CN222080300U - Composite board and rail transit floor - Google Patents
Composite board and rail transit floor Download PDFInfo
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- CN222080300U CN222080300U CN202323490701.1U CN202323490701U CN222080300U CN 222080300 U CN222080300 U CN 222080300U CN 202323490701 U CN202323490701 U CN 202323490701U CN 222080300 U CN222080300 U CN 222080300U
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Abstract
本公开的实施例提供一种复合板与轨道交通地板，所述复合板包括：芯层，包括：至少一层蜂窝结构，所述蜂窝结构的材料包括热塑性树脂；热塑性泡沫，填充于所述蜂窝结构中；表面层，位于所述芯层的相对两侧，与所述芯层粘接固定，所述表面层的材料包括金属。采用本公开的实施例的复合板，具有良好的力学性能与较轻的质量，且界面之间结合力强，不容易出现分层，使用寿命长。
The embodiments of the present disclosure provide a composite board and a rail transit floor, wherein the composite board comprises: a core layer, comprising: at least one honeycomb structure, wherein the material of the honeycomb structure comprises a thermoplastic resin; a thermoplastic foam filled in the honeycomb structure; a surface layer, located on opposite sides of the core layer, bonded and fixed to the core layer, wherein the material of the surface layer comprises a metal. The composite board using the embodiments of the present disclosure has good mechanical properties and a light weight, and has a strong bonding force between interfaces, is not prone to delamination, and has a long service life.
Description
Technical Field
The disclosure relates to the technical field of composite boards, in particular to a composite board and a rail transit floor.
Background
Rail transit floors are important load bearing components inside rail transit vehicles and function to bear the weight of passengers or goods, and also bear vibration and impact during the running process of the transit vehicles. Therefore, the rail transit floor needs to have higher bearing capacity and durability, and good performances of skid resistance, fire resistance, sound insulation and the like.
Rail transit floors are typically made of composite panels whose materials and structures need to be designed and rigidly manufactured to ensure their safety and reliability.
Composite panels are typically made of composite structures of middle aluminum honeycomb, upper aluminum panels, lower aluminum panels, and mated with skeletal profiles, and embedments or connectors disposed therebetween to make flooring. However, the aluminum alloy has a relatively heavy mass, and the bonding force between the layers of the composite plate is linear contact bonding, so that the requirement of durability in long-term use is difficult to meet.
Therefore, there is a need to develop a new composite board and rail transit floor.
Disclosure of utility model
The embodiment of the disclosure provides a composite board, which comprises a core layer, a thermoplastic foam and surface layers, wherein the core layer comprises at least one layer of honeycomb structure, the material of the honeycomb structure comprises thermoplastic resin, the thermoplastic foam is filled in the honeycomb structure, the surface layers are positioned on two opposite sides of the core layer and are adhered and fixed with the core layer, and the material of the surface layers comprises metal.
In some embodiments, the core layer comprises a two-layer honeycomb structure with the cells of the two-layer honeycomb structure being offset from one another.
In some embodiments, the honeycomb material comprises one or more of polypropylene, polyethylene terephthalate, and nylon.
In some embodiments, the thermoplastic foam comprises one or more of polypropylene foam, polyethylene terephthalate foam, and nylon foam.
In some embodiments, the honeycomb material comprises one or both of polypropylene or polyethylene terephthalate and the thermoplastic foam is polypropylene foam.
In some embodiments, the honeycomb structure has a thickness of 3-300 mm.
In some embodiments, the core layer further comprises a reinforcing layer bonded to at least one face of the honeycomb and positioned between the honeycomb and the surface layer, the reinforcing layer material comprising a continuous fiber reinforced thermoplastic resin.
In some embodiments, the thickness of the reinforcing layer is 0.5mm to 2mm.
In some embodiments, the composite panel further comprises thermoplastic film layers on opposite sides of the core layer, bonded to the core layer and the surface layer, respectively.
In some embodiments, the surface layer comprises a bulk layer, the bulk layer material comprising an aluminum alloy, and a treated layer at a surface of the bulk layer, the treated layer material comprising aluminum oxide.
In some embodiments, the surface layer has a thickness of 0.3mm to 1mm.
In some embodiments, the composite panel has at least one of i) a peel strength of 150N cm/cm or more from the surface layer to the core layer, ii) a peel strength of 110N cm/cm or more between the two surface layers, iii) a flatness strength of 4.5MPa or more of the composite panel, iv) a flatness pull strength of 5.5MPa or more of the composite panel, and v) a bending strength of 40MPa or more of the composite panel.
