SUMMERY OF THE UTILITY MODEL
In view of the above problems in the prior art, the present invention is to provide a honeycomb core and a composite honeycomb structure having light weight, high strength, good fire-proof, heat-insulating and sound-insulating effects.
The technical means adopted by the utility model are as follows.
According to the utility model discloses an aim at, provide a honeycomb core, it contains a honeycomb board and a plurality of foaming layer, and this honeycomb board contains a plurality of honeycomb holes, and each this honeycomb hole is straight to the relative biplanar that link up this honeycomb board, and each this foaming layer is filled in respectively in each this honeycomb hole, and this foaming layer closely links with each wall of this honeycomb hole, and wherein this foaming layer is filled the shaping by a stereoplasm foaming agent.
According to the above technical features, the honeycomb board can be made of metal plate, plastic plate, fiber plate, etc.
According to the above technical features, the metal plate may be an aluminum plate or a copper plate.
According to the above technical features, the plastic board is a Polyphenylene sulfide board made of Polyphenylene sulfide (PPS), a polyvinyl chloride board made of polyvinyl chloride (PVC), a Polyethylene board made of Polyethylene (PE), a polyether ether ketone board made of polyether ether ketone (PEEK), a Polyurethane board made of Polyurethane (PU), a Polyethylene terephthalate board made of Polyethylene terephthalate (PET), a Polypropylene board made of Polypropylene (PP), or a Thermoplastic Polyurethane board made of Thermoplastic Polyurethane (TPU).
According to the above technical features, the fiber is preferably a fiber board composed of one or more of chemical fiber yarn, carbon fiber yarn, paper fiber yarn, organic fiber yarn, inorganic fiber yarn and mineral fiber yarn.
According to the above technical feature, an adhesive layer adhered to the foaming layer is disposed on the wall surface of each honeycomb hole.
According to the above technical feature, the honeycomb core further includes an outer frame attached to a peripheral surface of the honeycomb plate perpendicular to the opposite surfaces on which the honeycomb holes are formed.
According to the above technical features, the outer frame body can be made of a metal plate or a composite outer frame.
According to the above technical features, the composite outer frame body is an aluminum outer frame body, a copper outer frame body, a Polyphenylene sulfide outer frame body made of Polyphenylene sulfide (PPS), a polyvinyl chloride outer frame body made of PVC (polyvinyl chloride), a Polyethylene outer frame body made of PE (Polyethylene), a Polyetheretherketone outer frame body made of PEEK (polyether ether ketone), a Polyurethane outer frame body made of Polyurethane (PU), a composite outer frame body formed by compounding two or more of a Polyethylene terephthalate outer frame body made of Polyethylene terephthalate (PET), a Polypropylene outer frame body made of Polypropylene (PP) or a Thermoplastic Polyurethane outer frame body made of Thermoplastic Polyurethane (TPU), chemical fiber yarns, carbon fiber yarns, paper fiber yarns, organic fiber yarns, inorganic fiber yarns and mineral fiber yarns.
According to the above technical features, the thickness of the foaming layer is preferably equal to the thickness of the honeycomb panel.
According to the above technical features, the thickness of the foaming layer can be smaller than that of the honeycomb plate.
According to the above technical features, the thickness of the foaming layer may be greater than that of the honeycomb panel.
According to the above technical features, the thickness of the honeycomb panel is preferably further 1.5mm to 35mm, and further preferably 1.5mm to 4 mm.
