WO2021147125A1 - 连续蜂窝芯材、蜂窝芯三明治复合板及其制备方法和设备 - Google Patents

连续蜂窝芯材、蜂窝芯三明治复合板及其制备方法和设备 Download PDF

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WO2021147125A1
WO2021147125A1 PCT/CN2020/075505 CN2020075505W WO2021147125A1 WO 2021147125 A1 WO2021147125 A1 WO 2021147125A1 CN 2020075505 W CN2020075505 W CN 2020075505W WO 2021147125 A1 WO2021147125 A1 WO 2021147125A1
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Prior art keywords
honeycomb core
core material
continuous
connecting portion
layer
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PCT/CN2020/075505
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English (en)
French (fr)
Inventor
朱华平
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江苏奇一科技有限公司
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Application filed by 江苏奇一科技有限公司 filed Critical 江苏奇一科技有限公司
Priority to KR1020217038627A priority Critical patent/KR102411970B1/ko
Priority to JP2021569136A priority patent/JP7145345B2/ja
Priority to EP20915059.8A priority patent/EP3928974A4/en
Publication of WO2021147125A1 publication Critical patent/WO2021147125A1/zh
Priority to US17/477,317 priority patent/US11472153B2/en

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    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0089—Producing honeycomb structures
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Definitions

  • the invention belongs to the technical field of honeycomb structures, and more specifically, relates to a continuous honeycomb core material, a honeycomb core sandwich composite board, and a preparation method and equipment thereof.
  • honeycomb core sandwich composite panels have light weight, rigidity and mass ratio.
  • the characteristics of large and good compressive strength are widely used in many fields that require light weight, such as aramid honeycombs and aluminum honeycombs on airplanes, thermoplastic PP honeycomb sandwich composite panels in the transportation field, and paper honeycombs in the packaging industry.
  • Various honeycomb core sandwich composite panels such as backing panels for lightweight components in the photovoltaic industry.
  • the more economical and effective honeycomb core sandwich composite panel production process is to make a honeycomb core material with a narrow width and continuous length in a continuous production process technology, and process the continuous honeycomb core material according to the set length.
  • Cross-cut on-line to make a batch of honeycomb core materials of the same length.
  • a wide and arbitrary length honeycomb core sandwich composite panel is made by bonding or chemical bonding methods such as gluing and compounding.
  • the continuous honeycomb core material production technology includes the Belgian ECONCORE patent number CN101084108B, and the patent number CN105835484A and the American BRADFORD company patent numbers US8303744B2, US8663523B2, US9550336B2 and so on.
  • the continuous honeycomb core material production technology discussed in many of the above patents does not involve the production of wide and arbitrary length honeycomb core sandwiches when the continuous honeycomb core material is cut through online cross-cutting as a downstream secondary processing technology.
  • the effective connection method between the adjacent sections of honeycomb core material in the transverse direction Such a design will cause the defects of material disconnection and discontinuity of the structure when the sections of honeycomb core material adjacent to each other are connected laterally. This defect will reduce the bending strength of the finished honeycomb core sandwich composite panel along the length direction.
  • 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.
  • the present invention further improves and optimizes the structure design of the honeycomb core material on the basis of the continuous honeycomb core material production technology discussed in the patent number ZL201810629486.3 of Jiangsu Qiyi Technology Co., Ltd., and provides the edges of the honeycomb core material adjacent to each other.
  • An effective solution for the connection between departments. Without changing the panel material, structure and composite processing technology, the bending strength of the honeycomb core sandwich composite panel is improved.
  • the present invention provides a continuous honeycomb core material, a honeycomb core sandwich composite panel, and a preparation method and equipment thereof.
  • a continuous honeycomb core material containing a first joint part and a second joint part is made, and the continuous honeycomb core material is cut and cut online to make a section with a constant width or The same continuous honeycomb core material.
  • the length of a section of the continuous honeycomb core material after transverse cutting is used as the width of the honeycomb core material required for the honeycomb core sandwich composite panel.
  • the connecting structure contained in each section of the honeycomb core material the continuous honeycomb core of each adjacent section is formed.
  • the continuous honeycomb core material with the connecting structure is effectively connected by the material, and the honeycomb core sandwich composite board of any width and length is made by the hot-pressing composite process on the upper and lower surfaces and the designed panel. Its characteristic is that it can effectively improve the bending strength of the honeycomb core sandwich composite panel along the running direction without changing the panel material, structure and composite processing technology.
  • the present invention provides a continuous honeycomb core material, including a honeycomb core material, the honeycomb core material includes a plurality of cells arranged in rows, and the cells are hexagonal columns surrounded by side walls, and the side walls include a support layer And the 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. Adjacent side walls of the unit are bonded or attached to each other through the adhesion layer;
  • a joint structure is provided between the adjacent honeycomb core materials.
  • the joint structure includes a first joint part and a second joint part corresponding to the first joint part.
  • the first joint part and the second joint part are respectively located in the honeycomb Different sides on the two lateral sides of the core material form a continuous honeycomb core material, and the first connecting part of one segment of the continuous honeycomb core material is connected to the second connecting part of the other segment of the continuous honeycomb core material to form the connecting structure.
  • first connecting portion of one segment of the continuous honeycomb core material and the second connecting portion of the other segment of the continuous honeycomb core material are alternately arranged to form an engaging structure with a quadrilateral or hexagonal cross-sectional shape.
  • first connecting portion of one segment of the continuous honeycomb core material and the second connecting portion of the other segment of the continuous honeycomb core material are attached to each other to form an engaging structure with a trapezoidal cross-sectional shape, wherein the cross-section of the first engaging portion
  • the shape is an inner figure eight
  • the cross-sectional shape of the second connecting portion is an outer figure eight.
  • first connecting portion of one segment of the continuous honeycomb core material and the second connecting portion of the other segment of the continuous honeycomb core material are attached to each other to form a cross-shaped connecting structure, wherein the first connecting portion and The cross-sectional shapes of the second connecting parts are all T-shaped.
  • first connecting portion of one segment of the continuous honeycomb core material is inserted into the second connecting portion of the other segment of the continuous honeycomb core material to form an engaging structure with a quadrangular cross-sectional shape, and the first connecting portion is stuck in the second
  • the groove formed by the connecting portion forms the connection of two adjacent segments of the continuous honeycomb core material, wherein the cross-sectional shape of the first connecting portion is in the shape of an inner figure.
  • first connecting portion of one segment of the continuous honeycomb core material is inserted into the second connecting portion of the other segment of the continuous honeycomb core material to form an engaging structure with a hexagonal cross-sectional shape, and the first connecting portion is stuck in the In the groove formed by the second connecting portion, a connection between two adjacent sections of the continuous honeycomb core material is formed.
  • first connecting portion of one segment of the continuous honeycomb core material is inserted into the second connecting portion of the other segment of the continuous honeycomb core material to form an engaging structure with a hexagonal cross-sectional shape, wherein the cross-sectional shape of the first engaging portion It is a hexagonal structure with openings, and the cross-sectional shape of the second connecting portion is Y-shaped.
  • first connecting portion of one segment of the continuous honeycomb core material is inserted into the second connecting portion of the other segment of the continuous honeycomb core material to form an engaging structure with a pentagonal cross-sectional shape, wherein the cross-sectional shape of the first engaging portion It is a pentagonal structure with openings, and the cross-sectional shape of the second connecting portion is T-shaped.
  • first connecting portion and the second connecting portion are respectively provided with at least one barb structure, the first connecting portion of a section of the continuous honeycomb core material and the second section of the continuous honeycomb core material
  • the barb structures in the connecting part are connected to each other to form a connecting structure.
  • the structure or shape of the first connecting portion and the second connecting portion of the continuous honeycomb core material are the same.
  • the structure or shape of the first connecting portion and the second connecting portion of the continuous honeycomb core material are different.
  • the side wall of the unit has a three-layer structure, wherein there is an adhesion layer on each side of the support layer.
  • the present invention also provides a honeycomb core sandwich composite panel, which includes at least two continuous honeycomb core materials as described in any one of the above, and a continuous honeycomb core material containing a connecting structure is formed through the connecting structure, and Panels respectively provided on the upper and lower surfaces of the continuous honeycomb core material with a connecting structure;
  • the panel includes a main body layer and an interface layer, the interface layer is a layer connected to the upper and lower surfaces of the continuous honeycomb core material containing the connecting structure, the main body layer is arranged on the interface layer, and the main body
  • the layer is made of continuous fiber reinforced thermoplastic material
  • the interface layer is made of continuous fiber reinforced thermoplastic material or thermoplastic resin film.
  • the present invention also provides a method for preparing a honeycomb core sandwich composite panel, which is used to manufacture the aforementioned honeycomb core sandwich composite panel, and includes the following steps:
  • thermoplastic resin film is formed into a plurality of connected semi-hexagonal structures longitudinally continuous and transversely through a heating compression molding process or a heating vacuum suction molding process, and the plurality of connected semi-hexagonal structures include spaced-apart semi-hexagonal structures.
  • Half-hexagonal unit parts, adjacent connecting parts, and first and second semi-joining parts respectively provided on both sides;
  • At least two sections of continuous honeycomb core material with a certain width are connected by a connecting structure to form a continuous honeycomb core material with a connecting structure, and heating makes the upper and lower surfaces of the continuous honeycomb core material with a connecting structure and the interface layer of the panel reach the setting The heat-melting temperature is hot-pressed and composited, and then cooled to form a honeycomb core sandwich composite board.
  • the first connecting part of a section of continuous honeycomb core material and the second connecting part of another section of continuous honeycomb core material can be connected by facing each other, or by inserting up and down, and can be connected in a horizontal direction or a vertical direction. , But not limited to what is stated here.
  • thermoplastic resin film of the preparation 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. It is a plurality of connected hexagonal column structures and the sides of the lateral sides respectively contain the first joint part and the second joint part.
  • the outer side of the core plate is an adhesion layer.
  • the units are connected side by side after being folded by heating.
  • the sidewall adhesion layer is hot-melt connected, and the heating temperature is between the melting point of the adhesion layer and the softening point of the support layer.
  • thermoplastic resin film of the preparation unit has a single-layer structure.
  • the single-layer thermoplastic resin film is used as the support layer, and a thermal composite process is used to thermally composite a layer of thermoplastic resin on both sides of the support layer.
  • the 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 sidewall adhesion layers of the units connected side by side after folding heat-melt connection, wherein the heating temperature is at the melting point of the adhesion layer and serves as the support Layer between the softening points of the thermoplastic resin film.
  • the panel is a single structure, and the S6 further includes the following steps:
  • At least one layer of continuous fiber reinforced thermoplastic material is used as the main body layer on the outer side of the panel, and a hot-melt connection film is bonded on the inner surface of the panel to form an interface layer;
  • a hot-melt connection film is formed on the inner surface of the panel through an extrusion molding or thermal compounding process, and the thickness of the hot-melt connection film is 0.01-0.5 mm;
  • At least two sections of continuous honeycomb core material with a constant width are connected by a connecting structure to form the continuous honeycomb core material containing the connecting structure, and heating makes the upper and lower surfaces of the continuous honeycomb core material containing the connecting structure contact the surface of the continuous honeycomb core material.
  • the interface layer of the panel reaches the set hot-melt temperature, undergoes hot-compression composite, and then cools and forms a honeycomb core sandwich composite board.
  • preparation method further includes:
  • S7 Preliminarily heat-press and paste the decorative layer during the preparation process of the panel, or heat-press and paste the decorative layer on the upper and lower surfaces of the honeycomb core sandwich composite panel formed by cooling in advance.
  • the decorative layer has the appearance and decoration characteristics.
  • Thermoplastic resin film is
  • the present invention also provides a preparation device of a honeycomb core sandwich composite panel, which is used to realize the preparation method of a honeycomb core sandwich composite panel according to any one of the above, including:
  • a first conveyor belt device used to realize continuous transmission from the thermoplastic resin film to the honeycomb core sandwich composite board
  • 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 vacuum suction molding process forms two pieces of longitudinally continuous and transversely connected semi-hexagonal structures.
