of the following ways: metal or non-metal blade cutting, laser cutting, high-pressure hydraulic cutting, wire cutting, resistance wire cutting or plasma cutting, etc.

S4: Take the incision as the folding position and the connecting edge of the incision as the folding axis of rotation. The core plate with the incision is rotated by plus or minus 90 degrees in the direction of the incision to fold the core plate and heat it. The state of the adhesion layer 212 forms the honeycomb core material 69 in which the side walls 2 of adjacent cells are bonded and connected to each other. After the folding of the core board, the bonded and connected connection parts 5 constitute the connection wall 3 that connects the horizontally adjacent cells 1, and the longitudinal direction Adjacent side walls between adjacent units are attached to each other, and the adhesion layers 212 of the adjacent side walls of the longitudinally adjacent units after being folded are thermally connected by heating to form a honeycomb core 69, wherein the heating temperature is at the temperature of the adhesion layer 212 Between the melting point and the softening point of the support layer 211, while effectively maintaining the cell geometry, a higher bonding strength of adjacent side walls is obtained, and the compressive strength of the honeycomb core material 69 is improved.

S5: The upper and lower surfaces 69a of the honeycomb core material are attached to the interface layer 72 of the panel 73, and the interface layer 72 of the panel 73 and the upper and lower surfaces 69a of the honeycomb core material are heated to the set melting temperature. The interface of the panel 73 The layer 72 forms a hot-melt connection layer and heat-compresses the upper and lower surfaces of the honeycomb core material, and then cools to form a honeycomb core sandwich composite board.

The panel 73 is a single structure, and the single structure is a composite layer structure composed of at least one continuous fiber reinforced thermoplastic material. S5 includes the following steps:

S51: The hot-melt connecting film is made by extrusion or hot pressing, and the thickness of the hot-melt connecting film is 0.01～0.5mm;

S52: At least one layer of continuous fiber reinforced thermoplastic material is used as the main body layer 71 in the panel 73, and the inner surface of the panel 73 is continuous fiber whose weight ratio of thermoplastic resin 74 to the corresponding continuous fiber 75 is 40-70% Reinforce the thermoplastic material sheet or bond a layer of hot-melt connection film to form the interface layer 72;

S53: Laminate the upper and lower surfaces 69a of the honeycomb core material with the interface layer 72 of the panel 73, heat the interface layer 72 of the panel 73 and the upper and lower surfaces 69a of the honeycomb core material to the set melting temperature, the interface of the panel 73 The layer 72 forms a hot-melt connection layer and heat-compresses the upper and lower surfaces of the honeycomb core material, and then cools and forms a honeycomb core sandwich composite board.

In one embodiment, the film of the preparation unit 1 includes a support layer 211 and an adhesion layer 212. The support layer 211 and the adhesion layer 212 are made of different materials. The melting point of the adhesion layer 212 is lower than the softening point of the support layer 211. In step S2 Two pieces of the core board formed by a plurality of longitudinally continuous and transversely connected semi-hexagonal structures are used as the adhesion layer 212. In step S4, the side walls 2 of the unit 1 connected side by side after being folded are adhered by heating. The layers are connected by heat fusion, wherein the heating temperature is between the melting point of the adhesion layer 212 and the softening point of the support layer 211. The melting point of the thermoplastic resin of the main body layer 71 is higher than the melting point of the thermoplastic resin of the interface layer 72, the melting point of the interface layer 72 is the same as or compatible with the melting point of the support layer 211, and the heating temperature is between the melting point of the main layer 71 and the interface layer 72 Between the melting points.