According to the purpose of the utility model, a composite honeycomb structure is proposed again, and it contains: the honeycomb core material as described above; one surface of each first adhesive layer is respectively connected with the two opposite surfaces of the honeycomb core material, which are provided with the plurality of honeycomb holes; the honeycomb core material comprises a honeycomb core material, two fiber material layers and a first adhesive layer, wherein one surface of each fiber material layer is connected with the other opposite surface of each first adhesive layer, which is connected with the honeycomb core material, respectively, each fiber material layer comprises a bonding resin structure and a fiber net structure, the fiber net structure is wrapped by the bonding resin structure, the fiber net structure is formed by a plurality of discontinuous fiber yarns which are distributed in a non-directional manner and mutually wound, and the bonding resin structure is filled in the space between the fiber yarns; one surface of each second adhesive layer is respectively connected with the other opposite surface of each fiber material layer connected with the first adhesive layer; and one surface of each surface layer is respectively connected with the other opposite surface of each second adhesive layer connected with the fiber material layer.
According to the above technical features, the average length of the plurality of filaments is preferably greater than or equal to 35 mm.
According to the above technical features, the average length of the plurality of filaments is preferably less than or equal to 500 mm.
According to the above technical feature, each of the fiber filaments includes a plurality of fibers, and the bonding resin structure fills the space between the plurality of fibers to cover the fibers.
According to the above technical feature, at least one of the plurality of fibers forms two independent piles.
According to the technical characteristics, the plush is distributed in a non-directional way.
According to the above technical feature, the plurality of fibers have a plurality of piles.
According to the above technical feature, at least one of the fibers of at least one of the fiber filaments and at least one of the fibers of another of the fiber filaments of the fiber web structure are intertwined with each other in a non-directional distribution.
According to the above technical feature, at least one of the piles of at least one of the fiber filaments of the web structure and at least one of the fibers of another of the fiber filaments are intertwined with each other in a non-directional distribution.
According to the above technical feature, at least one of the naps of at least one of the fibers of the web structure and at least one of the naps of another one of the fibers of the web structure are intertwined with each other in a non-directional distribution.
According to the technical characteristics, the fiber yarns are made of carbon fibers or glass fibers.
According to the above technical characteristics, the diameter of the fiber filament is between 3 μm and 30 μm.
According to the above technical features, the total fiber content in the fiber material layer is between 5% and 40% by weight, preferably between 5% and 30% by weight, of the fiber material layer.
Bearing the above, the utility model discloses a honeycomb core mainly pours into stereoplasm foaming agent in the honeycomb panel for all filled up through the fashioned foaming layer of stereoplasm foaming agent among each honeycomb hole of honeycomb panel, borrow by the combination on honeycomb panel and foaming layer, compare in knowing separately and adopting honeycomb panel, foaming board etc. as finishing material, under the same thickness condition, the utility model discloses except that can reach functions such as disconnected heat, fire prevention and lightweight equally, more can promote structural strength, especially X, Y and Z axle's intensity lets the utility model discloses a honeycomb core all has high rigidity in the direction of X, Y and Z axle, can bear the impact of higher strength to can also further promote syllable-dividing effect. In the composite honeycomb structure containing the honeycomb core material, the plurality of fiber yarns of the fiber material layer adopted by the composite honeycomb structure are mutually wound to be distributed in a non-directional manner, so that the tearing strength, the bending strength and the bending modulus of the fiber material layer in all directions can be uniform, and the destructive power from all directions can be resisted; the surface layer of the composite honeycomb structure can be used as a decorative surface, can be further made of metal materials such as aluminum and the like, and has the functions of fire prevention, impact resistance and the like as the outermost layer of the structure.
Detailed Description
The utility model discloses an applicable decoration material as the building of honeycomb core and compound honeycomb structure, for example, the compartment plane materiel, or the decoration material that can regard as the vehicle of car, high-speed train, aircraft, boats and ships etc. again, for example the built-in or the shell of vehicle, except possessing the function of fire prevention and disconnected heat, more can reach the lightweight and promote structural strength's purpose.