  • the multiple connected semi-hexagonal structures include semi-hexagonal unit parts distributed at intervals, adjacently connected Part and the first half-joining part and the second half-joining part respectively arranged on both sides; two pieces of longitudinally continuous and transversely connected semi-hexagonal structures enter the meshing place of the upper and lower pressing synthetic molds, Through the counter-roll pressure formed by the gap between the upper and lower pressing synthetic molds, the two pieces of longitudinally continuous and transversely connected semi-hexagonal structures are pressed together to form a piece of longitudinally continuous and transversely connected parts.
  • a plurality of connected hexagonal column structures, and the side portions on both sides of the transverse direction respectively contain the core plates of the first connecting portion and the second connecting portion;
  • a slitting device for cutting the core plate cooled by the first cooling device the slitting device cuts the core plate cooled by the first cooling device at an upper and lower interval to form an upper and lower interval And partly connected incision;
  • An indexing roller device for folding the core plate cut by the incision device folds the core plate with the incision to form a continuous unit that is connected side by side in front and back, and provides The pushing force required when the side walls are connected;
  • a hot-melting device for heating and melting the core plate folded by the indexing roller device.
  • the hot-melting device heats the folded units connected side by side to heat-melt the adjacent side walls between the units to make Continuous honeycomb core material;
  • An unwinding mechanism for unwinding the upper and lower panels of the roll includes an upper panel unwinding mechanism and a lower panel unwinding mechanism;
  • the preparation equipment also includes the following equipment:
  • a first cutting device for transversely cutting the continuous honeycomb core material according to a set length
  • a hot-pressing laminating machine for hot-pressing and laminating the upper and lower surfaces of the continuous honeycomb core material with a connecting structure and the panel to form a honeycomb core sandwich composite board.
  • the hot-pressing laminating machine includes a heating device, a hot-pressing composite roller, and a second The second cooling device and the second conveyor belt device.
  • the preparation equipment also includes a packing device for stacking and packaging a section of continuous honeycomb core material with a certain width.
  • the preparation equipment also includes a slitting device for longitudinally trimming the longitudinal sides of the honeycomb core sandwich composite panel.
  • the preparation equipment also includes a second cutting device for transversely cutting the honeycomb core sandwich composite board according to a set length.
  • the present invention achieves the beneficial effects: by optimizing and improving the structure of the honeycomb core material, the bending strength of the honeycomb core sandwich composite panel is improved without changing the panel material, structure and composite processing technology. . Not only the preparation method is simple, less materials are used to obtain better mechanical properties, and the production cost is reduced, but also a wide and arbitrary length honeycomb core sandwich composite panel can be made from multiple sections of continuous honeycomb core materials with constant or same width.
  • Fig. 1 is a schematic structural diagram of a continuous honeycomb core material according to an embodiment of the present invention
  • Figure 1a is a schematic structural view of a continuous honeycomb core material containing a connecting structure according to an embodiment of the present invention
  • FIG. 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;
  • FIG. 3 is a schematic plan view of a continuous honeycomb core material with a cross-sectional shape of a quadrangular joint structure formed by staggered joints according to an embodiment of the present invention
  • FIG. 4 is a schematic plan view of a continuous honeycomb core material with a cross-sectional shape of a hexagonal joint structure formed by staggered joints according to an embodiment of the present invention
  • Fig. 4a is an enlarged schematic diagram of the connecting structure at A in Fig. 4;
  • 4b is a schematic view of the overall structure of a continuous honeycomb core material with a hexagonal cross-sectional shape of the continuous honeycomb core material according to the embodiment of the present invention
  • FIG. 5 is a schematic plan view of the continuous honeycomb core material of the embodiment of the present invention, which is laminated and joined to form a joint structure with a trapezoidal cross-sectional shape;
  • FIG. 6 is a schematic plan view of the continuous honeycomb core material of the embodiment of the present invention that is laminated and connected to form a cross-sectional connection structure of the continuous honeycomb core material;
  • Fig. 6a is an enlarged schematic diagram of the connection structure at A in Fig. 6;
  • 6b is a schematic diagram of the overall structure of the continuous honeycomb core material of the embodiment of the present invention that is bonded and joined to form a cross-shaped joint structure;
  • Fig. 7 is a schematic plan view of a continuous honeycomb core material with a quadrilateral cross-sectional shape by inserting and joining to form a joining structure according to an embodiment of the present invention
  • FIG. 8 is a schematic plan view of a continuous honeycomb core material inserted into a joint structure with a hexagonal cross-sectional shape according to an embodiment of the present invention
  • Fig. 8a is an enlarged schematic diagram of the connection structure at A in Fig. 8;
  • FIG. 8b is a schematic diagram of the overall structure of a continuous honeycomb core material inserted into a joint structure with a hexagonal cross-sectional shape according to an embodiment of the present invention
  • FIG. 9 is a schematic plan view of another continuous honeycomb core material inserted into a joint structure with a hexagonal cross-sectional shape according to an embodiment of the present invention.
  • Fig. 9a is an enlarged schematic diagram of the connection structure at A in Fig. 9;
  • 9b is a schematic diagram of the overall structure of another continuous honeycomb core material inserted into a joint structure with a hexagonal cross-sectional shape according to an embodiment of the present invention.
  • FIG. 10 is a schematic plan view of a continuous honeycomb core material with a pentagonal cross-sectional shape by inserting and joining to form a joint structure according to an embodiment of the present invention
  • Fig. 10a is an enlarged schematic diagram of the connection structure at A in Fig. 10;
  • 10b is a schematic diagram of the overall structure of a continuous honeycomb core material inserted into a joint structure with a pentagonal cross-sectional shape according to an embodiment of the present invention
  • FIG. 11 is a schematic plan view of a continuous honeycomb core material in which barbs are connected to form a barb structure-containing connection structure according to an embodiment of the present invention
  • Fig. 11a is an enlarged schematic diagram of the connecting structure at A in Fig. 11;
  • 11b is a schematic diagram of the overall structure of a continuous honeycomb core material in which barbs are connected to form a barb structure-containing connection structure according to an embodiment of the present invention
  • FIG. 12 is a schematic diagram of forming a core board during the preparation process of the honeycomb core sandwich composite board according to an embodiment of the present invention
  • FIG. 13 is a schematic diagram of the structure of the panel of the embodiment of the present invention.
  • Fig. 13a is a schematic structural view of a panel containing a decorative layer according to an embodiment of the present invention.
  • Figure 14 is a schematic structural view of a honeycomb core sandwich composite panel according to an embodiment of the present invention.
  • Fig. 14a 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. 15 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
  • Figure 16 is a schematic diagram of a continuous honeycomb core material preparation equipment according to an embodiment of the present invention.
  • Fig. 17 is a schematic diagram of a preparation equipment for a honeycomb core sandwich composite panel according to an embodiment of the present invention.
  • 1 unit 110 continuous honeycomb core material, 111, 111a, 111b, 111c, 111d, 111e, 111f, 111g, 111h, 111i first connection part, 112, 112a, 112b, 112c, 112d, 112e, 112f, 112g , 112h, 112i second connecting part, 113, 113a, 113b, 113c, 113d, 113e, 113f, 113g, 113h, 113i connecting structure, 114 barbed structure, 2 side walls, 21 adjacent side walls, 211 supporting layer, 212 adhesion layer, 3 connecting wall, 40 half hexagon unit part, 41 connecting part, 42 first half connecting part, 43 second half connecting part, 61 first conveyor belt device, 62 thermoforming device, 63 cutting device , 64 indexing roller device, 65 hot-melt device, 66 extrusion device, 67 pressing device, 68 first cooling device, 69 continuous honeycomb core material containing the joint structure,
  • the continuous honeycomb core material 110 includes a honeycomb core material, which includes a plurality of cells 1 arranged in rows.
  • the connecting walls 3 arranged horizontally are connected, and the longitudinally adjacent units 1 are attached to or adhered to each other through adjacent side walls 21.
  • 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.
  • a connecting structure 113 is provided between adjacent honeycomb core materials.
  • the connecting structure 113 includes a first connecting portion 111 and a second connecting portion 112 corresponding to it.
  • the first connecting portion 111 and the second connecting portion 112 are located at different sides of the honeycomb core material on both lateral sides to form a continuous honeycomb core material 110.
  • the first connecting portion 111 of one segment of the continuous honeycomb core material 110 is connected to the second connecting portion 112 of another segment of the continuous honeycomb core material 110 to form a connecting structure 113.
  • At least two continuous honeycomb core materials 110 are connected by a connecting structure 113 to form a continuous honeycomb core material 69 containing a connecting structure.
  • 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.
  • 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.
  • 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.
  • 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 improving the compressive strength of the honeycomb core material.
  • 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.
  • 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.
  • 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.
  • suitable fiber reinforced thermoplastic 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
  • 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.
  • a core plate composed of a plurality of connected hexagonal column structures in a longitudinal direction and a transverse direction, and the sides on both sides of the transverse direction respectively contain a first connecting portion 111 and a second connecting portion 112.
  • a plurality of connected semi-hexagonal structures are formed by pressing together, wherein the plurality of connected semi-hexagonal structures includes semi-hexagonal unit parts 40 distributed at intervals, adjacent connecting parts 41 and two The first half-connecting portion 42 and the second half-connecting portion 43 of the side portion.
  • the panel 73 of the honeycomb core sandwich composite board is made by the main body layer 71 and the interface layer 72 through the superimposed layer design through the heating composite process.
  • 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
  • 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, 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, and the melting point of the interface layer 72 is the same as or compatible with the melting point of the support layer 211 .
  • 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. It is designed and manufactured with alternating high and low layers.
  • the panel 73 further includes a decoration layer 70, the decoration layer 70 is disposed on the outer side of the main body layer 71, and the inner side of the main body layer 71 is an interface layer 72.
  • the decoration layer 70 is made of a thermoplastic resin film material, and may 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.
  • the honeycomb core sandwich composite panel includes at least two continuous honeycomb core materials 110 connected by a connecting structure 113 to form a continuous honeycomb core material 69 containing a connecting structure and arranged on the continuous honeycomb core material containing the connecting structure, The panel 73 of the lower surface 69a.
  • the upper and lower panels 73 are respectively attached to the upper and lower surfaces of the continuous honeycomb core material containing the connecting structure, and the honeycomb core sandwich composite panel is finally formed by hot pressing and compounding.
  • 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 continuous honeycomb core material containing the connecting structure.
  • the force F and the reaction force F required are according to Figure 17, Or similar thermal composite process equipment to produce the key process design parameters of high-performance honeycomb core sandwich composite panels.
  • the first connecting portion 111a of a segment of continuous honeycomb core material and the second connecting portion 112a of another segment of continuous honeycomb core material are alternately arranged to form an engaging structure 113a with a quadrangular cross-sectional shape.
  • the first connecting portion 111b of a continuous honeycomb core material and the second connecting portion 112b of another continuous honeycomb core material are alternately arranged to form an engaging structure 113b with a hexagonal cross-sectional shape.
  • the first connecting portion 111c of a section of continuous honeycomb core material and the second connecting portion 112c of another section of continuous honeycomb core material are attached to each other to form an engaging structure 113c with a trapezoidal cross-sectional shape.
  • the cross-sectional shape is an inner figure eight
  • the cross-sectional shape of the second connecting portion 112c is an outer figure eight.
  • first connecting portion 111d of a section of continuous honeycomb core material and the second connecting portion 112d of another section of continuous honeycomb core material are attached to each other to form an engaging structure 113d with a cross-shaped cross-sectional shape.
  • the cross-sectional shapes of the connecting portion 111d and the second connecting portion 112d are both T-shaped.