In another embodiment, the thermoplastic resin film of the preparation unit 1 has a single-layer structure, and the single-layer thermoplastic resin film is used as the supporting layer 211 in the honeycomb core material 69, and the thermal compounding process is used on both sides of the supporting layer 211. A layer of thermoplastic resin film is thermally laminated as the adhesion layer 212, the melting point of the adhesion layer 212 is lower than the softening point temperature of the support layer 211; the thermoplastic resin film is formed into a longitudinally continuous and a transverse direction through a heating compression molding process or a heating vacuum suction molding process It is a plurality of connected semi-hexagonal structures, the semi-hexagonal structure includes spaced semi-hexagonal unit parts 4 and adjacent connecting parts 5; using heating and pressing or ultrasonic heating welding process, the two pieces The connecting parts 5 of a plurality of connected semi-hexagonal structures are aligned and connected by the adhesion layer 212 so as to form a core board that is continuous longitudinally and horizontally with a plurality of connected hexagonal structures; Take the incision as the folding position and the connecting edge of the incision as the folding rotation axis, fold the core plate with the incision to form a unit 1 connected side by side; heating makes the side walls 2 of the unit 1 connected side by side adhere to each other after folding The layer 211 is thermally fused, in which the heating temperature is between the melting point of the adhesion layer 212 and the softening point of the thermoplastic resin film as the supporting layer.

In another embodiment, S1 further includes forming the thermoplastic resin film into a semi-hexagonal structure containing reinforcing ribs or reinforcing ribs 6a, 6b through a heating molding process or a vacuum suction molding process, and including reinforcing ribs or reinforcing ribs 6a, The semi-hexagonal structure of 6b includes spaced semi-hexagonal unit parts 4 and adjacent connecting parts 5, reinforcing ribs or reinforcing ribs 6a, 6b, and the reinforcing ribs or reinforcing ribs 6a, 6b are distributed in the semi-hexagonal unit On the part 4 and on the adjacent connecting part 5.

In another embodiment, the decorative layer 70 is thermally pressed and bonded in advance during the manufacturing process of the panel 73, or the upper and lower surfaces of the honeycomb core sandwich composite board formed by cooling are secondarily thermally pressed and bonded to the decorative layer 70. The decorative layer 70 is a thermoplastic resin film with decorative appearance or fire and scalding properties.

Example 3

6 is a specific embodiment of the honeycomb core material manufacturing equipment of the present invention, which includes a first conveyor belt device 61, a thermoplastic molding device 62, a slitting device 63, an indexing roller device 64, and a hot melting device 65.

Among them, the first conveyor belt device 61 is used to realize continuous transportation from the thermoplastic resin film to the forming of the honeycomb core material.

The thermoplastic molding device 62 may include upper and lower molding dies and infrared heating equipment. The two layers of thermoplastic resin film are respectively passed through the upper and lower molding dies, heated compression molding process or heated vacuum suction molding process to form two upper and lower separated halves. Hexagonal structure, the semi-hexagonal structure includes spaced semi-hexagonal unit parts 4 and adjacent connecting parts 5; two pieces are continuous longitudinally and horizontally for multiple connected semi-hexagonal structures to enter the upper and lower pressures The meshing part of the synthetic mold is formed by the set gap between the upper and lower pressing synthetic molds. The roller pressure is continuous longitudinally, and the transverse is the connecting part of a plurality of connected semi-hexagonal structures, forming a longitudinal continuous , The horizontal direction is a core board of a plurality of connected hexagonal column structures. Suitable processing techniques include, but are not limited to, those stated here, and also include thermoforming techniques such as heating roll thermoforming techniques.

The slitting device 63 cuts the core plate of the hexagonal column structure formed by pressing a plurality of consecutive semi-hexagonal column structures in the longitudinal direction and transversely into an integral hexagonal column structure at upper and lower intervals to form upper and lower intervals and partially connected When cutting, the core board is not completely cut off, but the connecting edge is reserved at the incision; optionally, the incision device can be cutting by metal or non-metal blades, laser cutting, high pressure hydraulic cutting, wire cutting, resistance wire cutting Or plasma cutting equipment for cutting.