Please refer to fig. 1A, which is a first schematic view of a honeycomb core according to the present invention. As shown in the drawings, the honeycomb core 10 of the present invention includes a honeycomb plate 11 and a plurality of foam layers 12. The honeycomb plate 11 includes a plurality of honeycomb holes 111, each honeycomb hole 111 penetrates through two opposite faces of the honeycomb plate 11 in a vertical direction (Z-axis direction), wherein the thickness of the honeycomb plate 11, which is the distance between the two opposite faces of the honeycomb plate 11 having the plurality of honeycomb holes 111, is preferably 1.5mm to 35mm, more preferably 1.5mm to 4mm, but not limited thereto.
Please refer to fig. 1B, which is another schematic diagram of the honeycomb core of the present invention. As shown in the figure, each of the foam layers 12 is filled in each of the honeycomb holes 111, and the foam layers 12 are tightly connected with each wall surface of the honeycomb holes 111 without any gap, specifically, each of the foam layers 12 is formed by filling a hard foaming agent into each of the honeycomb holes 111 and performing thermal foaming and hardening. Preferably, each wall surface of each honeycomb hole 111 of the honeycomb plate 11 can be further provided with an adhesive layer 112, so that the foam layer 12 can be bonded with the honeycomb hole 111 by the adhesive layer 112 during molding, thereby achieving more stable combination strength.
The honeycomb plate 11 can be made of metal plate, plastic plate or fiber plate, for example.
Wherein, the metal plate can be an aluminum plate or a copper plate.
The plastic board is a Polyphenylene sulfide board made of Polyphenylene sulfide (PPS), a polyvinyl chloride board made of polyvinyl chloride (PVC), a Polyethylene board made of Polyethylene (PE), a polyether ether ketone board made of polyether ether ketone (PEEK), a Polyurethane board made of Polyurethane (PU), a Polyethylene terephthalate board made of Polyethylene terephthalate (PET), a Polypropylene board made of Polypropylene (PP), or a Thermoplastic Polyurethane board made of Thermoplastic Polyurethane (TPU).
The fiber board is preferably one or more of chemical fiber, carbon fiber, paper fiber, organic fiber, carbon fiber, inorganic fiber and mineral fiber.
The foam layer 12 may be made of Polyurethane (PU) foam layer, Polyvinyl Chloride (PVC) foam layer, or polyethylene terephthalate (PET) foam layer.
In the above, the thickness of the foam layer 12 is preferably equal to the thickness of the honeycomb plate 11, that is, the foam layer 12 completely covers the honeycomb holes 111, and of course, the thickness of the foam layer 12 can be smaller or larger than the thickness of the honeycomb plate 11 according to the requirement of use.
Please refer to the following table one, table two and table three, which are the results of comparing the compression strength and compression modulus of the honeycomb core material 10 of the present invention with those of the light weight decoration material (honeycomb board) used in the prior art. Wherein the density of the honeycomb core material is 0.14g/cm3Therefore, the honeycomb core material meets the requirement of light weight.
Watch 1
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First, the compressive strength and the modulus of compression of tables one to three are comparative values measured under the condition that all materials have the same thickness.
As shown in the table i, the comparison of the X axial values shows that the compression strength of the honeycomb core 10 combined with the honeycomb plate and the hard foam of the present invention is 1050 times higher than that of the honeycomb plate alone; in the compression modulus part, this honeycomb core 10 and the compression modulus who is the honeycomb board alone, this honeycomb core 10 of the utility model has promoted 545 times.
As shown in table two, the comparison of the Y-axis values shows that the compression strength of the honeycomb core 10 combined with the honeycomb plate and the hard foam of the present invention is 1110 times higher than that of the honeycomb plate alone; in the compression modulus part, the compression modulus of the honeycomb core plate 10 and the compression modulus of the honeycomb plate alone is improved by 316 times.
Although the structural strength of the honeycomb core 10 of the present invention in the X-axis and Y-axis directions is superior to other known materials, as shown in table three, in the aspect of the strength performance in the Z-axis direction, it can be seen that the portion of the honeycomb core 10 combining the honeycomb board and the hard foam in the compressive strength is increased by 4.8 times compared with the compressive strength of the honeycomb board alone; in the compression modulus part, this honeycomb core 10 and the compression modulus who is the honeycomb board alone, the utility model discloses a this honeycomb core 10 has promoted 1.4 times. It can be seen that the honeycomb core 10 of the present invention has a significant improvement in the overall structural strength or rigidity, particularly in the structural strength of the Z-axis.