The embodiment of the disclosure also provides a rail transit floor which comprises the composite board and a frame, wherein the frame is arranged on at least one side face of the core layer in a laminating mode, and the frame is made of metal or fiber reinforced thermoplastic resin.
In some embodiments, the material of the frame is an aluminum alloy, and an oxide layer is formed on the surface of the frame.
In some embodiments, the material of the frame is a short glass fiber reinforced polyethylene terephthalate resin, and the material of the honeycomb structure is a polyethylene terephthalate resin.
Compared with the prior art, the technical scheme of the embodiment of the disclosure has the following beneficial effects:
The core layer of the embodiment of the disclosure, because the honeycomb structure is filled with the thermoplastic foam, the surface of the honeycomb structure presents a surface without holes, so that the contact area between the honeycomb structure and the surface layer or the reinforcing layer is increased, the interface binding force is further increased, the layering problem is not easy to occur, and the durability of the use is increased.
The core layer of the embodiments of the present disclosure, a thermoplastic resin honeycomb filled with a thermoplastic foam, has a lighter mass and good mechanical properties as compared to conventional aluminum honeycomb.
The core layer of the embodiment of the disclosure comprises two or more layers of honeycomb structures, the honeycombs of the honeycomb structures of the adjacent layers are staggered, and compared with a single-layer honeycomb structure with the same thickness, the multi-layer honeycomb structure has better mechanical properties, particularly has higher concentrated load, and can be applied to scenes with higher concentrated load requirements.
The reinforcing layer of the embodiment of the disclosure further enhances the mechanical property of the composite board, and can reduce the thickness of the surface layer of the metal material, thereby reducing the overall quality of the composite board.
The rail transit floor of the embodiment of the disclosure has good load performance, can meet the use requirement of the rail transit floor, and has lighter weight compared with the traditional aluminum honeycomb floor.
Drawings
Other features and advantages of the present disclosure will be better understood from the following detailed description of alternative embodiments taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts, and in which:
fig. 1 illustrates a schematic structural view of a composite panel according to an embodiment of the present disclosure;
Fig. 2 shows a schematic structural view of a core layer according to an embodiment of the present disclosure.
Detailed Description
Embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings, are described in detail below. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions. The embodiments described below by referring to the drawings are exemplary only for explaining the present disclosure and are not to be construed as limiting the present disclosure.
Unless defined otherwise, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure belongs. In the description of the present disclosure, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the drawings, are merely for convenience in describing the present disclosure and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present disclosure.
In order to solve the problems of heavy quality and poor durability of the existing composite board, embodiments of the present disclosure provide a composite board, a rail transit floor and a preparation method thereof, and technical schemes of the embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.
Fig. 1 shows a schematic structural view of a composite panel according to an embodiment of the present disclosure, fig. 2 shows a schematic structural view of a core layer according to an embodiment of the present disclosure, and to more clearly show the structure of the composite panel according to an embodiment of the present disclosure, the structural views shown in fig. 1 and 2 are exploded views. Referring to fig. 1 and 2, an embodiment of the present disclosure provides a composite panel 1, the composite panel 1 including a core layer 11, and surface layers 12 located at opposite sides of the core layer 11, the core layer 11 being adhesively fixed with the surface layers 12. The core layer 11 includes at least one layer of honeycomb 111 and thermoplastic foam 112, the material of the honeycomb 111 including thermoplastic resin, the thermoplastic foam being filled in the honeycomb 111.
The core layer 11 of the embodiment of the present disclosure has a thermoplastic resin honeycomb 111 filled with a thermoplastic foam 112, which has a lighter mass and good mechanical properties as compared to an aluminum honeycomb.
Because the honeycomb 111 is filled with the thermoplastic foam 112, the surface of the honeycomb 111 presents a void-free surface, and compared with a honeycomb not filled with the thermoplastic foam, the surface area of the honeycomb 111 is increased, so that the interfacial bonding force between the honeycomb 111 and other layers is increased, the delamination problem is not easy to occur, and the service life of the composite board 1 is prolonged. The mechanical properties of the honeycomb 111 filled with the thermoplastic foam 112 are further enhanced, thereby enhancing the mechanical properties of the composite panel 1 as a whole.