  • the first connecting portion 111e of a section of continuous honeycomb core material is inserted into the second connecting portion 112e of another section of continuous honeycomb core material to form a connecting structure 113e with a quadrangular cross-sectional shape, and the first connecting portion 111e is stuck in the second connecting portion
  • the groove formed by the portion 112e forms a connection between two adjacent sections of continuous honeycomb core material, wherein the cross-sectional shape of the first connection portion 111e is an inner figure eight.
  • the first connecting portion 111f of a section of continuous honeycomb core material is inserted into the second connecting portion 112f of another section of continuous honeycomb core material to form a connecting structure 113f with a hexagonal cross-sectional shape, and the first connecting portion 111f It is caught in the groove formed by the second connecting portion 112f to form the connection of two adjacent sections of continuous honeycomb core material.
  • the first connecting portion 111g of one segment of continuous honeycomb core material is inserted into the second connecting portion 112g of another segment of continuous honeycomb core material to form an engaging structure 113g with a hexagonal cross-sectional shape, wherein the first engaging portion
  • the cross-sectional shape of 111g is a hexagonal structure with openings
  • the cross-sectional shape of the second connecting portion 112g is Y-shaped.
  • the first connecting portion 111g is clamped in the groove formed by the second connecting portion 112g to form a connection between two adjacent sections of continuous honeycomb core material.
  • the first connecting portion 111g of a section of continuous honeycomb core material and the second connecting portion 112g of another section of continuous honeycomb core material are connected by up-and-down insertion.
  • the first connecting portion 111h of a section of continuous honeycomb core material is inserted into the second connecting portion 112h of another section of continuous honeycomb core material to form a connecting structure 113h with a pentagonal cross-sectional shape, wherein the first connecting portion
  • the cross-sectional shape of 111h is a pentagonal structure with openings
  • the cross-sectional shape of the second connecting portion 112h is T-shaped.
  • the first connecting portion 111h is clamped in the groove formed by the second connecting portion 112h to form a connection between two adjacent sections of continuous honeycomb core material.
  • the first connecting portion 111h of a section of continuous honeycomb core material and the second connecting portion 112h of another section of continuous honeycomb core material are connected by up and down insertion.
  • the first connecting portion 111i and the second connecting portion 112i are respectively provided with at least one barb structure 114, the first connecting portion 111i of a continuous honeycomb core material and the other continuous honeycomb core material
  • the barb structures 114 in the second connecting portion 112i are connected to each other to form a connecting structure 113i with a quadrilateral cross-sectional shape.
  • the structure or shape of the first connecting portion 111 and the second connecting portion 112 of the continuous honeycomb core material may be the same, and the first connecting portion 111 of the continuous honeycomb core material
  • the structure or shape of the second connecting portion 112 may be different.
  • the cross-sectional shapes of the first connecting portion and the second connecting portion include polygons such as quadrilaterals, pentagons, and hexagons, but are not limited to those stated here.
  • the connection mode of the first connecting portion of a continuous honeycomb core material and the second connecting portion of another continuous honeycomb core material includes staggered connection, fit connection, insertion connection, barb connection, etc., but is not limited to what is stated here.
  • thermoplastic resin film As shown in FIG. 15, 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 has a low melting point. It is at the softening point of the support layer 211.
  • the preparation method includes the following steps:
  • thermoplastic resin film is formed into a plurality of connected semi-hexagonal structures in the longitudinal direction and the transverse direction through the heating compression molding process or the heating vacuum suction molding process, and the multiple connected semi-hexagonal structures include the semi-hexagons distributed at intervals A polygonal unit portion 40, adjacent connecting portions 41, and a first half-connecting portion 42 and a second half-connecting portion 43 provided on both sides;
  • Adopt heating pressing or ultrasonic heating welding process to align and connect the two connecting parts 41 of the semi-hexagonal structure that are continuous in the longitudinal direction and in the transverse direction, so as to form a piece of continuous longitudinally and multiple transversely.
  • the connecting parts 42 connected to each other form the connecting wall 3 connecting the transversely adjacent units 1.
  • the first half-connecting part 42 and the second half-connecting part 43 of the lateral sides in the core plate are respectively attached to each other to form the first In the connecting portion 111 and the second connecting portion 112, the adjacent side walls 21 of the longitudinally adjacent units are attached to each other, and the adhesive layer 212 in the hot-melt state is formed on the adjacent side walls 21 of the longitudinally adjacent units after being folded.
  • the adjacent side walls 21 are attached to each other to form a continuous honeycomb core material 110; wherein the heating temperature is between the melting point of the adhesion layer 212 and the softening point of the support layer 211, thereby effectively maintaining the cell geometry while obtaining a higher phase
  • the adhesion strength of adjacent side walls improves the compressive strength of the continuous honeycomb core material
  • S6 At least two sections of continuous honeycomb core material 110 with a constant width are connected by a connecting structure 113 to form a continuous honeycomb core material 69 containing a connecting structure.
  • the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure are attached to the upper and lower surfaces, respectively.
  • the panel 73 is heated so that the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure and the interface layer 72 of the panel 73 reach the set hot-melt temperature, perform hot-compression composite, and then cool to form a honeycomb core sandwich Composite board.
  • first connecting portion 111 of a section of continuous honeycomb core material and the second connecting portion 112 of another section of continuous honeycomb core material can be connected by facing each other, or by inserting up and down, which can be connected horizontally or vertically. The direction is connected, but not limited to what is stated here.
  • the thermoplastic resin 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, and the melting point of the adhesion layer 212 is lower than the softening point of the support layer 211,
  • step S2 a vertically-longitudinal-continuous, horizontally-connected hexagonal column structure is adopted, and the sides on both sides of the lateral direction respectively contain the first connecting portion 111 and the second connecting portion 112.
  • the outer side of the core plate is the adhesion layer 212.
  • the sidewall adhesion layers 212 of the folded units connected side by side are thermally welded by heating, wherein the heating temperature is between the melting point of the adhesion layer 212 and the softening point of the support layer 211.
  • the thermoplastic resin film of the preparation unit 1 has a single-layer structure.
  • step S1 the single-layer thermoplastic resin film is used as the support layer 211, and the thermal compound process is used to heat the two sides of the support layer 211.
  • a layer of thermoplastic resin film is laminated as the adhesion layer 212, the melting point of the adhesion layer 212 is lower than the softening point of the support layer 211; in step S4, heating makes the sidewall adhesion layer 212 of the unit connected side by side after folding heat-melt connection, wherein the heating The temperature is between the melting point of the adhesion layer 212 and the softening point of the thermoplastic resin film as the support layer 211.
  • 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.
  • the single structure is the main layer 71.
  • S6 also includes the following steps:
  • At least one layer of continuous fiber reinforced thermoplastic material is used as the main body layer 71 on the outer side of the panel 73, and a hot-melt connection film is adhered to the inner surface of the panel 73 to form a bonded interface layer 72;
  • a hot-melt connection film is formed on the inner surface of the panel 73 by extrusion molding or thermal compounding process, and the thickness of the hot-melt connection film is 0.01-0.5mm;
  • At least two sections of continuous honeycomb core material 110 with a constant width are connected by a connecting structure 113 to form a continuous honeycomb core material 69 containing a connecting structure, and heating makes the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure stick to the panel
  • the interface layer 72 of 73 reaches the set hot-melt temperature, performs hot-compression composite, and then cools and forms a honeycomb core sandwich composite board.
  • the preparation method further includes:
  • the decorative layer 70 is thermally pressed and pasted in advance during the preparation process of the panel 73, or the upper and lower surfaces of the honeycomb core sandwich composite panel formed by cooling are thermally pressed and pasted to the decorative layer 70 twice, and the decorative layer 70 has an appearance decoration Features or fire-resistant, anti-scalding thermoplastic resin film.
  • a specific embodiment of the preparation equipment of the honeycomb core sandwich composite panel of the present invention includes a first conveyor belt device 61, a thermoplastic molding device 62, a slitting device 63, an indexing roller device 64, and a second A cooling device 68, a hot melt device 65, a hot-pressing compound machine 91, a lower panel unwinding mechanism 92, an upper panel unwinding mechanism 93, a pushing mechanism 94, a pushing mechanism 95, a slitting device 97, and a second cutting device 98.
  • a first conveyor belt device 61 for realizing continuous transfer between the various processes from the thermoplastic resin film to the honeycomb core sandwich composite board.
  • thermoforming device 62 for thermoforming a thermoplastic resin film.
  • the thermoforming device 62 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 vacuum suction molding process forms two pieces of longitudinally continuous and transversely connected semi-hexagonal structures.
  • the multiple connected semi-hexagonal structures include semi-hexagonal unit parts 40 distributed at intervals, and adjacent connecting parts 41 and the first half-joining portion 42 and the second half-joining portion 43 arranged on both sides of the transverse direction; two pieces of longitudinally continuous and transversely connected semi-hexagonal structures enter into the meshing of the upper and lower pressing synthetic molds At the place, through the counter-roll pressure formed by the set gap between the upper and lower pressing synthetic molds, the two pieces of longitudinally continuous and transversely connected semi-hexagonal connecting parts 42 are pressed together to form a longitudinally continuous piece.
  • the transverse direction is a core board with a plurality of connected hexagonal column structures and the sides on both sides of the transverse direction contain the first connecting portion 111 and the second connecting portion 112.
  • a cooling device 68 may be an air cooling device.
  • An incision device 63 for cutting the core plate cooled by the first cooling device The incision device 63 cuts the core plate cooled by the first cooling device 68 at an upper and lower interval to form an upper and lower interval and Partially connected incision.
  • the cutting device 63 may be a device for cutting by means of metal or non-metal blade cutting, laser cutting, high-pressure hydraulic cutting, wire cutting, resistance wire cutting, or plasma cutting.
  • the indexing roller device 64 folds the core plate with the slit to form a continuous front and back connected unit, and provide side The pushing force required when the walls are connected.
  • the indexing roller device 64 includes a set of rollers with indexing teeth.
  • the thickness of the continuous honeycomb core material is used as the indexing reference to apply pressure to the incision, and the indexing roller device 64 is transported by the first roller by setting the indexing roller device 64
  • the difference between the speed of the belt device 61 and the linear speed of the indexing wheel realizes that the horizontal unit after the incision is folded and rotated by about 90 degrees, and the unit is folded to form a continuous unit that is connected side by side.
  • the hot-melting device 65 heats the folded units connected side by side, so that the adjacent side walls between the units are thermally connected to form a continuous Honeycomb core material 110.
  • the heating temperature can be controlled between the melting point of the adhesion layer 212 of the side wall and the softening point of the support layer 211, so as to effectively maintain the cell geometry while obtaining higher bonding strength of adjacent side walls and improve the continuous honeycomb core
  • the compressive strength of the material 110 can be controlled between the melting point of the adhesion layer 212 of the side wall and the softening point of the support layer 211, so as to effectively maintain the cell geometry while obtaining higher bonding strength of adjacent side walls and improve the continuous honeycomb core The compressive strength of the material 110.
  • the unwinding mechanism for realizing the unwinding of the upper and lower panels 73 in a roll.
  • the unwinding mechanism includes an upper panel unwinding mechanism 92 and a lower panel unwinding mechanism 93.
  • the preparation equipment also includes the following equipment:
  • a first cutting device for transversely cutting the continuous honeycomb core material according to a set length can be entanglement cutting, infrared cutting, or laser cutting, but is not limited to what is stated here.
  • a pushing mechanism 94 for orderly conveying the continuous honeycomb core material formed by transverse cutting by the first cutting device to the set position.
  • a hot-pressing laminating machine 91 for hot-pressing and laminating the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure and the panel 73 to form a honeycomb core sandwich composite board.
  • the hot-pressing laminating machine 91 includes a heating device 79 and a hot-pressing composite. Roller 80, second cooling device 81, and second conveyor belt device 82.
  • the second conveyor belt device 82 is used to realize the continuous transfer from the continuous honeycomb core material containing the connecting structure to the honeycomb core sandwich composite board, which is resistant to high temperature and prevents hot melt adhesive adhesion.