Therefore, the compression strength of the honeycomb core plate 10 at the X, Y, Z axis is 1.05Mpa, 1.11Mpa, 1.84Mpa, i.e., the honeycomb core plate 10 has uniform compression strength in all directions; the compression modulus of the honeycomb core plate 10 at X, Y, Z axes is 18Mpa, 24Mpa, 38.2Mpa, respectively, that is, the honeycomb core plate 10 has similar compression modulus in each direction. Therefore, the honeycomb core plate 10 of the present invention can further enhance the structural strength, particularly X, Y and the Z-axis strength, in addition to achieving the light weight.
Please refer to fig. 2, which is a second schematic view of the honeycomb core of the present invention. As shown in the figure, the honeycomb core 10 of the present invention may further include an outer frame 13, the outer frame 13 is attached to the peripheral surface of the honeycomb plate 11 perpendicular to the two opposite surfaces of the honeycomb holes 111, so as to further increase the structural strength of the honeycomb core 10. The outer frame 13 may be made of metal or a composite outer frame, and the composite outer frame may be an aluminum outer frame, a copper outer frame, a Polyphenylene sulfide outer frame made of Polyphenylene sulfide (PPS), a polyvinyl chloride outer frame made of PVC (polyvinyl chloride), a Polyethylene outer frame made of Polyethylene (PE), a polyether ether ketone outer frame made of PEEK, a Polyurethane outer frame made of Polyurethane (PU), a Polyethylene terephthalate outer frame made of PET, a Polypropylene outer frame made of PP or a Thermoplastic Polyurethane (TPU), a chemical fiber, a carbon fiber, a paper fiber, an organic fiber, or a Thermoplastic Polyurethane outer frame made of TPU, a chemical fiber, a carbon fiber, a paper fiber, or an organic fiber, Two or more of inorganic fiber yarn and mineral fiber yarn are compounded to form the composite outer frame body.
Referring to fig. 3, a flow chart of a method for manufacturing a honeycomb core according to the present invention is shown, which is suitable for manufacturing the honeycomb core 10 as described above, wherein the manufacturing method comprises the following steps.
Step S11: an upper mold, a lower mold, the rigid foaming agent and the honeycomb panel 11 are provided.
Step S12: one side of the honeycomb plate 11 having the honeycomb holes 111 is placed on the lower mold, the hard foaming agent is filled into the plurality of honeycomb holes 111 from the other side of the honeycomb plate 11 having the honeycomb holes 111, and the upper mold is covered on the other side of the honeycomb plate 11 having the honeycomb holes 111.
Step S13: the honeycomb board 11 impregnated with the hard foaming agent is heated.
Step S14: the upper mold and the lower mold are removed to form the honeycomb core 10 including the honeycomb panel 11 and the plurality of foam layers 12 formed by the hard foaming agent.
Referring to fig. 1A and fig. 4 together, fig. 4 is a first schematic view of the composite honeycomb structure of the present invention. As shown in the figures, the composite honeycomb structure 100 of the present invention comprises the honeycomb core 10, two first glue layers 20, two fiber material layers 30, two second glue layers 40 and two surface layers 50, wherein the first glue layers 20 and the second glue layers 40 can be made of resin layers or other adhesive material layers, and the surface layers 50 can be metal layers, paper layers, rubber layers or plastic layers.