As shown in Fig. 6a, the indexing roller device 64 includes a set of rollers 641 with indexing teeth. The thickness of the honeycomb core 69 can be used as the indexing reference to apply pressure to the incision, and set the index to adjust the rollers. The difference between the speed of the first conveyor belt device 61 and the linear speed of the indexing wheel on the device 64 realizes the folding and rotating of the horizontal unit after the incision is carried out by about 90 degrees to form a continuous unit connected side by side. By indexing the teeth of the counter roller and setting the center of the counter roller in the horizontal and vertical directions, the indexing and folding requirements of honeycomb cores with different incision spacing and different hexagonal cross-sectional dimensions can be realized.

The hot-melt device 65 can heat the folded units connected side by side to heat-melt the adjacent side walls between the units to form a honeycomb core 69. The heating temperature can be controlled at the melting point of the adhesion layer 212 of the side wall 2 and the support layer 211 Between the softening points, while effectively maintaining the geometric shape of the unit, a higher bonding strength of adjacent side walls is obtained, and the compressive strength of the honeycomb core material is improved.

As shown in FIG. 6, the honeycomb core material manufacturing equipment of the present invention may further include an extrusion device 66 for preparing a thermoplastic resin film for extruding and forming a thermoplastic resin film used as a raw material.

The honeycomb core material manufacturing equipment of the present invention may further include a first cooling device 68. The first cooling device may be an air cooling device for cooling the core plate of the hexagonal column structure formed by pressing.

The honeycomb core material preparation equipment of the present invention may further include a pressing device 67 for pressing the formed two pieces of longitudinally continuous and transversely connected semi-hexagonal structures to form a hexagonal column with a complete unit part. Structure of the core board.

The honeycomb core material preparation equipment of the present invention may also include a belt pressing device for cooperating with the indexing roller device 64 to press adjacent units after the cutting, folding, and heating processes to achieve bonding of the honeycomb core The side wall of the honeycomb core is used in combination to squeeze the operating side of the honeycomb core production line to achieve effective bonding of the honeycomb core side wall.

As shown in Fig. 9a, the required force F and reaction force F'when the upper and lower panels 73 of the honeycomb core sandwich composite panel are thermally combined with the upper and lower surfaces 69a of the honeycomb core material are according to Fig. 10 or Fig. 10a, or similar The key process design parameters for the production of high-performance honeycomb core sandwich composite panels with the thermal composite process equipment.

10 is a specific embodiment of the manufacturing equipment of the honeycomb core sandwich composite panel made of honeycomb core material according to the present invention, which includes a second conveyor belt device 82, a heating device 79, a second cooling device 81, and a hot pressing composite roller 80.

The second conveyor belt device 82 is used to realize the continuous transmission between the various processes from the thermoplastic resin film to the honeycomb core sandwich composite board, which is resistant to high temperatures and prevents hot melt adhesive adhesion. Among them, the second conveyor belt device 82 can be a double-sided steel belt or a double-sided high temperature resistant Teflon belt, but is not limited to what is stated here

The heating device 79 includes upper and lower contact heat conduction heating devices, which respectively heat the upper and lower panels 73, and pass through the outer main body layer 71 of the panel 73, and the heat transfer path from the outside to the inside is combined with heat conduction and heat convection. The hybrid heat transfer method heats the interface layer 72 of the panel 73 to a set temperature to form a hot-melt connection layer;

One or more sets of hot-pressing composite rollers 80 are used to heat-press composite the interface layer 72 of the panel 73 and the upper and lower surfaces 69a of the honeycomb core material;

The second cooling device 81, the second cooling device 81 includes an upper and a lower contact type cooling device, which is used for cooling and forming the honeycomb core sandwich composite panel hot-pressed by the hot-pressing composite roller.