  • the second conveyor belt device 82 may 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 for hot-pressing composite the interface layer 72 of the panel 73 and the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure;
  • 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.
  • the honeycomb core sandwich composite board preparation equipment of the present invention may also include a packing device for stacking and packaging a section of continuous honeycomb core material with a constant or same width.
  • the honeycomb core sandwich composite panel preparation equipment of the present invention can also include a slitting device 97 for longitudinal trimming on both longitudinal sides of the honeycomb core sandwich composite panel.
  • the honeycomb core sandwich composite panel preparation equipment of the present invention can also include a second cutting device 98 for transversely cutting the honeycomb core sandwich composite panel according to a set length.
  • the device can be entanglement cutting, infrared cutting, or laser cutting, etc. , But not limited to what is stated here.
  • the manufacturing equipment of the honeycomb core sandwich composite panel of the present invention may further include an extrusion device 66 for preparing a thermoplastic resin film for extruding to form the thermoplastic resin film used as a raw material.
  • the preparation device of the honeycomb core sandwich composite panel of the present invention may also include a pressing device 67 for pressing the two formed sheets continuous in the longitudinal direction and a plurality of connected semi-hexagonal structures in the transverse direction to form a longitudinally continuous and a plurality of transversely connected semi-hexagonal structures.
  • the connected hexagonal column structure and the sides on both sides of the transverse direction contain the core plates of the first joint part and the second joint part.
  • the honeycomb core sandwich composite panel preparation equipment of the present invention may further include a traction mechanism 96 for pulling the honeycomb core sandwich composite panel.
  • the honeycomb core sandwich composite panel preparation equipment of the present invention may further include a drop-off device 99 for automatically stacking the honeycomb core sandwich composite panels that have been longitudinally trimmed and trimmed by the slitting device 97 and transversely cut by the second cutting device 98.
  • 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 melting point of the adhesion layer 212 is lower than the softening point of the support layer 211.
  • the two layers of thermoplastic resin film are respectively passed through the upper and lower molding dies, and are heated through a heating compression molding process or a heated vacuum suction molding process to form two longitudinally continuous and transversely connected semi-hexagonal structures, and multiple connected semi-hexagonal structures.
  • the polygonal structure includes semi-hexagonal unit parts 40 distributed at intervals, adjacent connecting parts 41, and first and second semi-joining parts 42 and 43 arranged on both lateral sides of the transverse direction; the two longitudinally continuous and transversely continuous parts
  • the connecting portion 41 of a plurality of connected semi-hexagonal structures in the horizontal direction forms a piece of hexagonal column structure which is continuous in the longitudinal direction and a plurality of connected in the horizontal direction.
  • the sides on both sides of the horizontal direction contain a first connecting portion 111 and a second connecting portion 111.
  • the core plate which is continuous in the longitudinal direction and in the transverse direction, is a plurality of connected hexagonal column structures, and the sides on both sides of the transverse direction contain the first connecting portion 111 and the second connecting portion 112, which are cooled by the first cooling device 68 and then sent to the cutting device 63
  • the cutting device 63 performs upper and lower spacing on a core plate with a longitudinally continuous and transversely connected hexagonal column structure and the sides on both sides of the transverse direction contain the first connecting portion 111 and the second connecting portion 112.
  • the core plate is not completely cut off during cutting, but the connecting edges are retained at the incisions.
  • the core board is conveyed by the first conveyor belt device 61 to the indexing roller device 64.
  • the roller with indexing teeth in the indexing roller device 64 presses the incision.
  • the incision is the folding position and the incision is
  • the connecting side is the folding rotation axis, and the core plate with the incision is rotated by positive or negative 90 degrees in the direction of the incision to fold the core plate to form a continuous front and rear side-by-side connected unit.
  • a conveyor belt device 61 is transported 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 between the units 2 Hot melt connection to form a continuous honeycomb core material 110.
  • the continuous honeycomb core material 110 is cut by the first cutting device to form a section of the continuous honeycomb core material 110 with a constant or same width.
  • the lower panel unwinding mechanism 92 continuously conveys the lower panel, and the upper panel unwinding mechanism 93 continuously conveys the upper panel.
  • the upper and lower panels 73 and the continuous honeycomb core material 110 with constant or the same width enter the hot-pressing compound machine along with the third conveyor belt device. 90.
  • At least two continuous honeycomb core materials 110 are pushed by the pushing mechanism 95, so as to form a continuous honeycomb core material 69 with a connecting structure.
  • 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.
  • the honeycomb containing the connecting structure is transferred by a mixed heat transfer method of heat conduction and heat convection.