The fibrous material layer 30 includes a binder resin structure 31 and a web structure 32. The fiber net structure 32 is covered by the bonding resin structure 31, and the fiber net structure 32 is formed by a plurality of discontinuous fiber filaments which are distributed in a non-directional manner and mutually wound, and the bonding resin structure 31 is filled in the space between the fiber filaments, wherein the average length of the plurality of fiber filaments is greater than or equal to 35mm and less than or equal to a predetermined average length to form the discontinuity, for example, the average length is less than or equal to 500 mm; preferably, the length of each fiber filament is greater than or equal to 35mm and less than or equal to 500 mm.
As mentioned above, the plurality of filaments are intertwined with each other to form a non-directional distribution, the non-directional distribution is to project the web structure 32 onto a two-dimensional plane (not shown), and the projections of the plurality of filaments onto the two-dimensional plane extend randomly or randomly in various directions. Since the plurality of filaments are mutually wound to be distributed in a non-directional manner and the average length of the plurality of filaments is greater than or equal to 35mm, the properties of the fiber material layer 30 are uniform in all directions, in other words, the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions can be uniform, and the fiber material layer can resist the destructive power from all directions.
Further, the filament may comprise a single fiber or a plurality of fibers, for example, the filament may comprise one fiber or one hundred fibers or between one and one hundred fibers. In the embodiment where the filament comprises a plurality of fibers, the filament is not covered with the slurry, and the binder resin structure 31 can penetrate and fill the spaces between the plurality of fibers to cover the fibers, thereby further reinforcing the fiber material layer 30. In addition, at least one of the fibers in the fiber yarn forms two independent piles, the two piles are distributed in a non-directional manner, and the binding resin structure 31 also covers the piles, so that the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions are enhanced and can be uniform. Preferably, the plurality of fibers has a plurality of the piles.
It is particularly worth noting that at least one of the fibers of at least one of the fiber filaments and at least one of the fibers of another of the fiber filaments in the web structure 32 are intertwined with each other in a non-directional distribution. At least one of the piles of at least one of the fiber filaments in the fiber web structure 32 and at least one of the fibers of another of the fiber filaments are intertwined with each other in a non-directional distribution; more preferably, at least one of the piles of at least one of the filaments and at least one of the piles of another of the filaments in the web structure 32 are intertwined with each other in a non-directional distribution. Thus, the porosity of the fiber web structure 32 is reduced, and the tear strength, the bending strength and the bending modulus of the fiber material layer 30 in all directions are enhanced again and can be uniform. In the above, the fiber filament or the fiber can be preferably carbon fiber, glass fiber or recycled fiber, and the diameter of the fiber filament is between 3 μm and 30 μm; in embodiments where the filament or the fiber is a carbon fiber, the diameter of the carbon fiber is between 3 μm and 8 μm; in embodiments where the filament or the fiber is a glass fiber, the diameter of the glass fiber is between 20 μm and 35 μm. In addition, the total fiber content in the fiber material layer 30 may be between 5% and 40%, and preferably between 5% and 30%, by weight of the fiber material layer 30.
In the above, the adhesive resin structure 31 can be made of a thermosetting resin or a thermoplastic resin; further, the bonding resin structure 31 may include a solid filler selected from at least one of Calcium carbonate (Calcium carbonate), Magnesium oxide (Magnesium oxide), Zinc stearate (Zinc stearate), Aluminum hydroxide (Aluminum hydroxide), Antimony oxide (Antimony oxide), Polybrominated diphenyl ethers (Polybrominated diphenyl ethers), Polybrominated biphenyls (Polybrominated biphenyls), tetrabromobisphenol a (tetrabromobisphenol a), Hexabromocyclododecane (Hexabromocyclododecane), and N, N-Dimethylaniline.