In some embodiments, the material of the honeycomb 111 of embodiments of the present disclosure includes one or more of polypropylene (PP), polyethylene terephthalate (PET), and nylon (PA).
In some embodiments, the thermoplastic foam 112 of embodiments of the present disclosure includes one or more of polypropylene (PP) foam, polyethylene terephthalate (PET) foam, and nylon (PA) foam.
The honeycomb 111 and the thermoplastic foam 112 may be made of the same or different thermoplastic polymers. In some embodiments, the material of the honeycomb 111 includes one or both of polypropylene or polyethylene terephthalate, and the thermoplastic foam 112 is a polypropylene foam.
In order to increase the flame retardant properties of composite panel 1, in some embodiments, the material of honeycomb 111 is a flame retardant modified thermoplastic resin, in some embodiments, the material of honeycomb 111 is a homo-polypropylene modified with a nitrogen-phosphorus flame retardant, the compressive strength of the honeycomb is above 4Mpa, and the density is about 150kg/m 3.
To increase the flame retardant properties of composite panel 1, in some embodiments, thermoplastic foam 112 is a flame retardant modified thermoplastic foam, and in some embodiments, thermoplastic foam 112 is a nitrogen-phosphorus flame retardant modified polypropylene.
In some embodiments, the honeycomb 111 includes a plurality of honeycomb walls, a plurality of honeycomb holes, each honeycomb hole formed between the plurality of honeycomb walls, the thermoplastic foam 112 filling the honeycomb holes.
In some embodiments, the thickness of the cell walls of the honeycomb structure 111 is 0.3mm to 0.6mm.
In some embodiments, the cell pores of the honeycomb 111 have a pore size of 6mm to 9mm, and the thermoplastic foam 112 fills the cell pores, and in some embodiments, the thermoplastic foam 112 fills all of the cell pores.
In some embodiments, the cell openings of the honeycomb structure 111 are oriented toward the surface layer 12.
The thickness of the honeycomb structure 111 may be obtained by cutting according to practical application requirements, and in some embodiments, the thickness of the honeycomb structure 111 is 3-300 mm, in some embodiments, the thickness of the honeycomb structure 111 is 4-50 mm, and in some embodiments, the thickness of the honeycomb structure 111 is 15-30 mm.
In some embodiments, the core layer 11 includes a two-layer honeycomb structure, and the honeycomb holes of the two-layer honeycomb structure are staggered, so that the two-layer honeycomb structure has better mechanical properties, particularly has higher concentrated load, and can be applied to a scene with higher requirement on the concentrated load compared with a single-layer honeycomb structure with the same thickness. In some embodiments, the core layer 11 comprises a three-layer honeycomb structure, and the honeycombs of the adjacent layers are staggered so as to have better mechanical properties, especially higher concentrated loads.
With continued reference to FIG. 2, in some embodiments, composite panel 1 further includes a reinforcing layer 113 bonded to at least one face of honeycomb structure 111 between honeycomb structure 111 and face layer 12. In some embodiments, the honeycomb 111 has reinforcing layers 113 bonded to opposite sides thereof
In some embodiments, the material of the reinforcing layer 113 includes a continuous fiber reinforced thermoplastic resin, and the continuous fiber may be one or more of glass fiber, plant fiber, and carbon fiber, and the thermoplastic resin includes one or more of polypropylene (PP) resin, polyethylene terephthalate (PET) resin, polyamide (PA) resin, polyphenylene Sulfide (PPs) resin, and Polyetheretherketone (PEEK) resin.
The reinforcing layer 113, the honeycomb 111 and the thermoplastic foam 112 are made of thermoplastic materials, and are combined into a whole by a hot melting and cooling mode, so that the interface strength is high. In some embodiments, the reinforcing layer 113, the honeycomb 111 and the thermoplastic foam 112 are composed of the same thermoplastic resin, in some embodiments, the reinforcing layer 113 is made of continuous fiber reinforced polypropylene resin, the honeycomb 111 is made of polypropylene, the thermoplastic foam 112 filled in the honeycomb 111 is made of polypropylene foam, and the polypropylene material is heated and fused in the molding process and has good interfacial bonding force after cooling.
Compared with thermosetting plastic, the thermoplastic plastic has better recoverability, reduces the influence on the environment and is also beneficial to the saving and utilization of resources.
In some embodiments, the thickness of the reinforcing layer 113 is 0.5 mm-2 mm, specifically, for example, 0.5mm, 0.8mm, 1mm, 1.5mm, 2mm, and the like.