  • the upper and lower surfaces 69a of the core material and the interface layer 72 of the panel 73 are heated 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 at least one set of hot pressing composite rollers 80
  • the interface layer 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the continuous honeycomb core material containing the connecting structure are hot-pressed and composited, and then transported by the second conveyor belt device 82 to the second cooling device 81, after the cooling process , To complete the production of honeycomb core sandwich composite panels with continuous process flow.
  • the honeycomb core sandwich composite panel is drawn into the slitting device 97 by the traction mechanism 96, and the longitudinal sides of the honeycomb core sandwich composite panel are longitudinally trimmed by the slitting device 97, and then sent to the second cutting device 98, and then cut by the second cutting device.
  • the device 98 performs transverse cutting according to the set length to form the final honeycomb core sandwich composite panel.
  • the first connecting portion and the second connecting portion are provided on the lateral sides of the honeycomb core material, and the first connecting portion of a continuous honeycomb core material and the second connecting part of another continuous honeycomb core material are passed through.
  • the connecting parts are connected to form a connecting structure, which can further manufacture wide and arbitrary length honeycomb core sandwich composite panels, and improve the bending strength of the honeycomb core sandwich composite panels.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
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Abstract

一种连续蜂窝芯材（110）、包含连续蜂窝芯材（110）的蜂窝芯三明治复合板及其制备方法和设备，该连续蜂窝芯材（110）包括蜂窝芯材，蜂窝芯材包括多个排列成行的单元（1），其中横向相邻单元（1）间通过横向设置的连接壁（3）连接，纵向相邻单元（1）的相邻侧壁（2）通过粘连层（212）相互粘接或贴合；相邻的蜂窝芯材之间设有一衔接结构（113、113a、113b、113c、113d、113e、113f、113g、113h、113i），衔接结构（113、113a、113b、113c、113d、113e、113f、113g、113h、113i）包括第一衔接部（111、111a、111b、111c、111d、111e、111f、111g、111h、111i）和与其相对应的第二衔接部（112、112a、112b、112c、112d、112e、112f、112g、112h、112i），第一衔接部（111、111a、111b、111c、111d、111e、111f、111g、111h、111i）和第二衔接部（112、112a、112b、112c、112d、112e、112f、112g、112h、112i）分别位于蜂窝芯材的横向两侧不同的边部形成连续蜂窝芯材（110），一段连续蜂窝芯材（110）的第一衔接部（111、111a、111b、111c、111d、111e、111f、111g、111h、111i）与另一段连续蜂窝芯材（110）的第二衔接部（112、112a、112b、112c、112d、112e、112f、112g、112h、112i）连接形成衔接结构（113、113a、113b、113c、113d、113e、113f、113g、113h、113i）。该衔接结构（113、113a、113b、113c、113d、113e、113f、113g、113h、113i）为相邻各段蜂窝芯材边部之间提供了有效连接，在不改变面板材料、结构以及复合加工工艺的条件下，提升了蜂窝芯三明治复合板的弯曲强度。

Description

连续蜂窝芯材、蜂窝芯三明治复合板及其制备方法和设备 技术领域
本发明属于蜂窝结构技术领域，更具体地说，涉及连续蜂窝芯材、蜂窝芯三明治复合板及其制备方法和设备。
背景技术
以轻质、高强材料为上、下面板和以低密度的蜂窝芯材为中间体经过热压复合工艺制成蜂窝芯三明治复合板，该蜂窝芯三明治复合板具有质量轻、刚度与质量之比大以及良好的抗压强度等特性，被广泛应用于很多要求轻量化的领域，如飞机上的芳纶蜂窝、铝蜂窝，交通运输领域的热塑性PP蜂窝三明治复合板，以及包装行业的纸蜂窝、光伏行业轻量化组件的背衬板等各式蜂窝芯三明治复合板。
当下，较为经济、有效的蜂窝芯三明治复合板生产工艺，是以连续生产工艺技术制成宽度较窄且长度方向连续的蜂窝芯材，并按照设定的长度对制成的连续蜂窝芯材进行在线横切裁断，制成一批长度相同的一段段的蜂窝芯材。将上述一段段长度相同的蜂窝芯材分别旋转90度，形成以其长度做为蜂窝芯三明治复合板所需蜂窝芯材的宽度尺寸，采用前后拼接相连与所设配置的面板通过热复合等物理粘接方式或涂胶复合等化学粘接方式制成宽幅的、任意长度的蜂窝芯三明治复合板。
目前，连续蜂窝芯材生产工艺技术包括，比利时的ECONCORE专利号为CN101084108B，以及专利号CN105835484A和美国BRADFORD公司专利号为US8303744B2，US8663523B2，US9550336B2等。但上述的诸多专利所论述的连续的蜂窝芯材生产工艺技术，没有涉及对连续蜂窝芯材经过在线横切裁断后，做为下游的二次加工工艺时制造宽幅、任意长度的蜂窝芯三明治复合板时，前后相邻的一段段蜂窝芯材横向之间的有效连接方法。如此设计会造成前后相邻的一段段蜂窝芯材在横向连接时产生材料断开，结构不连续的缺陷。该缺陷会降低成品蜂窝芯三明治复合板沿长度方向的弯曲强度。然而蜂窝芯三明治复合板的抗压强度以及抗弯强度与其面积重之比值是该产品应用的主要技术性能指标。
本发明在江苏奇一科技有限公司专利号ZL201810629486.3所论述的连续蜂 窝芯材生产工艺技术的基础上，进一步改进和优化了蜂窝芯材结构设计，提供了前后相邻各段蜂窝芯材边部之间连接的有效解决办法。在不改变面板材料，结构以及复合加工工艺的条件下，提升了蜂窝芯三明治复合板的弯曲强度。
发明内容
为了实现上述目的，本发明提供了一种连续蜂窝芯材、蜂窝芯三明治复合板及其制备方法和设备。通过对蜂窝芯材结构的改进和优化，制成含有第一衔接部和第二衔接部的连续蜂窝芯材，并采用对连续蜂窝芯材进行在线横切裁断工序，制成一段段宽度一定或相同的连续蜂窝芯材。随后以横向裁断后的一段段连续蜂窝芯材的长度做为蜂窝芯三明治复合板所需蜂窝芯材的宽度，借助各段蜂窝芯材所含的衔接结构，形成前后相邻各段连续蜂窝芯材有效连接的含有衔接结构的连续蜂窝芯材，并以其上、下表面与所设计的面板经热压复合工艺制成任意宽度和长度尺寸的蜂窝芯三明治复合板。其特点是在不改变面板材料、结构以及复合加工工艺的条件下，可以有效提升蜂窝芯三明治复合板沿运行方向的弯曲强度。
本发明提供了一种连续蜂窝芯材，包括蜂窝芯材，所述蜂窝芯材包括多个排列成行的单元，所述单元是由侧壁围绕形成的六边形柱体，侧壁包括支撑层和粘连层，支撑层和粘连层由不同材料制成，粘连层的熔点低于支撑层的软化点，其中横向相邻的所述单元间通过横向设置的连接壁连接，纵向相邻的所述单元的相邻侧壁通过粘连层相互粘接或贴合；
相邻的所述蜂窝芯材之间设有一衔接结构，所述衔接结构包括第一衔接部和与其相对应的第二衔接部，所述第一衔接部和第二衔接部分别位于所述蜂窝芯材的横向两侧不同的边部形成连续蜂窝芯材，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部连接形成所述衔接结构。
进一步地，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部交错设置形成截面形状为四边形或六边形的衔接结构。
进一步地，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部相互贴合形成截面形状为梯形的衔接结构，其中所述第一衔接部的截面形状呈内八字型，所述第二衔接部的截面形状呈外八字型。
进一步地，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材 的第二衔接部相互贴合形成截面形状为十字型的衔接结构，其中所述第一衔接部与第二衔接部的截面形状均呈T字型。
进一步地，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为四边形的衔接结构，所述第一衔接部卡在所述第二衔接部形成的凹槽内，形成相邻两段所述连续蜂窝芯材的衔接，其中所述第一衔接部的截面形状呈内八字型。
进一步地，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为六边形的衔接结构，所述第一衔接部卡在所述第二衔接部形成的凹槽内，形成相邻两段所述连续蜂窝芯材的衔接。
进一步地，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为六边形的衔接结构，其中所述第一衔接部的截面形状为设有开口的六边形结构，所述第二衔接部的截面形状呈Y字型。
进一步地，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为五边形的衔接结构，其中所述第一衔接部的截面形状为设有开口的五边形结构，所述第二衔接部的截面形状呈T字型。
进一步地，所述第一衔接部与所述第二衔接部上分别设有至少一个倒刺结构，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部中的倒刺结构相互衔接形成衔接结构。
可选地，所述连续蜂窝芯材的第一衔接部与第二衔接部的结构或形状相同。
可选地，所述连续蜂窝芯材的第一衔接部与第二衔接部的结构或形状不同。
进一步地，所述单元的侧壁为三层结构，其中支撑层的两侧各有一层粘连层。
本发明还提供了一种蜂窝芯三明治复合板，该蜂窝芯三明治复合板包括至少两个上述任意一项所述的连续蜂窝芯材通过所述衔接结构形成含有衔接结构的连续蜂窝芯材，以及所述含有衔接结构的连续蜂窝芯材的上、下表面分别设置的面板；
所述面板包括主体层与界面层，所述界面层为分别与所述含有衔接结构的连续蜂窝芯材的上、下表面相连接的层，所述主体层设置在界面层上，所述主体层采用连续纤维增强热塑材料制造而成，所述界面层采用连续纤维增强热塑材料或热塑树脂膜制造而成。
本发明还提供了一种蜂窝芯三明治复合板的制备方法，该制备方法用于制造上述所述的一种蜂窝芯三明治复合板，包括以下步骤：
S1：通过加热模压成型工艺或加热真空吸塑成型工艺使热塑树脂薄膜形成纵向连续、横向为多个相连的半六边形结构，所述多个相连的半六边形结构包括间隔分布的半六边形单元部分，相邻的连接部分以及分别设置在两侧边部的第一半衔接部分和第二半衔接部分；
S2：采用加热压合或超声波加热焊接工艺，将两片纵向连续、横向为多个相连的半六边形结构的连接部分对齐贴合连接，使其整体形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板；
S3：对已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口，切割时不将已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板完全切断，而是在切口处保留连接边；
S4：以切口处为折叠位置，以切口处的连接边为折叠转动轴，将带有切口的芯板按照切口方向进行正90度或负90度的旋转进行折叠，并通过加热使相邻侧壁形成呈热熔状态的粘连层，相邻侧壁相互贴合连接形成连续蜂窝芯材；
S5：对所述连续蜂窝芯材按照设定的长度进行横向切割，制成一段段宽度一定的连续蜂窝芯材；
S6：至少两段宽度一定的连续蜂窝芯材通过衔接结构连接形成含有衔接结构的连续蜂窝芯材，加热使含有衔接结构的连续蜂窝芯材的上、下表面与面板的界面层达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。其中，一段连续蜂窝芯材的第一衔接部与另一段连续蜂窝芯材的第二衔接部包括可以通过相向衔接方式，也可以通过上下插入式衔接，可以水平方向衔接，也可以竖直方向衔接，但不限于在此所陈述的。
进一步地，制备单元的热塑树脂薄膜包括支撑层和粘连层，支撑层和粘连层由不同材料制成，粘连层的熔点低于支撑层的软化点，在步骤S2中是采用纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部 和第二衔接部的芯板外侧为粘连层，在步骤S4中通过加热使折叠后并排连接的单元的侧壁粘连层热熔连接，其中加热温度在粘连层的熔点和支撑层的软化点之间。