As shown in Figure 10a, the honeycomb core sandwich composite panel manufacturing equipment of the present invention can also include a plasma emission device 83, which uses plasma technology to separately surface the interface layer 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core material. Polarity treatment increases the surface energy of the interface layer 72 of the upper and lower panels 73 of the honeycomb core sandwich composite panel and the upper and lower surfaces 69a of the honeycomb core material, thereby increasing the interface layer 72 of the upper and lower panels 73 and the honeycomb core The bonding strength between the upper and lower surfaces 69a of the material. The plasma emission device 83 installed at the entrance of the thermal composite process equipment respectively performs plasma treatment on the interface layer 72 of the upper and lower panels 73 and the upper and lower surface layers 69a of the honeycomb core material, which can effectively control the interface layers of the upper and lower panels 73 72 and the upper and lower surface layers 69a of the honeycomb core material meet the required heat to reach the molten state while ensuring the compressive strength of the honeycomb core material to the utmost. The process technology to improve the surface polarity of the thermoplastic material can be, but is not limited to the ones stated here, including plasma emission devices, corona devices for plastic surface treatment, and high calorific value gas flame combustion devices. The process technology device suitable for increasing the surface energy of the connecting interface of thermoplastic materials and realizing rapid hot melt can be, but is not limited to the ones stated here, including natural gas nozzle heating process device, acetylene gas nozzle heating process device, infrared heating process device, And laser heating process equipment, etc.

In a specific embodiment of the present invention, the working mode of the preparation equipment of the present invention is: the extruding device 66 extrudes to form two thermoplastic resin films with a two-layer structure, and the two-layer structure of the thermoplastic resin film is followed by adhesion. The layer 212 and the supporting layer 211, wherein the melting point of the adhesion layer 212 is lower than the softening point of the supporting layer 211. Two pieces of thermoplastic resin film enter the thermoplastic forming device 66, respectively pass through the upper and lower forming molds at the same time, and are thermoformed by a heating compression molding process or a heating vacuum suction process to form two separate longitudinally continuous upper and lower sheets. , The transverse direction is a plurality of connected semi-hexagonal structures, and the semi-hexagonal structure includes spaced semi-hexagonal unit parts and adjacent connecting parts. The two pieces are continuous in the longitudinal direction, and in the transverse direction, a plurality of connected semi-hexagonal structures enter the meshing place of the upper and lower pressing synthetic molds, and press the roller pressure formed by the set gap between the upper and lower pressing synthetic molds. The two pieces are continuous longitudinally and horizontally are the connecting parts of a plurality of connected semi-hexagonal structures, forming a core board of a hexagonal column structure. The core plate of the hexagonal column structure is cooled by the first cooling device 68 and then transferred to the slitting device 63 for cutting. The slitting device 63 performs longitudinally continuous and transversely continuous core plates of a plurality of connected semi-hexagonal column structures. The upper and lower are cut at intervals to form upper and lower separated and partially connected incisions. The core plate is not completely cut off during cutting, but the connecting edges are retained at the incision. After the cutting is completed, the core board is conveyed by the first conveyor belt device 61 to the indexing roller device 64. The roller 641 with indexing teeth in the indexing roller device 64 presses the incision, and the incision is the folding position. The connecting edge at the position is the folding rotation axis. The core plate with the cutout is rotated by plus or minus 90 degrees in the direction of the cut to fold the core plate to form a continuous front and back connected unit. The conveyor belt device 61 is transferred to the hot-melting device 65. The hot-melting device 65 can heat the units connected side by side after being folded. The heating temperature is controlled between the melting point of the adhesion layer 212 and the softening point of the support layer 211, so that the adjacent side walls 2 between the units The heat-melt connection forms the honeycomb core 69. The roll-shaped panel 73a continuously conveys the panel 73, and enters the thermal composite process equipment synchronously with the honeycomb core material 69. The plasma emission device 83 respectively targets the interface layer 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core material. For surface polarity treatment, the heating device 79 heats the upper and lower panels 73 respectively, and passes through the outer main body layer 71 of the panel 73, and the heat transfer path from the outside to the inside, using a mixed heat transfer method of heat conduction and heat convection Heat the upper and lower surfaces 69a of the honeycomb core material and the inner layer 72a of the interface layer of the panel 73 to the set temperature, and immediately enter the hot pressing process, that is, the second conveyor belt device 82 conveys it and then passes through a set of hot pressing composite The roller 80 heats and presses the inner layer 72a of the interface layer of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core material, and then is transported by the second conveyor belt device 82 to the second cooling device 81. After the cold cut process , To complete the production of honeycomb core sandwich composite panels with continuous process flow. The decorative layer 70 is preliminarily hot-pressed during the manufacturing process of the panel 73, or the upper and lower surfaces of the honeycomb core sandwich composite panel formed by cooling are secondarily hot-pressed and bonded to the decorative layer 70 to form a more beautiful honeycomb core sandwich composite panel.