The reinforcing layer 113 of the embodiment of the disclosure further enhances the mechanical properties of the composite board, and can reduce the thickness of the surface layer 12 of the metal material, thereby reducing the overall quality of the composite board 1 while ensuring the mechanical properties.
With continued reference to fig. 1, in some embodiments, the composite panel 1 further includes a thermoplastic film layer 13 disposed on opposite sides of the core layer 11 and bonded to the core layer 11 and the surface layer 12, respectively, i.e., the core layer 11 and the surface layer 12 are adhesively secured by the thermoplastic film layer 13.
In some embodiments, the thermoplastic film layer 13 includes a film carrier and a modifying layer adhered to both sides of the film carrier.
In some embodiments, the material of the adhesive film carrier is thermoplastic resin, which can be, but not limited to, ethylene-propylene-based resin, and the adhesive film carrier can resist high temperature above 100 ℃.
In some embodiments, the material of the modified layer may be a thermoplastic resin modified by maleic anhydride and a polyolefin elastomer to improve the binding force with metal and toughness, and further, may be a thermoplastic resin modified by an antioxidant to enhance the antioxidant capability, where specific modifications are selected according to actual needs, and are only illustrative herein and not limiting the technical solutions of the present disclosure.
In some embodiments, the material of the modifying layer is an ethylene propylene-based resin modified with maleic anhydride, polyolefin elastomer, and antioxidant.
In some embodiments, the total thickness of the two modified layers is 20% -30% of the thickness of the adhesive film carrier.
Compared with the traditional polyurethane glue, the thermoplastic film layer 13 of the embodiment of the disclosure has the advantages of easy pulverization phenomenon and layering after long-time use, good bonding effect and stability for bonding the core layer 11 and the surface layer 12, capability of meeting the requirements of damp and heat resistance/salt spray resistance, good toughness and strong fatigue resistance.
With continued reference to fig. 1, in some embodiments, surface layer 12 of composite panel 1 includes a bulk layer and a treatment layer at a surface of the bulk layer.
In some embodiments, the material of the bulk layer comprises an aluminum alloy and the material of the handle layer comprises aluminum oxide.
In some embodiments, the treated layer is formed by oxidizing the surface of the surface layer 12, the treated layer being closer to the core layer 11 than the bulk layer, the treated layer having a better bond with the thermoplastic resin than the bulk layer.
In some embodiments, the surface layer 12 has a thickness of 0.3mm to 1mm and the handle layer has a thickness of 0.015 to 0.02mm.
The composite sheet 1 of the embodiments of the present disclosure has at least one of the following properties:
i) The peel strength of the surface layer and the core layer is more than 150N cm/cm;
ii) the peel strength between the two surface layers is 110N cm/cm or more;
iii) The flattening intensity of the composite board is more than 4.5 MPa;
iv) the horizontal pulling strength of the composite board is more than 5.5 MPa;
v) the bending strength of the composite plate is above 40 MPa.
In some embodiments, the composite board 1 is tested according to the national standard GB/T1457-2022 sandwich roller peel strength test method, the peel strength of the surface layer 12 and the core layer 11 of the composite board 1 is more than 150N cm/cm, the composite board is subjected to 4-week circulation according to the procedure of D4 in the annex D of the national standard GB/T35489-2017 adhesive ageing condition guide, after ageing circulation, the composite board has no problems of detachment, cracking, deformation, layering and the like, and the peel strength of the surface layer 12 and the core layer 11 is still more than 150N cm/cm.
In some embodiments, the test is carried out according to the national standard GB/T1457-2022 sandwich roller peel strength test method, the peel strength between two surface layers 12 is more than 110N cm/cm, the test is carried out according to the procedure of D4 in annex D of the national standard GB/T35489-2017 adhesive ageing condition guide, after ageing circulation, the composite board has no problems of detachment, cracking, deformation, layering and the like, and the peel strength between two surface layers 12 is more than 95N cm/cm.
In some embodiments, the method is tested according to national standard GB/T1453-2022 sandwich structure or core flat pressing performance test method, the flat pressing intensity of the composite board 1 is above 4.5MPa, the method is circulated for 4 weeks according to the procedure of D4 in annex D of national standard GB/T35489-2017 adhesive aging condition guide, after aging circulation, the composite board has no problems of detachment, cracking, deformation, layering and the like, and the flat pressing intensity of the composite board 1 is above 4.4 MPa.