进一步地，制备单元的热塑树脂薄膜为单层结构，在步骤S1中以单层热塑树脂薄膜作为支撑层，采用热复合工艺分别在所述支撑层的两侧各热复合一层热塑树脂薄膜作为粘连层，粘连层的熔点低于支撑层的软化点；在步骤S4中加热使折叠后并排连接的单元的侧壁粘连层热熔连接，其中加热温度在粘连层的熔点和作为支撑层的热塑树脂薄膜的软化点之间。
进一步地，所述面板为单体结构，所述S6还包括以下步骤：
S61：在所述面板中外侧以至少一层的连续纤维增强热塑材料作为主体层，且在所述面板的内侧表面粘接一层热熔连接膜形成界面层；
S62：通过挤出成形或者热复合工艺在所述面板的内侧表面制成热熔连接膜，所述热熔连接膜的厚度是0.01～0.5mm；
S63：至少两段宽度一定的连续蜂窝芯材通过衔接结构连接形成所述含有衔接结构的连续蜂窝芯材，加热使所述含有衔接结构的连续蜂窝芯材的上、下表面贴合面与所述面板的界面层达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。
进一步地，该制备方法还包括:
S7:预先在所述面板的制备过程中热压贴合装饰层，或对冷却成型的蜂窝芯三明治复合板的上、下表面二次热压贴合装饰层，装饰层是具有外观装饰特征的热塑树脂薄膜。
本发明还提供了一种蜂窝芯三明治复合板的制备设备，该制备设备用于实现上述任意一项所述的一种蜂窝芯三明治复合板的制备方法，包括：
一用于实现从热塑树脂薄膜到制成蜂窝芯三明治复合板各工序间的连续传送的第一输送带装置；
一用于对热塑树脂薄膜热塑成型的热塑成型装置，所述热塑成型装置包括上、下成型模具，两层热塑树脂薄膜分别通过上、下成型模具，经过加热模压成型工艺或加热真空吸塑成型工艺形成两片纵向连续、横向为多个相连的半六边形结构，所述多个相连的半六边形结构包括间隔分布的半六边形单元部分，相邻的连接部 分以及分别设置在两侧边部的第一半衔接部分和第二半衔接部分；两片纵向连续、横向为多个相连的半六边形结构进入上、下压合成型模具的啮合处，通过设定的上、下压合成型模具啮合处的间隙形成的对辊压力，压合两片纵向连续、横向为多个相连的半六边形结构的连接部分，形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板；
一用于冷却纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板的第一冷却装置；
一用于对经所述第一冷却装置冷却的芯板进行切割的切口装置，所述切口装置对经所述第一冷却装置冷却的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口；
一用于对所述切口装置切割的芯板进行折叠的分度对辊装置，所述分度对辊装置将带有切口的芯板进行折叠，形成连续的前后并排相连接的单元，并提供侧壁连接时所需的推挤压力；
一用于对所述分度对辊装置折叠的芯板进行加热熔化的热熔装置，所述热熔装置加热折叠后并排连接的单元，使单元间相邻的侧壁热熔连接，制成连续蜂窝芯材；
一用于实现将成卷的上、下面板展开的放卷机构，所述放卷机构包括上面板放卷机构和下面板放卷机构；
该制备设备还包括以下设备：
一用于对连续蜂窝芯材按照设定的长度进行横向裁断的第一切断装置；
一用于实现将经所述第一切断装置横向切断形成的连续蜂窝芯材有序地输送至所设定位置的推送机构；
一用于实现将至少两段前后相邻的连续蜂窝芯材之间通过推挤衔接结构紧密衔接形成含有衔接结构的连续蜂窝芯材的推挤机构；
一用于对含有衔接结构的连续蜂窝芯材的上、下表面与面板热压复合形成蜂窝芯三明治复合板的热压复合机，所述热压复合机包括加热装置、热压复合辊、第二冷却装置和第二输送带装置。
进一步地，该制备设备还包括一用于对一段段宽度一定的连续蜂窝芯材进行成垛包装的打包装置。
进一步地，该制备设备还包括一用于对蜂窝芯三明治复合板的纵向两侧进行纵向修边的纵切装置。
进一步地，该制备设备还包括一用于将蜂窝芯三明治复合板按照设定的长度进行横向裁断的第二切断装置。
采用如上的技术方案，本发明达到的有益效果是：通过对蜂窝芯材的结构优化和改进，在不改变面板材料，结构以及复合加工工艺的条件下，提升了蜂窝芯三明治复合板的弯曲强度。不仅制备方法简单，使用较少的材料获得更好的力学性能，生产成本降低，而且还可以通过多段宽度一定或相同的连续蜂窝芯材制成宽幅的、任意长度的蜂窝芯三明治复合板。
附图说明
图1是本发明实施例的连续蜂窝芯材的结构示意图；
图1a是本发明实施例的含有衔接结构的连续蜂窝芯材的结构示意图；
图2是本发明实施例的单元侧壁为两层时的侧壁结构示意图；
图3是本发明实施例的交错衔接形成截面形状为四边形的衔接结构的连续蜂窝芯材平面结构示意图；
图4是本发明实施例的交错衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材平面结构示意图；
图4a是图4中A处的衔接结构放大示意图；
图4b是本发明实施例的交错衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材整体结构示意图；
图5是本发明实施例的贴合衔接形成截面形状为梯形的衔接结构的连续蜂窝芯材平面结构示意图；
图6是本发明实施例的贴合衔接形成截面形状为十字型的衔接结构的连续蜂窝芯材平面结构示意图；
图6a是图6中A处的衔接结构放大示意图；
图6b是本发明实施例的贴合衔接形成截面形状为十字型的衔接结构的连续蜂窝芯材整体结构示意图；
图7是本发明实施例的插入衔接形成截面形状为四边形的衔接结构的连续 蜂窝芯材平面结构示意图；
图8是本发明实施例的插入衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材平面结构示意图；
图8a是图8中A处的衔接结构放大示意图；
图8b是本发明实施例的插入衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材整体结构示意图；
图9是本发明实施例的另一个插入衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材平面结构示意图；
图9a是图9中A处的衔接结构放大示意图；
图9b是本发明实施例的另一个插入衔接形成截面形状为六边形的衔接结构的连续蜂窝芯材整体结构示意图；
图10是本发明实施例的插入衔接形成截面形状为五边形的衔接结构的连续蜂窝芯材平面结构示意图；
图10a是图10中A处的衔接结构放大示意图；
图10b是本发明实施例的插入衔接形成截面形状为五边形的衔接结构的连续蜂窝芯材整体结构示意图；
图11是本发明实施例的倒刺衔接形成含有倒刺结构的衔接结构的连续蜂窝芯材平面结构示意图；
图11a是图11中A处的衔接结构放大示意图；
图11b是本发明实施例的倒刺衔接形成含有倒刺结构的衔接结构的连续蜂窝芯材整体结构示意图；
图12是本发明实施例的蜂窝芯三明治复合板制备过程中形成芯板的示意图；
图13是本发明实施例的面板的结构示意图；
图13a是本发明实施例的含有装饰层的面板的结构示意图；
图14是本发明实施例的蜂窝芯三明治复合板的结构示意图；
图14a是本发明实施例的蜂窝芯三明治复合板热复合时受力示意图；
图15是本发明实施例的使用两层结构的热塑树脂薄膜制备蜂窝芯三明治复合板的制备方法的流程示意图；
图16是本发明实施例的连续蜂窝芯材的制备设备示意图；
图17是本发明实施例的蜂窝芯三明治复合板的制备设备示意图；
其中，1单元，110连续蜂窝芯材，111、111a、111b、111c、111d、111e、111f、111g、111h、111i第一衔接部，112、112a、112b、112c、112d、112e、112f、112g、112h、112i第二衔接部，113、113a、113b、113c、113d、113e、113f、113g、113h、113i衔接结构，114倒刺结构，2侧壁，21相邻侧壁，211支撑层，212粘连层，3连接壁，40半六边形单元部分，41连接部分，42第一半衔接部分，43第二半衔接部分，61第一输送带装置，62热塑成型装置，63切口装置，64分度对辊装置，65热熔装置，66挤出装置，67压合装置，68第一冷却装置，69含有衔接结构的连续蜂窝芯材，69a含有衔接结构的连续蜂窝芯材的上、下表面，70装饰层，71主体层，72界面层，73面板，79加热装置，80热压复合辊，81第二冷却装置，82第二输送带装置，91热压复合机，92下面板放卷机构，93上面板放卷机构，94推送机构，95推挤机构，96牵引机构，97纵切装置，98第二切断装置，99落板装置。
具体实施方式
下面通过具体实施方式来进一步说明本发明，以下实施例为本发明较佳的实施方式，但本发明的实施方式并不受下述实施例的限制。
实施例1
如图1所示，连续蜂窝芯材110包括蜂窝芯材，蜂窝芯材包括多个排列成行的单元1，单元1是由侧壁2围绕形成的柱体，其中横向相邻的单元1之间通横向设置的连接壁3连接，纵向相邻的单元1的通过相邻侧壁21相互贴合或相互粘接。本实施例中单元1为六边形柱体，但应当理解的是，蜂窝芯材中单元的截面形状可以根据需要选择，例如可以是多边形，优选为偶数多边形。
如图1a所示，相邻的蜂窝芯材之间设有一衔接结构113，衔接结构113包括第一衔接部111和与其相对应的第二衔接部112，第一衔接部111和第二衔接部112分别位于蜂窝芯材横向两侧不同的边部形成连续蜂窝芯材110，一段连续蜂窝芯材110的第一衔接部111与另一段连续蜂窝芯材110的第二衔接部112连接形成衔接结构113，至少两个连续蜂窝芯材110通过衔接结构113连接形成含有衔接结构的连续蜂窝芯材69。
如图2所示，单元1的侧壁2为两层结构，包括支撑层211和粘连层212，其中内层为支撑层211，外层为粘连层212，当然，本领域技术人员应当理解，本发明对于侧壁2的层数和分布并无特别限制，只要保证纵向相邻的单元1的相邻侧壁21可以通过粘连层212热熔连接即可，例如，本发明单元1的侧壁2也可以是三层结构，其中支撑层211的两侧各有一层粘连层212。
在本实施例中，单元1的侧壁2中支撑层211和粘连层212由不同材料制成，其中支撑层211采用聚丙烯材料，粘连层212采用醋酸乙烯(VA)含量为28的乙烯-醋酸乙烯共聚物(EVA)材料，其中支撑层211的软化点为130℃，粘连层212的熔点为60℃，在热熔连接纵向相邻的单元1的相邻侧壁21时，可将加热温度控制在80～100℃之间，使粘连层212处于熔化状态实现热熔连接，同时支撑层211所接受的热量还低于软化点，具有常温下的机械力学性能，从而使得支撑层211在相邻单元1折叠贴合时能够提供了所需的支撑力，实现在有效保持单元几何形状的同时，获得较高的相邻侧壁21的贴合强度，大幅提升蜂窝芯材的抗压强度。粘连层采用熔点温度在40～80℃的材料制成，支撑层采用软化点温度在150～160℃的材料制成。
其中，粘连层212采用乙烯类共聚物制成，如EVA(乙烯-醋酸乙烯共聚物)、EAA(乙烯-丙烯酸酯共聚物)、EMA(乙烯-马来酸酐-丙烯酸酯共聚物)；支撑层211采用可流延加工的聚合物材料制成，如PP(聚丙烯)、PA(聚酰胺)、PC(聚碳酸酯)、PET(聚对苯二甲酸乙二醇酯)等。支撑层还可采用纤维增强热塑树脂材料等改性树脂材料，适合本发明的，但不限于在此所述的纤维改性增强热塑树脂材料，如LFT(long fiber thermoplastics)以及LFT-D等纤维增强热塑树脂；相合适的增强纤维包括，但不限于在此陈述的，如玻璃纤维，碳纤维等；与之相适应的纤维增强的热塑树脂，但不限于在此陈述的，如聚丙烯类树脂PP，聚酯类树脂PET，尼龙类树脂PA6或PA66，PC树脂，PEEK树脂，PPS树脂等。利用纤维增强热塑树脂的力学性能，在不更换主体热塑树脂以及不影响面板与蜂窝芯材上、下表面相连接界面的热熔连接特性的情况下提升蜂窝芯材的抗压强度。
如图12所示，组成纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部111和第二衔接部112的芯板，由两片纵向连续、横向为多个相连的半六边形结构压合形成，其中多个相连的半六边形结构包括间 隔分布的半六边形单元部分40，相邻的连接部分41以及分别设置在两侧边部的第一半衔接部分42和第二半衔接部分43。
如图13所示，蜂窝芯三明治复合板的面板73是由主体层71与界面层72通过上下叠加铺层设计经加热复合工艺制成。其中，主体层71为面板73的外层，采用的是力学性能及熔点较高的连续纤维增强热塑材料制造而成，界面层72为面板73的内层，采用熔点较低的连续纤维增强热塑材料或热塑树脂膜制造而成。面板73至少包括一层连续纤维增强热塑片材，主体层71的热塑树脂的熔点高于界面层72的热塑树脂的熔点，界面层72的熔点与支撑层211的熔点相同或相兼容。面板73的主体层71是由至少一层且各层材料性能不同的连续纤维增强热塑材料制造而成，面板73的主体层71是采用以性能较高的连续纤维增强热塑片材为外层和以性能较低的连续纤维增强热塑片材为相邻的内层制造而成，或采用性能较高的连续纤维增强热塑片材与性能较低的连续纤维增强热塑片材呈高低交替铺层的设计制造而成。
如图13a所示，面板73还包括装饰层70，装饰层70设置在主体层71的外侧，主体层71的内侧是界面层72。装饰层70由热塑树脂薄膜材料制成的，可以为一层，也可以为多层。使用具有外观装饰特征或防火、防烫的装饰层70可以使蜂窝芯三明治复合板更加美观。热塑树脂薄膜材料包括，但不限于在此陈述的，如：聚碳酸脂，聚氯乙烯，聚甲基丙烯酸甲酯，聚对苯二甲酸乙二醇酯，聚苯醚，聚苯硫醚，聚醚醚酮等。
如图14所示，蜂窝芯三明治复合板包括至少两个连续蜂窝芯材110通过衔接结构113连接形成的含有衔接结构的连续蜂窝芯材69和设置在含有衔接结构的连续蜂窝芯材的上、下表面69a的面板73。在含有衔接结构的连续蜂窝芯材的上、下表面分别贴合上、下面板73，经热压复合最终形成蜂窝芯三明治复合板。如图14a所示，蜂窝芯三明治复合板的上、下面板73与含有衔接结构的连续蜂窝芯材上、下表面69a热复合时所需的作用力F和反作用力F,是按照图17，或类似的热复合工艺装备生产制造高性能蜂窝芯三明治复合板的关键工艺设计参数。
实施例1-1
如图3所示，一段连续蜂窝芯材的第一衔接部111a与另一段连续蜂窝芯材 的第二衔接部112a交错设置形成截面形状为四边形的衔接结构113a。
实施例1-2