The specific embodiments of the present invention are described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and changes according to the concept of the present invention without creative work. Therefore, all technical solutions that can be obtained by those skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should fall within the protection scope determined by the claims.

Claims

A honeycomb core sandwich composite panel includes a honeycomb core material composed of a plurality of cells arranged in rows. The cells are hexagonal columns surrounded by sidewalls. The sidewalls include a support layer and an adhesion layer, and a support layer and an adhesion layer. The layers are made of different materials. The melting point of the adhesion layer is lower than the softening point of the support layer. The units adjacent to each other in the transverse direction are connected by connecting walls arranged in the transverse direction, and the adjacent side walls of the units adjacent in the longitudinal direction are connected by adhesion. The layers are bonded or laminated to each other;

It is characterized in that the upper and lower surfaces of the honeycomb core material are respectively provided with panels, the panels include a main body layer and an interface layer, and the interface layer is a layer connected to the upper and lower surfaces of the honeycomb core material, respectively. The main body layer is arranged on the interface layer, the main body layer is made of continuous fiber reinforced thermoplastic material, and the interface layer is made of continuous fiber reinforced thermoplastic material or thermoplastic resin film.
The honeycomb core sandwich composite panel of claim 1, wherein the melting point of the thermoplastic resin of the main body layer of the panel is higher than the melting point of the thermoplastic resin of the interface layer of the panel, and the melting point of the interface layer of the panel is It is the same as or compatible with the melting point of the supporting layer of the unit.
The honeycomb core sandwich composite panel according to claim 1, wherein the side wall of the unit has a three-layer structure, and each side of the support layer has a layer of adhesion layer.
The honeycomb core sandwich composite panel according to claim 1, wherein the six side walls of the unit and the connecting wall are respectively provided with at least one reinforcing rib or reinforcing rib parallel to the element line.
The honeycomb core sandwich composite panel according to claim 4, wherein the reinforcing ribs or reinforcing ribs are staggered or aligned on the adjacent or corresponding side walls and the connecting wall of the unit.
The honeycomb core sandwich composite panel according to claim 1, wherein the interface layer of the panel is made of a thermoplastic resin film, and the thickness of the film layer is 0.01-0.5 mm.
The honeycomb core sandwich composite panel of claim 1, wherein the main body layer and the interface layer of the panel are made of the same material, and the fiber content of the main body layer of the panel to the interface layer of the panel is High to low

The weight ratio of the fiber content of each layer constituting the main layer to the corresponding thermoplastic resin is 30-80%, and the weight ratio of the fiber content of each layer constituting the interface layer to the corresponding thermoplastic resin is 20-40%.
The honeycomb core sandwich composite panel of claim 1, wherein the main body layer and the interface layer of the panel are made of different materials, and the main body layer of the panel is made of high-performance continuous fiber reinforced thermoplastic materials. The interface layer of the panel is made of continuous fiber reinforced thermoplastic material or thermoplastic resin film with lower mechanical properties than the main layer.
The honeycomb core sandwich composite panel according to claim 1, wherein the main body layer of the panel is made of at least one layer of continuous fiber reinforced thermoplastic material with different material properties, and the main body of the panel The layer is made of a continuous fiber reinforced thermoplastic sheet with higher performance as the outer layer and a continuous fiber reinforced thermoplastic sheet with lower performance as the adjacent inner layer, or a higher performance continuous fiber reinforced Thermoplastic sheet and low-performance continuous fiber reinforced thermoplastic sheet are designed and manufactured in alternate layers of high and low.
The honeycomb core sandwich composite panel according to claim 1, wherein the panel further comprises a decoration layer, the decoration layer and the interface layer are disposed on both sides of the main body layer, and the decoration layer is Thermoplastic resin film with decorative appearance.
A preparation method of a honeycomb core sandwich composite panel, which is used to manufacture the honeycomb core sandwich composite panel according to any one of claims 1-10, and is characterized in that it comprises the following steps:

S1: The thermoplastic resin film is formed into a longitudinally continuous and transversely connected semi-hexagonal structure through a heating compression molding process or a heating vacuum suction molding process, and the semi-hexagonal structure includes semi-hexagonal shapes distributed at intervals Unit part and adjacent connecting part;

S2: Adopt heating press bonding or ultrasonic heating welding process to align the connecting parts of the two connected semi-hexagonal structures to form a piece of hexagons that are continuous in the longitudinal direction and connected in the transverse direction. Core board of column structure;

S3: Cut the core plates of the multiple connected hexagonal column structures that have been connected into one body at upper and lower intervals to form upper and lower intervals and partially connected incisions. The hexagonal column structure is not cut when cutting. The core plate is completely cut off, but the connecting edge is retained at the cut;

S4: Take the incision as the folding position and the connecting edge of the incision as the folding axis of rotation. The core plate with the incision is rotated by plus or minus 90 degrees in the direction of the incision to fold the core plate, and heat it The adhesive layer in the hot-melt state forms a honeycomb core material in which the side walls of adjacent units are attached to each other;

S5: Laminate the upper and lower surfaces of the honeycomb core material to the panel, so that the interface layer of the panel and the upper and lower surfaces of the honeycomb core material are heated to the set hot melt temperature, and the interface layer of the panel forms the hot melt connection layer and the honeycomb core The upper and lower surfaces of the material are hot-pressed and composited, and then cooled to form a honeycomb core sandwich composite board.
The method for preparing a honeycomb core sandwich composite panel according to claim 11, wherein the thermoplastic resin film for preparing the unit comprises a support layer and an adhesion layer, and the support layer and the adhesion layer are made of different materials. The melting point is lower than the softening point of the support layer. In step S2, two core plates formed by a plurality of longitudinally continuous and transversely connected semi-hexagonal structures are used as the adhesion layer. In step S4, the folding is performed by heating The sidewall adhesion layers of the units connected side by side are thermally fused, wherein the heating temperature is between the melting point of the adhesion layer and the softening point of the support layer.
The method for preparing a honeycomb core sandwich composite panel according to claim 11, wherein the thermoplastic resin film for preparing the unit is a single-layer structure, and in step S1, the single-layer thermoplastic resin film is used as the supporting layer, and The thermal compounding process respectively thermally compound a layer of thermoplastic resin film on both sides of the support layer as the adhesion layer, and the melting point of the adhesion layer is lower than the softening point of the support layer; in step S4, heating is performed to make the units connected side by side after being folded. The adhesion layer on the side wall is thermally fused, and the heating temperature is between the melting point of the adhesion layer and the softening point of the thermoplastic resin film as the support layer.
The method for preparing a honeycomb core sandwich composite panel according to claim 11, wherein the panel is a single structure, and the S5 includes the following steps:

S51: Using extrusion molding or hot pressing to form a hot-melt connection film, the thickness of the hot-melt connection film is 0.01-0.5mm;

S52: Using at least one layer of continuous fiber reinforced thermoplastic material in the panel as the main layer, and bonding a layer of hot-melt connection film on the inner surface of the panel to form an interface layer;

S53: Heat the interface layer between the upper and lower surfaces of the honeycomb core material and the panel to the desired melting point temperature, and heat-press the interface layer of the panel and the upper and lower surfaces of the honeycomb core material Composite, and then cooled and formed into a honeycomb core sandwich composite board.
The method for preparing a honeycomb core sandwich composite panel according to claim 11, wherein the S1 further comprises forming a thermoplastic resin film containing reinforcing ribs or reinforcing ribs through a heating compression molding process or a heating vacuum suction molding process Semi-hexagonal structure, the semi-hexagonal structure containing reinforcing ribs or reinforcing flutes includes spaced semi-hexagonal unit parts and adjacent connecting parts, and the reinforcing ribs or reinforcing flute structures are distributed in the semi-hexagonal structure. The hexagonal unit part and the adjacent connecting part.
The preparation method of the honeycomb core sandwich composite panel according to claim 11, wherein the preparation method further comprises:

S6: Preliminarily heat and press the decorative layer during the preparation process of the panel, or heat and press the decorative layer on the upper and lower surfaces of the honeycomb core sandwich composite panel formed by cooling in advance, and the decorative layer has the appearance and decoration characteristics Thermoplastic resin film.
An equipment for realizing the honeycomb core sandwich composite panel of the preparation method of any one of claims 11-16, comprising:

A first conveyor belt device for continuous conveying between the various processes from the thermoplastic resin film to the honeycomb core material;

A thermoforming device for thermoforming a thermoplastic resin film. The thermoforming device includes an upper and a lower forming mold. The two layers of thermoplastic resin film pass through the upper and lower forming molds respectively, and undergo a heating compression molding process or The heating and vacuum suction molding process forms two pieces of longitudinally continuous and horizontally connected semi-hexagonal structures, the semi-hexagonal structure includes spaced apart semi-hexagonal unit parts and adjacent connecting parts; two pieces Vertically continuous, horizontally, a plurality of connected semi-hexagonal structures enter the meshing place of the upper and lower pressing synthetic molds, and press the two rollers through the set gap between the upper and lower pressing synthetic molds. The connecting part of the semi-hexagonal structure forms a longitudinally continuous core plate with a plurality of connected hexagonal column structures in the transverse direction;

A first cooling device for cooling the core plate of the hexagonal cylindrical structure formed by pressing;

An incision device for cutting a core plate of a hexagonal column structure formed by pressing a plurality of connected semi-hexagonal structures in a longitudinal direction and a transverse direction. The incision device is continuous in the longitudinal direction of two pieces and has a plurality of transversely. The connected semi-hexagonal structure is pressed into an integrated core board to cut upper and lower intervals to form upper and lower intervals and partly connected incisions;

An indexing roller device for folding the core board cut by the slitting device. The indexing roller device folds the core board with the slit to form a continuous unit that is connected side by side and connected side by side. Provide the pushing and squeezing force required when connecting the side walls;

A hot-melting device for heating and melting the core plate folded by the indexing roller device, the hot-melting device heats the units connected side by side after being folded, so that the adjacent side walls between the units are heat-melt connected;

It is characterized in that the equipment also includes:

A second conveyor belt device for continuous conveying between the honeycomb core material and the honeycomb core sandwich composite board;

A heating device for heating the upper and lower surfaces of the honeycomb core material and the panel. The heating device includes an upper and lower contact type heat conduction heating device for heating the upper and lower surfaces of the honeycomb core material and the interface of the panel. The layer is heated to the set temperature;

At least one set of hot-pressing composite rollers for hot-pressing and pressing the upper and lower surfaces of the honeycomb core material and the interface layer of the panel to form a honeycomb core sandwich composite board;

A second cooling device for cooling the honeycomb core sandwich composite board hot-pressed and composited by the hot-pressing composite roller, and the second cooling device includes an upper and a lower contact type cooling device.
17. The equipment for preparing a honeycomb core sandwich composite panel according to claim 17, wherein the indexing pair-roller device comprises a set of rollers with indexing teeth.
The equipment for preparing honeycomb core sandwich composite panels according to claim 17, characterized in that the equipment further comprises an adjacent unit for cooperating with the indexing roller device for cutting, folding, and heating after the steps The squeezing to realize the belt-type pressing device for bonding the side wall of the honeycomb core material.
The equipment for preparing a honeycomb core sandwich composite panel according to claim 17, wherein the equipment further comprises a plasma emission device for polarizing the upper and lower surfaces of the honeycomb core material and the inner surface of the panel .