In some embodiments, the flat pull strength of the composite board 1 is tested according to the national standard GB/T1452-2018 sandwich structure flat pull strength test method, the flat pull strength of the composite board 1 is more than 5.5MPa, the flat pull strength of the composite board 1 is tested to be more than 5.0MPa after 4 weeks of circulation according to the procedure of D4 in annex D of the national standard GB/T35489-2017 adhesive aging condition guide, and the composite board is free from problems of detachment, cracking, deformation, layering and the like after aging circulation.
In some embodiments, the bending strength of the composite board 1 is above 40MPa according to the test of the bending performance test method of the national standard GB/T1456-2021 sandwich structure, the 4-week cycle is carried out according to the procedure of D4 in the annex D of the national standard GB/T35489-2017 adhesive aging condition guide, and after the aging cycle, the composite board has no problems of detachment, cracking, deformation, layering and the like, and the bending strength of the composite board 1 is above 33 MPa.
In some embodiments, the areal density of the composite panel 1 is 9.0 to 9.3kg/m 2.
The surface density of the aluminum honeycomb composite board formed by the aluminum honeycomb board and the aluminum plates at the two sides of the aluminum honeycomb board is about 11.5, the peeling strength between the honeycomb core layer and the aluminum plates is about 50N cm/cm, the peeling strength between the two aluminum plates is about 50N cm/cm, the flat pressing strength of the aluminum honeycomb composite board is about 4.0MPa, the flat pulling strength is about 3.5MPa, and the bending strength is about 28 MPa.
As described above, the composite panel 1 of the embodiment of the present disclosure has good mechanical properties and aging resistance, has lighter mass, and simultaneously has more excellent mechanical properties than the conventional aluminum honeycomb composite panel.
To facilitate the installation and securing of the composite panel 1 of the embodiments of the present disclosure, in some embodiments, a bezel is provided for securing the composite panel 1 in a particular location. Referring to fig. 1, the frame 2 is attached to at least one side of the core layer 11, and the material of the frame 2 is metal or fiber reinforced thermoplastic resin. In some embodiments, the rim 2 fits on all sides of the core layer 11, and the shape of the rim 2 matches the shape of the core layer 11 to facilitate a complete fit of the bonded core layer 11.
In some embodiments, the material of the frame 2 is aluminum alloy, which has good supporting performance and rigidity, good nail holding power and high dimensional stability, in some embodiments, an oxide layer is formed on the surface of the frame 2, the oxide layer can be formed by oxidizing and sand blasting the surface of the frame 2, so that the bonding area of the frame 2 is improved, and in some embodiments, the thickness of the frame 2 is 0.015 mm-0.02 mm.
In some embodiments, the material of the frame 2 is a fiber reinforced thermoplastic resin, which is integrally formed with the core layer 11 by thermal fusion bonding, and has stable interface performance with the core layer 11.
In some embodiments, the material of the frame 2 is a short glass fiber reinforced polyethylene terephthalate resin, the material of the honeycomb 111 is a polyethylene terephthalate resin, and the material of the reinforcing layer 113 is a continuous glass fiber reinforced polyethylene terephthalate resin, so that the frame 2, the honeycomb 111 and the reinforcing layer 113 have excellent hot melt adhesion, and the frame is formed into a whole by hot melt cooling, and has strong interfacial bonding force.
To facilitate installation and securing of composite panel 1, in some embodiments, the thickness of border 2 matches the thickness of core layer 11, and in some embodiments, the thickness of border 2 matches the thickness of composite panel 1.
In some embodiments, the composite panel 1 and the rim 2 are mounted on a plate-like structure or a beam-like structure, for example as a floor installation and use.
It should be noted that, the frame 2 may be provided with a fixing structure to fix the composite board 1 at a specific position, where the fixing structure may be a hole, a snap fit structure, or the like, and may be designed according to actual needs, which is not limited herein.
The embodiment of the disclosure also provides a rail transit floor which comprises the composite board and a frame, wherein the frame is arranged on at least one side face of the core layer in a laminating mode, and the frame is made of metal or fiber reinforced thermoplastic resin.
The composite board and the frame are the same as those in any of the above embodiments, and are not described herein.
Fig. 1 also shows a schematic exploded view of the structure of a rail transit floor of an embodiment of the present disclosure. Referring to fig. 1, in some embodiments, the frame 2 is adhesively disposed on the side of the core layer 11, the thickness of the frame 2 is the same as the thickness of the core layer 11, and one side of the thermoplastic film layer 13 is adhesively bonded to the core layer 11 and the frame 2, and the other side is adhesively bonded to the surface layer 12.