如图4至图4b所示，一段连续蜂窝芯材的第一衔接部111b与另一段连续蜂窝芯材的第二衔接部112b交错设置形成截面形状为六边形的衔接结构113b。
实施例1-3
如图5所示，一段连续蜂窝芯材的第一衔接部111c与另一段连续蜂窝芯材的第二衔接部112c相互贴合形成截面形状为梯形的衔接结构113c，其中第一衔接部111c的截面形状呈内八字型，第二衔接部112c的截面形状呈外八字型。
实施例1-4
如图6至图6b所示，一段连续蜂窝芯材的第一衔接部111d与另一段连续蜂窝芯材的第二衔接部112d相互贴合形成截面形状为十字型的衔接结构113d，其中第一衔接部111d与第二衔接部112d的截面形状均呈T字型。
实施例1-5
如图7所示，一段连续蜂窝芯材的第一衔接部111e插入另一段连续蜂窝芯材的第二衔接部112e形成截面形状为四边形的衔接结构113e，第一衔接部111e卡在第二衔接部112e形成的凹槽内，形成相邻两段连续蜂窝芯材的衔接，其中第一衔接部111e的截面形状呈内八字型。
实施例1-6
如图8至图8b所示，一段连续蜂窝芯材的第一衔接部111f插入另一段连续蜂窝芯材的第二衔接部112f形成截面形状为六边形的衔接结构113f，第一衔接部111f卡在第二衔接部112f形成的凹槽内，形成相邻两段连续蜂窝芯材的衔接。
实施例1-7
如图9至图9b所示，一段连续蜂窝芯材的第一衔接部111g插入另一段连续蜂窝芯材的第二衔接部112g形成截面形状为六边形的衔接结构113g，其中第一衔接部111g的截面形状为设有开口的六边形结构，第二衔接部112g的截面形状呈Y字型。第一衔接部111g卡在第二衔接部112g形成的凹槽内，形成相邻两段连续蜂窝芯材的衔接。其中，一段连续蜂窝芯材的第一衔接部111g与另一段连续蜂窝芯材的第二衔接部112g采用上下插入式衔接。
实施例1-8
如图10至图10b所示，一段连续蜂窝芯材的第一衔接部111h插入另一段连续蜂窝芯材的第二衔接部112h形成截面形状为五边形的衔接结构113h，其中第一衔接部111h的截面形状为设有开口的五边形结构，第二衔接部112h的截面形状呈T字型。第一衔接部111h卡在第二衔接部112h形成的凹槽内，形成相邻两段连续蜂窝芯材的衔接。其中，一段连续蜂窝芯材的第一衔接部111h与另一段连续蜂窝芯材的第二衔接部112h采用上下插入式衔接。
实施例1-9
如图11至图11b所示，第一衔接部111i与第二衔接部112i上分别设有至少一个倒刺结构114，一段连续蜂窝芯材的第一衔接部111i与另一段连续蜂窝芯材的第二衔接部112i中的倒刺结构114相互衔接形成截面形状为四边形的衔接结构113i。
其中，如实施例1-1至实施例1-9所示，连续蜂窝芯材的第一衔接部111与第二衔接部112的结构或形状可以相同，连续蜂窝芯材的第一衔接部111与第二衔接部112的结构或形状可以不同。第一衔接部以及第二衔接部的截面形状包括四边形、五边形、六边形等多边形，但不限于在此所陈述的。一段连续蜂窝芯材的第一衔接部和另一段连续蜂窝芯材的第二衔接部的衔接方式包括交错衔接，贴合衔接，插入衔接，倒刺衔接等，但不限于在此所陈述的。
实施例2
如图15所示，使用具有两层结构的热塑树脂薄膜制备蜂窝芯三明治复合板，其中热塑树脂薄膜中包括由不同材料制成的支撑层211和粘连层212，粘连层212的熔点低于支撑层211的软化点。制备方法包括如下步骤：
S1：通过加热模压成型工艺或加热真空吸塑成型工艺使热塑树脂薄膜形成纵向连续、横向为多个相连的半六边形结构，多个相连的半六边形结构包括间隔分布的半六边形单元部分40，相邻的连接部分41以及设置在两侧边部的第一半衔接部分42和第二半衔接部分43；
S2：采用加热压合或超声波加热焊接工艺，将两片纵向连续、横向为多个相连的半六边形结构的连接部分41对齐贴合连接，使其整体形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部111和第二衔接部112的芯板，该芯板的外侧为粘连层212，内侧为支撑层211；
S3：对已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部111和第二衔接部112的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口，切割时不将已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部111和第二衔接部112的芯板完全切断，而是在切口处保留连接边。其中切割的方式可根据实际需要采用现有技术中已知的方法进行，以实现不同厚度的连续蜂窝芯材的生产要求，例如可采用如下方式中的一种进行切割：金属或非金属刀片切割、激光切割、高压水力切割、线切割、电阻丝切割或等离子切割等；
S4：以切口处为折叠位置，以切口处的连接边为折叠转动轴，将带有切口的芯板按照切口方向进行正90度或负90度相间隔的旋转进行折叠，折叠后芯板中相互贴合连接的连接部分42构成连接横向相邻的单元1的连接壁3，芯板中横向两侧边部的第一半衔接部分42和第二半衔接部分43分别相互贴合构成第一衔接部111和第二衔接部112，纵向相邻的单元间相邻侧壁21相互贴合，通过加热使折叠后纵向相邻的单元的相邻侧壁21上形成热熔状态的粘连层212，相邻侧壁21相互贴合形成连续蜂窝芯材110；其中加热温度在粘连层212的熔点和支撑层211的软化点之间，从而在有效保持单元几何形状的同时，获得较高的相邻侧壁的贴合强度，提升连续蜂窝芯材的抗压强度；
S5：对连续蜂窝芯材110按照设定的长度进行横向切割，制成一段段宽度一定或相同的连续蜂窝芯材110；
S6：至少两段宽度一定的连续蜂窝芯材110通过衔接结构113连接形成含有衔接结构的连续蜂窝芯材69，在含有衔接结构的连续蜂窝芯材的上、下表面69a分别贴合上、下面板73，加热使连含有衔接结构的连续蜂窝芯材的上、下表面69a与面板73的界面层72达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。其中，一段连续蜂窝芯材的第一衔接部111与另一段连续蜂窝芯材的第二衔接部112包括可以通过相向衔接方式，也可以通过上下插入式衔接，可以水平方向衔接，也可以竖直方向衔接，但不限于在此所陈述的。
在一个实施方式中，制备单元1的热塑树脂薄膜包括支撑层211和粘连层212，支撑层211和粘连层212由不同材料制成，粘连层212的熔点低于支撑层 211的软化点，在步骤S2中是采用纵纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部111和第二衔接部112的芯板外侧为粘连层212，在步骤S4中通过加热使折叠后并排连接的单元的侧壁粘连层212热熔连接，其中加热温度在粘连层212的熔点和支撑层211的软化点之间。
在另一个实施方式中，制备单元1的热塑树脂薄膜为单层结构，在步骤S1中以单层热塑树脂薄膜作为支撑层211，采用热复合工艺分别在支撑层211的两侧各热复合一层热塑树脂薄膜作为粘连层212，粘连层212的熔点低于支撑层211的软化点；在步骤S4中加热使折叠后并排连接的单元的侧壁粘连层212热熔连接，其中加热温度在粘连层212的熔点和作为支撑层211的热塑树脂薄膜的软化点之间。
在另一个实施方式中，面板73为单体结构，单体结构为至少一层同种连续纤维增强热塑材料组成的复合层结构，在该实施方式中，单体结构为主体层71。S6还包括以下步骤：
S61：在面板73中外侧以至少一层的连续纤维增强热塑材料作为主体层71，且在面板73的内侧表面粘接一层热熔连接膜形成粘接的界面层72；
S62：通过挤出成形或者热复合工艺在面板73的内侧表面制成热熔连接膜，热熔连接膜的厚度是0.01～0.5mm；
S63：至少两段宽度一定的连续蜂窝芯材110通过衔接结构113连接形成含有衔接结构的连续蜂窝芯材69，加热使含有衔接结构的连续蜂窝芯材的上、下表面69a贴合面与面板73的界面层72达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。
在另一个实施方式中，该制备方法还包括:
S7:预先在面板73的制备过程中热压贴合装饰层70，或对冷却成型的蜂窝芯三明治复合板的上、下表面二次热压贴合装饰层70，装饰层70是具有外观装饰特征或者防火、防烫的热塑树脂薄膜。
实施例3
如图16和图17所示，本发明蜂窝芯三明治复合板的制备设备一个具体实施例其中包括第一输送带装置61、热塑成型装置62、切口装置63、分度对辊装置64、第一冷却装置68、热熔装置65、热压复合机91、下面板放卷机构92、上面 板放卷机构93、推送机构94、推挤机构95、纵切装置97、第二切断装置98。
一用于实现从热塑树脂薄膜到制成蜂窝芯三明治复合板各工序间的连续传送的第一输送带装置61。
一用于对热塑树脂薄膜热塑成型的热塑成型装置62，热塑成型装置62包括上、下成型模具，两层热塑树脂薄膜分别通过上、下成型模具，经过加热模压成型工艺或加热真空吸塑成型工艺形成两片纵向连续、横向为多个相连的半六边形结构，多个相连的半六边形结构包括间隔分布的半六边形单元部分40，相邻的连接部分41以及设置在横向两侧边部的第一半衔接部分42和第二半衔接部分43；两片纵向连续、横向为多个相连的半六边形结构进入上、下压合成型模具的啮合处，通过设定的上、下压合成型模具啮合处的间隙形成的对辊压力，压合两片纵向连续、横向为多个相连的半六边形结构的连接部分42，形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部111和第二衔接部112的芯板。
一用于冷却纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部111和第二衔接部112的芯板的第一冷却装置68，第一冷却装置68可以为风冷装置。
一用于对经第一冷却装置冷却的芯板进行切割开切口的切口装置63，切口装置63对经第一冷却装置68冷却的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口。切口装置63可以为通过金属或非金属刀片切割、激光切割、高压水力切割、线切割、电阻丝切割或等离子切割等方式进行切割的设备。
一用于对切口装置63切割的芯板进行折叠的分度对辊装置64，分度对辊装置64将带有切口的芯板进行折叠，形成连续的前后并排相连接的单元，并提供侧壁连接时所需的推挤压力。分度对辊装置64包括一组带有分度齿的辊子，以连续蜂窝芯材的厚度为分度基准，对切口处施压，并通过设定分度对辊装置64上由第一输送带装置61的速度与分度轮线速度的差，实现实施切口后的呈水平状的单元折叠旋转约90度，折叠形成连续的前后并排相连接的单元。通过分度对辊的齿及对辊在水平方向和垂直方向中心的设定，实现不同切口间距和不同六边形截面尺寸蜂窝芯的分度折叠要求。
一用于对分度对辊装置64折叠的芯板进行加热熔化的热熔装置65，热熔装 置65加热折叠后并排连接的单元，使单元间相邻的侧壁热熔连接，制成连续蜂窝芯材110。加热温度可控制在侧壁的粘连层212的熔点和支撑层211的软化点之间，从而在有效保持单元几何形状的同时，获得较高的相邻侧壁的贴合强度，提升连续蜂窝芯材110的抗压强度。
一用于实现将成卷的上、下面板73展开的放卷机构，放卷机构包括上面板放卷机构92和下面板放卷机构93。
该制备设备还包括以下设备：
一用于对连续蜂窝芯材按照设定长度进行横向裁断的第一切断装置，该装置可以是盘踞切割，红外切割，或激光切割等，但不限于在此所陈述的。
一用于实现将经第一切断装置横向切断形成的连续蜂窝芯材有序地输送至所设定位置的推送机构94。
一用于实现将至少两段前后相邻的连续蜂窝芯材110之间通过衔接结构紧密衔接的的推挤机构95。
一用于对含有衔接结构的连续蜂窝芯材的上、下表面69a与面板73热压复合形成蜂窝芯三明治复合板的热压复合机91，热压复合机91包括加热装置79、热压复合辊80、第二冷却装置81和第二输送带装置82。
第二输送带装置82用于实现从含有衔接结构的连续蜂窝芯材到制成蜂窝芯三明治复合板各工序间的连续传送，既耐高温，又防热熔胶粘连。其中，第二输送带装置82可以是双面钢带或双面耐高温铁氟龙带，但不限于在此所陈述的。
加热装置79包括上、下接触式热传导加热装置，分别对上、下面板73进行加热，并经由面板73的外层主体层71，且由外至内的热传递路径，以热传导与热对流的混合热传递方式对面板73的界面层72加热至所设定的温度，形成热熔连接层；
一对或多组热压复合辊80，用于对面板73的界面层72和含有衔接结构的连续蜂窝芯的材上、下表面69a进行热压复合；
第二冷却装置81，第二冷却装置81包括上、下接触式冷却装置，用于对经热压复合辊热压的蜂窝芯三明治复合板冷却成型。
本发明的蜂窝芯三明治复合板制备设备还可包括一用于对一段段宽度一定或相同的连续蜂窝芯材进行成垛包装的打包装置。
本发明的蜂窝芯三明治复合板制备设备还可包括一用于蜂窝芯三明治复合板纵向两侧进行纵向修边的纵切装置97。
本发明的蜂窝芯三明治复合板制备设备还可包括一用于蜂窝芯三明治复合板按照设定的长度进行横向裁断的第二切断装置98，该装置可以是盘踞切割，红外切割，或激光切割等，但不限于在此所陈述的。
本发明的蜂窝芯三明治复合板的制备设备还可包括用于制备热塑树脂薄膜的挤出装置66，用于挤出形成用作原料的热塑树脂薄膜。
本发明的蜂窝芯三明治复合板的制备设还可包括压合装置67，用于将成型的两片纵向连续，横向为多个相连的半六边形结构压合形成纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部和第二衔接部的芯板。
本发明的蜂窝芯三明治复合板制备设备还可包括一用于牵引蜂窝芯三明治复合板的牵引机构96。
本发明的蜂窝芯三明治复合板制备设备还可包括一用于将经纵切装置97纵切修边和第二切断装置98横向裁断的蜂窝芯三明治复合板自动叠放的落板装置99。