Please refer to fig. 5, which is a second schematic view of the composite honeycomb structure of the present invention. As shown in the figure, one surface of each first adhesive layer 20 is connected to the opposite surface of the honeycomb core material 10 where the plurality of honeycomb holes 111 are formed; one surface of each fiber material layer 30 is connected with the other surface of each first adhesive layer 20 opposite to the honeycomb core material 10; one surface of each second adhesive layer 40 is connected to the other surface of each fiber material layer 30 opposite to the surface connected to the first adhesive layer 20; one surface of each surface layer 50 is connected to the other surface of each second adhesive layer 40 opposite to the surface connected to the fiber material layer 30. Wherein, the honeycomb core material 10, the two first adhesive layers 20, the two fiber material layers 30, the two second adhesive layers 40 and the two surface layers 50 can be formed into the composite honeycomb structure 100 by a hot press forming method.
In the above, the thickness of the honeycomb core material 10 may be preferably 1.5mm to 35mm, and more preferably 1.5mm to 4 mm; the thickness of the fiber material layer 30 is preferably 1mm to 5mm, and most preferably 1 mm; the thickness of the surface layer 50 is preferably 1mm to 5mm, and more preferably 1 mm. The thickness ratio of the fiber material layer 30 and the surface layer 50 in the overall structure can be adjusted according to the requirement, and is not limited by the above-mentioned exemplary structure.
Specifically, the composite honeycomb structure 100 mainly comprises the honeycomb core material 10, the fiber material layer 30 and the surface layer 50, wherein the honeycomb core material 10 is formed by combining the honeycomb plate 11 and the plurality of foaming layers 12, and when the composite honeycomb structure is applied to a structure, the purpose of improving the structural strength can be achieved, so that the composite honeycomb structure has the functions of buffering and impact resistance, and also has the effects of light weight, fire prevention, heat insulation, sound insulation and the like; the plurality of filaments of the fiber material layer 30 are mutually twisted to form a non-directional distribution, so that the tear strength, bending strength and bending modulus of the fiber material layer 30 in all directions can be uniform, and the fiber material layer can resist the destructive power from all directions; the surface layer 50 may be made of metal material such as aluminum, and has fireproof and impact-resistant functions as the outermost layer of the structure.
In view of the above, the present invention further provides a method for manufacturing a composite honeycomb structure, please refer to fig. 6 and fig. 7. The method of manufacturing the composite honeycomb structure 100 as described above includes the following process steps.
A material providing step S21: the honeycomb core material 10, the two fiber material layers 30, the two surface layers 50 and the resin material are provided.
A first attaching step S22: the resin material is uniformly coated on one surface of the honeycomb core material 10 having the honeycomb holes 111 to form the first adhesive layer 20, one of the fiber material layers 30 is attached to the first adhesive layer 20, the resin material is coated on the fiber material layer 30 to form the second adhesive layer 40, and then one of the surface layers 50 is attached to the second adhesive layer 40 to form a semi-finished product structure.
A second attaching step S23: the semi-finished structure is turned over, and the resin material is uniformly coated on the other side of the honeycomb core material 10 having the honeycomb holes 111 to form the first adhesive layer 20, and then the other fiber material layer 30 is attached to the first adhesive layer 20, and then the resin material is coated on the fiber material layer 30 to form the second adhesive layer 40, and then the other surface layer 50 is attached to the second adhesive layer 40.
A hot press forming step S24: applying pressure to the two surface layers 50 at opposite ends to form the honeycomb core 10, the two first adhesive layers 20, the two fiber material layers 30, the two second adhesive layers 40, and the two surface layers 50 into the composite honeycomb structure 100.
In summary, the utility model discloses a honeycomb core mainly pours into stereoplasm foaming agent in the honeycomb panel for all filled up through the fashioned foaming layer of stereoplasm foaming agent among each honeycomb hole of honeycomb panel, borrow by the combination of honeycomb panel and stereoplasm foaming, compare in knowing and adopting the honeycomb panel alone, foaming board etc. as finishing material, under the same thickness condition, the utility model discloses except that can reach functions such as disconnected heat, fire prevention and lightweight equally, more can promote structural strength, especially Z axle's intensity, let the utility model discloses a honeycomb core has high rigidity, can bear the impact of higher strength to can also further promote syllable-dividing effect.