In some embodiments, the core layer 11 includes a honeycomb 111, a thermoplastic foam 112 filling the cells of the honeycomb 111, and a reinforcing layer 113 bonded to the surface of the honeycomb 111.
The shape of the rail transit floor of the embodiments of the present disclosure may be prepared according to practical application needs, and is not limited herein.
The core layer 11, the thermoplastic film layer 13 and the surface layer 12 are in surface contact, so that the contact area is large, and the core layer 11 and the thermoplastic film layer 13 are made of thermoplastic resin, so that the thermoplastic film layer is integrated by hot melting during processing, has good interface binding force and is not easy to delaminate.
Because of the filling of the thermoplastic foam 112, the honeycomb 111 and the thermoplastic foam 112 are in surface contact with the reinforcing layer 113, have large contact area and strong interfacial bonding force, are thermoplastic resin and are hot-melted into a whole, and further enhance the overall mechanical strength.
The rail transit floor of the embodiments of the present disclosure is capable of withstanding a load of 10 people/m 2 (60 kg per person). 4-point support, the support interval of the floor is 600mm multiplied by 300mm (rectangular support, the size of the support block is 100mm multiplied by 50mm, the interval is the distance between the edges of the support points), and the deflection is not more than 1mm.
The rail transit floors of the embodiments of the present disclosure were subjected to a floor point load test according to ISO4586 standard, and balls having a weight of 324g±5.0g and a diameter of 42.8mm±0.2mm were dropped from 0.8m, with no visible cracks on the floors and pit diameters of less than 10mm.
The rail transit floor of the embodiment of the disclosure can bear a vertical load of 6kN per square meter, can bear a vertical load of 2kN in an area of 300mm 2, has no permanent deformation or indentation, and has good static load performance.
The rail transit floor of the embodiment of the disclosure can be applied to vehicles such as trains, subways, light rails, trams, maglev trains and the like.
The embodiment of the disclosure also provides a preparation method of the rail transit floor, which is used for preparing the rail transit floor according to any embodiment, and comprises the steps of providing two surface layers, two adhesive film layers and a core layer, sequentially paving the surface layers, the adhesive film layers, the core layer, the frame, the adhesive film layers and the surface layers, heating and compounding, and cooling to form the rail transit floor.
In some embodiments, the method for forming the core layer includes placing a thermoplastic foam blank for forming a thermoplastic foam on a lower surface of a mold, and placing a thermoplastic resin having a honeycomb structure into the mold;
The temperature of the die is raised to 140-150 ℃, supercritical carbon dioxide gas is injected, the thermoplastic foaming blank is fully immersed, the temperature is reduced to 130-140 ℃ of the foaming temperature of the thermoplastic foaming blank, and the pressure is rapidly released at a speed of 1-3 MPa/s to form thermoplastic foam and fill a honeycomb structure formed by thermoplastic resin.
In some embodiments, the core layer further comprises a reinforcing layer, and correspondingly, the forming method of the core layer further comprises the steps of providing a honeycomb structure filled with thermoplastic foam and two reinforcing layers, wherein the reinforcing layers are made of continuous fiber reinforced thermoplastic resin, layering the reinforcing layers, the honeycomb structure and the reinforcing layers in sequence, heating and compounding, and cooling to form the core layer. In some embodiments, the reinforcing layer, the honeycomb structure and the reinforcing layer are sequentially paved and fed into a continuous Teflon belt conveyor or a steel belt conveyor for compounding, the gap of the compounding machine is set according to the thickness requirement, and the materials are subjected to thermal compounding and then cooled for molding.
In some embodiments, the thermoplastic resin forming the honeycomb is polypropylene or polyethylene terephthalate and the thermoplastic foam blank used to form the thermoplastic foam is polypropylene.
In some embodiments, the thermoplastic resin material of the reinforcing layer, which is the same type as the honeycomb and thermoplastic foam, is, for example, a polypropylene resin, and the resin is hot-melted into a whole during processing without interfacial delamination.