在本发明的一个具体实施方式中，本发明的制备设备的工作方式为：挤出装置66挤出形成两块具有两层结构的热塑树脂薄膜，热塑树脂薄膜的两层结构依次为粘连层212、支撑层211，其中粘连层212的熔点小于支撑层211的软化点。两层热塑树脂薄膜分别通过上、下成型模具，经过加热模压成型工艺或加热真空吸塑成型工艺形成两片纵向连续、横向为多个相连的半六边形结构，多个相连的半六边形结构包括间隔分布的半六边形单元部分40，相邻的连接部分41以及设置在横向两侧边部的第一半衔接部分42和第二半衔接部分43；两片纵向连续、横向为多个相连的半六边形结构进入上、下压合成型模具的啮合处，通过设定的上、下压合成型模具啮合处的间隙形成的对辊压力，压合两片纵向连续、横向为多个相连的半六边形结构的连接部分41，形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部111和第二衔接部112的芯板。纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部111和第二衔接部112的芯板经第一冷却装置68降温后传送到切口装置63 进行切割，切口装置63对一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部含有第一衔接部111和第二衔接部112的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口，切割时不将芯板完全切断，而是在切口处保留连接边。切割完成后芯板被第一输送带装置61传送到分度对辊装置64，分度对辊装置64中带分度齿的辊子对切口处施压，以切口处为折叠位置，以切口处的连接边为折叠转动轴，将带有切口的芯板按照切口方向进行正90度或负90度相间隔的旋转对芯板进行折叠，折叠形成连续的前后并排相连接的单元，随后由第一输送带装置61传送到热熔装置65，热熔装置65可加热折叠后并排连接的单元，加热温度控制在粘连层212熔点和支撑层211软化点之间，使单元间相邻的侧壁2热熔连接，形成连续蜂窝芯材110。连续蜂窝芯材110经第一切断装置切割形成一段段宽度一定或相同的连续蜂窝芯材110。下面板放卷机构92不断输送下面板，上面板放卷机构93不断输送上面板，上、下面板73和宽度一定或相同的连续蜂窝芯材110随着第三输送带装置进入热压复合机90，在进入热压复合机90之前至少两个连续蜂窝芯材110通过推挤机构95的推挤，使得形成含有衔接结构的连续蜂窝芯材69。加热装置79分别对上、下面板73进行加热，并经由面板73的外层主体层71，且由外至内的热传递路径，以热传导与热对流的混合热传递方式对含有衔接结构的蜂窝芯材的上、下表面69a和面板73的界面层72加热至所设定的温度，即刻进入到热压工序，即第二输送带装置82输送过来，再通过至少一组热压复合辊80对上、下面板73的界面层72与含有衔接结构的连续蜂窝芯材的上、下表面69a进行热压复合，随后被第二输送带装置82输送至第二冷却装置81，经过冷却工序后，完成连续工艺流程的蜂窝芯三明治复合板的生产。蜂窝芯三明治复合板经牵引机构96的牵引进入纵切装置97，经纵切装置97对蜂窝芯三明治复合板纵向两侧进行纵向修边，随后送至第二切断装置98，再经第二切断装置98按照设定的长度进行横向裁断形成最终的蜂窝芯三明治复合板。
综上所述，本发明通过在蜂窝芯材的横向两侧边部设置第一衔接部和第二衔接部，通过一段连续蜂窝芯材的第一衔接部和另一段连续蜂窝芯材的第二衔接部衔接形成衔接结构，进一步可以制造宽幅的、任意长度的蜂窝芯三明治复合板，提升蜂窝芯三明治复合板的抗弯曲强度。
要说明的是，在本文中，诸如“第一”和“第二”等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种物品或者设备所固有的要素。
以上详细描述了本发明的具体实施例，应当理解，本领域的普通技术人员无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此，凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案，皆应在由权利要求书所确定的保护范围内。

Claims (22)

  1. 一种连续蜂窝芯材，包括蜂窝芯材，所述蜂窝芯材包括多个排列成行的单元，所述单元是由侧壁围绕形成的六边形柱体，侧壁包括支撑层和粘连层，支撑层和粘连层由不同材料制成，粘连层的熔点低于支撑层的软化点，其中横向相邻的所述单元间通过横向设置的连接壁连接，纵向相邻的所述单元的相邻侧壁通过粘连层相互粘接或贴合；
    其特征在于，相邻的所述蜂窝芯材之间设有一衔接结构，所述衔接结构包括第一衔接部和与其相对应的第二衔接部，所述第一衔接部和第二衔接部分别位于所述蜂窝芯材的横向两侧不同的边部形成连续蜂窝芯材，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部连接形成所述衔接结构。
  2. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部交错设置形成截面形状为四边形或六边形的衔接结构。
  3. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部相互贴合形成截面形状为梯形的衔接结构，其中所述第一衔接部的截面形状呈内八字型，所述第二衔接部的截面形状呈外八字型。
  4. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部相互贴合形成截面形状为十字型的衔接结构，其中所述第一衔接部与第二衔接部的截面形状均呈T字型。
  5. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为四边形的衔接结构，所述第一衔接部卡在所述第二衔接部形成的凹槽内，形成相邻两段所述连续蜂窝芯材的衔接，其中所述第一衔接部的截面形状呈内八字型。
  6. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为六边形的衔接结构，所述第一衔接部卡在所述第二衔接部形成的凹槽内，形成相邻两段所述连续蜂窝芯材的衔接。
  7. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝 芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为六边形的衔接结构，其中所述第一衔接部的截面形状为设有开口的六边形结构，所述第二衔接部的截面形状呈Y字型。
  8. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，一段所述连续蜂窝芯材的第一衔接部插入另一段所述连续蜂窝芯材的第二衔接部形成截面形状为五边形的衔接结构，其中所述第一衔接部的截面形状为设有开口的五边形结构，所述第二衔接部的截面形状呈T字型。
  9. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，所述第一衔接部与所述第二衔接部上分别设有至少一个倒刺结构，一段所述连续蜂窝芯材的第一衔接部与另一段所述连续蜂窝芯材的第二衔接部中的倒刺结构相互衔接形成衔接结构。
  10. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，所述连续蜂窝芯材的第一衔接部与第二衔接部的结构或形状相同。
  11. 如权利要求1所述的一种连续蜂窝芯材，其特征在于，所述连续蜂窝芯材的第一衔接部与第二衔接部的结构或形状不同。
  12. 如权利要求1-11任意一项所述的一种连续蜂窝芯材，其特征在于，所述单元的侧壁为三层结构，其中支撑层的两侧各有一层粘连层。
  13. 一种蜂窝芯三明治复合板，其特征在于，该蜂窝芯三明治复合板包括至少两个如权利要求1-12任意一项所述的连续蜂窝芯材通过所述衔接结构形成含有衔接结构的连续蜂窝芯材，以及所述含有衔接结构的连续蜂窝芯材的上、下表面分别设置的面板；
    所述面板包括主体层与界面层，所述界面层为分别与所述含有衔接结构的连续蜂窝芯材的上、下表面相连接的层，所述主体层设置在界面层上，所述主体层采用连续纤维增强热塑材料制造而成，所述界面层采用连续纤维增强热塑材料或热塑树脂膜制造而成。
  14. 一种蜂窝芯三明治复合板的制备方法，该制备方法用于制造如权利要求13所述的一种蜂窝芯三明治复合板，其特征在于，包括以下步骤：
    S1：通过加热模压成型工艺或加热真空吸塑成型工艺使热塑树脂薄膜形成纵向连续、横向为多个相连的半六边形结构，所述多个相连的半六边形结构包括间 隔分布的半六边形单元部分，相邻的连接部分以及分别设置在两侧边部的第一半衔接部分和第二半衔接部分；
    S2：采用加热压合或超声波加热焊接工艺，将两片纵向连续、横向为多个相连的半六边形结构的连接部分对齐贴合连接，使其整体形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板；
    S3：对已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口，切割时不将已连接成一体的纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板完全切断，而是在切口处保留连接边；
    S4：以切口处为折叠位置，以切口处的连接边为折叠转动轴，将带有切口的芯板按照切口方向进行正90度或负90度的旋转进行折叠，并通过加热使相邻侧壁形成呈热熔状态的粘连层，相邻侧壁相互贴合连接形成连续蜂窝芯材；
    S5：对所述连续蜂窝芯材按照设定的长度进行横向切割，制成一段段宽度一定的连续蜂窝芯材；
    S6：至少两段宽度一定的连续蜂窝芯材通过衔接结构连接形成含有衔接结构的连续蜂窝芯材，加热使含有衔接结构的连续蜂窝芯材的上、下表面与面板的界面层达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。
  15. 如权利要求14所述的一种蜂窝芯三明治复合板的制备方法，其特征在于，制备单元的热塑树脂薄膜包括支撑层和粘连层，支撑层和粘连层由不同材料制成，粘连层的熔点低于支撑层的软化点，在步骤S2中是采用纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板外侧为粘连层，在步骤S4中通过加热使折叠后并排连接的单元的侧壁粘连层热熔连接，其中加热温度在粘连层的熔点和支撑层的软化点之间。
  16. 如权利要求14所述的一种蜂窝芯三明治复合板的制备方法，其特征在于，制备单元的热塑树脂薄膜为单层结构，在步骤S1中以单层热塑树脂薄膜作为支撑层，采用热复合工艺分别在所述支撑层的两侧各热复合一层热塑树脂薄膜作为 粘连层，粘连层的熔点低于支撑层的软化点；在步骤S4中加热使折叠后并排连接的单元的侧壁粘连层热熔连接，其中加热温度在粘连层的熔点和作为支撑层的热塑树脂薄膜的软化点之间。
  17. 如权利要求14所述的一种蜂窝芯三明治复合板的制备方法，其特征在于，所述面板为单体结构，所述S6还包括以下步骤：
    S61：在所述面板中外侧以至少一层的连续纤维增强热塑材料作为主体层，且在所述面板的内侧表面粘接一层热熔连接膜形成界面层；
    S62：通过挤出成形或者热复合工艺在所述面板的内侧表面制成热熔连接膜，所述热熔连接膜的厚度是0.01～0.5mm；
    S63：至少两段宽度一定的连续蜂窝芯材通过衔接结构连接形成所述含有衔接结构的连续蜂窝芯材，加热使所述含有衔接结构的连续蜂窝芯材的上、下表面贴合面与所述面板的界面层达到所设定的热熔温度，进行热压复合，再经过冷却成型制成蜂窝芯三明治复合板。
  18. 如权利要求14所述的一种蜂窝芯三明治复合板的制备方法，其特征在于，该制备方法还包括:
    S7:预先在所述面板的制备过程中热压贴合装饰层，或对冷却成型的蜂窝芯三明治复合板的上、下表面二次热压贴合装饰层，装饰层是具有外观装饰特征的热塑树脂薄膜。
  19. 一种蜂窝芯三明治复合板的制备设备，该制备设备用于实现如权利要求14-18任意一项所述的一种蜂窝芯三明治复合板的制备方法，包括：
    一用于实现从热塑树脂薄膜到制成蜂窝芯三明治复合板各工序间的连续传送的第一输送带装置；
    一用于对热塑树脂薄膜热塑成型的热塑成型装置，所述热塑成型装置包括上、下成型模具，两层热塑树脂薄膜分别通过上、下成型模具，经过加热模压成型工艺或加热真空吸塑成型工艺形成两片纵向连续、横向为多个相连的半六边形结构，所述多个相连的半六边形结构包括间隔分布的半六边形单元部分，相邻的连接部分以及分别设置在两侧边部的第一半衔接部分和第二半衔接部分；两片纵向连续、横向为多个相连的半六边形结构进入上、下压合成型模具的啮合处，通过设定的上、下压合成型模具啮合处的间隙形成的对辊压力，压合两片纵向连续、横向为 多个相连的半六边形结构的连接部分，形成一块纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板；
    一用于冷却纵向连续、横向为多个相连的六边形柱体结构且横向两侧的边部分别含有第一衔接部和第二衔接部的芯板的第一冷却装置；
    一用于对经所述第一冷却装置冷却的芯板进行切割的切口装置，所述切口装置对经所述第一冷却装置冷却的芯板进行上、下间隔地切割，形成上、下间隔且部分连接的切口；
    一用于对所述切口装置切割的芯板进行折叠的分度对辊装置，所述分度对辊装置将带有切口的芯板进行折叠，形成连续的前后并排相连接的单元，并提供侧壁连接时所需的推挤压力；
    一用于对所述分度对辊装置折叠的芯板进行加热熔化的热熔装置，所述热熔装置加热折叠后并排连接的单元，使单元间相邻的侧壁热熔连接，制成连续蜂窝芯材；
    一用于实现将成卷的上、下面板展开的放卷机构，所述放卷机构包括上面板放卷机构和下面板放卷机构；
    其特征在于，该制备设备还包括以下设备：
    一用于对连续蜂窝芯材按照设定的长度进行横向裁断的第一切断装置；
    一用于实现将经所述第一切断装置横向切断形成的连续蜂窝芯材有序地输送至所设定位置的推送机构；
    一用于实现将至少两段前后相邻的连续蜂窝芯材之间通过推挤衔接结构紧密衔接形成含有衔接结构的连续蜂窝芯材的推挤机构；
    一用于对含有衔接结构的连续蜂窝芯材的上、下表面与面板热压复合形成蜂窝芯三明治复合板的热压复合机，所述热压复合机包括加热装置、热压复合辊、第二冷却装置和第二输送带装置。
  20. 如权利要求19所述的一种蜂窝芯三明治复合板的制备设备，其特征在于，该制备设备还包括一用于对一段段宽度一定的连续蜂窝芯材进行成垛包装的打包装置。
  21. 如权利要求19所述的一种蜂窝芯三明治复合板的制备设备，其特征在于，该制备设备还包括一用于对蜂窝芯三明治复合板的纵向两侧进行纵向修边的纵 切装置。
  22. 如权利要求19所述的一种蜂窝芯三明治复合板的制备设备，其特征在于，该制备设备还包括一用于将蜂窝芯三明治复合板按照设定的长度进行横向裁断的第二切断装置。
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