The preparation method of the embodiment of the disclosure further comprises, after the core layer is formed, layering according to a layering structure of the surface layer, the thermoplastic film layer, the frame+the core layer, the thermoplastic film layer and the surface layer, and enabling the core layer, the frame+the core layer, the thermoplastic film layer and the surface layer to enter a continuous Teflon belt conveyor or a steel belt conveyor for compounding at one time. And setting a gap of the compound machine according to the thickness requirement of the product, and performing thermal compounding and cooling to obtain the required rail transit floor.
In some embodiments, the surface layer, the thermoplastic film layer and the reinforcing layer may be sequentially laid to form a composite panel, and then the composite panel, the honeycomb structure filled with thermoplastic foam and the composite panel may be sequentially laid to form the rail transit floor.
In a specific embodiment, the preparation method comprises:
1) Preparing a thermoplastic foam filled honeycomb structure, namely placing a PP foam blank on the lower surface of a mould, placing the PET honeycomb structure in the mould, closing the mould, adjusting the mould closing pressure to 12MPa, heating the mould to 140-150 ℃, injecting supercritical carbon dioxide gas, fully impregnating the PP foam blank, cooling to 135 ℃, and rapidly releasing the pressure at the speed of 2MPa/s to form the PP foam filled PET honeycomb structure with the thickness of 26mm;
2) Preparing a composite panel, namely layering according to a layering structure of a 0.5mm aluminum plate, a thermoplastic film layer and a 0.5mm thick continuous glass fiber reinforced PET coiled material, heating to 250-280 ℃, cooling to 0-10 ℃, and preparing two composite panels by using a steel belt machine, wherein the composite gap is 1mm, and the production speed is 4m/min, so that the composite panel with the thickness of 1mm is obtained.
3) The finished product is prepared by layering according to a 1mm thick composite panel, a 25mm thick short glass fiber reinforced PET resin profile, a honeycomb structure filled with 26mm thick thermoplastic foam and a layering structure of the 1mm thick composite panel, and then putting the composite panel into a steel belt machine for compounding at a compounding speed of 2m/min, wherein the heating temperature is 240-250 ℃, and the cooling temperature is 5-10 ℃. The height of the compound machine is set to be 27mm. Cutting on line according to the size requirement, and engraving to obtain the final product.
According to the preparation method of the embodiment of the disclosure, continuous batch production can be realized, continuous unreeling of the glass fiber reinforced thermoplastic resin within 2mm can be realized, continuous unreeling of the aluminum plate with the thickness of 0.5-1 mm can also be realized, and continuous production can be realized on a continuous compounding machine.
The present disclosure is further illustrated by the following specific examples.
Examples
Description of the test methods
The peel strength between the surface layer and the core layer is tested according to GB/T1457-2022 method for testing the peel strength of a roller with a sandwich structure;
The peel strength between the two surface layers is tested according to GB/T1457-2022 Sandwich Structure roller peel Strength test method;
The flattening strength of the composite board is tested according to GB/T1453-2022 sandwich structure or core flattening performance test method;
the flat pull strength of the composite board is tested according to GB/T1452-2018 sandwich structure flat pull strength test method;
Bending strength of the composite board is tested according to GB/T1456-2021 method for testing bending property of sandwich structure;
oxygen index is tested according to GB/T8924-2005 method for testing the burning performance of fiber reinforced plastics;
The sound insulation performance is tested according to GB/T19889.3-2005 sound insulation measurement of acoustic buildings and building components;
static load, namely under the condition of bearing 6kN of vertical load per square meter and bearing 2kN of vertical load on 300mm 2 area, no permanent deformation or indentation is needed.
Example 1
1) The preparation of the thermoplastic foam filled honeycomb structure comprises the steps of firstly placing a PP foaming blank on the lower surface of a mould, then placing a homo-polymerization PP honeycomb with the density of 150kg/m 3 into the mould, locking the mould, setting the temperature to about 145 ℃, injecting supercritical carbon dioxide gas, fully impregnating the PP blank, cooling to the foaming temperature of 135 ℃ of the PP blank, rapidly releasing the pressure of a press, starting foaming of the PP blank, and automatically filling PP honeycomb holes with the PP density of 60kg/m 3. The obtained PP honeycomb structure filled with PP foam is sawn again, and the slice cutting thickness is 15.8mm. The areal density of the thermoplastic foam-filled honeycomb was 3.4kg/m 2.
2) The preparation of the core layer comprises the steps of feeding a continuous glass fiber reinforced PP layer with the thickness of 1mm, a honeycomb structure filled with thermoplastic foam and a layering structure of the continuous glass fiber reinforced PP layer with the thickness of 1mm into a continuous Teflon belt conveyor for compounding at the compounding speed of 1.5m/min, wherein the heating temperature is 220 ℃, and the cooling temperature is 5 ℃. The height of the compound machine is set to be 17mm. And cutting on line according to the required length and width dimensions to obtain the core layer. The thickness of the core layer is 17mm, and the surface density is 6.4kg/m 2.
3) The preparation of the rail transit floor comprises the steps of layering according to a layering structure of a 0.5mm thick aluminum alloy plate, a 0.15mm thick thermoplastic film layer, a 16.7mm thick aluminum profile frame and a 17mm thick core layer, a 0.15mm thick thermoplastic film layer and a 0.5mm thick aluminum alloy plate, and feeding the continuous Teflon belt conveyor at one time. The compounding speed is 1.5m/min, the heating temperature is 220-230 ℃, and the cooling temperature is 5-10 ℃. The height of the compound machine is set to be 18mm. And (5) cutting on line according to the size requirement, and finally engraving according to the drawing requirement to obtain the floor. The floor thickness is 18mm.
4) The prepared composite board was subjected to performance test, and the test results are recorded in table 1.
Comparative example 1
Taking an aluminum honeycomb floor as a comparative example, the aluminum alloy upper surface plate of the aluminum honeycomb floor has a thickness of 2mm, the lower surface of the aluminum alloy upper surface plate has a thickness of 1mm, the honeycomb core layer has a thickness of 15mm, the total thickness of the aluminum honeycomb floor is 18mm, performance tests are carried out on the aluminum honeycomb floor, and test results are recorded in table 1.
TABLE 1 Performance test results
According to the test results of table 1, the floor board prepared in example 1 has mechanical properties superior to industry requirements and meets the use conditions. In addition, the rail transit flooring of the present disclosure has better mechanical properties, flame retardant properties, and soundproof properties, while having lighter mass, than the conventional aluminum honeycomb flooring of comparative example 1.
The foregoing description of the exemplary embodiments has been presented only for the purpose of illustrating the principles of the present disclosure and is not intended to limit the scope of the present disclosure. Various modifications and improvements may be made by those skilled in the art without departing from the spirit and substance of the disclosure, and are also within the scope of the disclosure.
Claims (15)
1. A composite panel, comprising:
The sandwich layer comprises at least one layer of honeycomb structure, thermoplastic foam and a plurality of layers of heat insulation layers, wherein the honeycomb structure is made of thermoplastic resin;
and the surface layers are positioned at two opposite sides of the core layer and are adhered and fixed with the core layer, and the material of the surface layers comprises metal.
2. The composite panel of claim 1, wherein the core layer comprises a two-layer honeycomb structure having cells of the two-layer honeycomb structure offset from one another.
3. The composite panel of claim 1, wherein the honeycomb material comprises polypropylene, polyethylene terephthalate, or nylon.
4. The composite panel of claim 1, wherein the thermoplastic foam comprises a polypropylene foam, a polyethylene terephthalate foam, or a nylon foam.
5. The composite panel of claim 1, wherein the honeycomb material comprises polypropylene or polyethylene terephthalate and the thermoplastic foam is polypropylene foam.
6. The composite board of claim 1, wherein the honeycomb structure has a thickness of 3-300 mm.
7. The composite panel of claim 1, wherein the core layer further comprises a reinforcing layer bonded to at least one side of the honeycomb structure between the honeycomb structure and the surface layer, the reinforcing layer material comprising a continuous fiber reinforced thermoplastic resin.
8. The composite panel of claim 7, wherein the reinforcing layer has a thickness of 0.5mm to 2mm.
9. The composite panel of claim 1, further comprising:
And the thermoplastic adhesive film layers are positioned on two opposite sides of the core layer and are respectively bonded with the core layer and the surface layer.
10. The composite panel of claim 1, wherein the surface layer comprises:
a body layer, the material of the body layer comprising an aluminum alloy;
And the treatment layer is positioned on the surface of the body layer, and the material of the treatment layer comprises aluminum oxide.
11. The composite panel of claim 7, wherein the surface layer has a thickness of 0.3mm to 1mm.
12. The composite panel according to any one of claims 1-11, wherein the composite panel has at least one of the following properties:
i) The peel strength between the surface layer and the core layer is more than 150N cm/cm;
ii) the peel strength between two of the surface layers is 110N cm/cm or more;
iii) The flatness intensity of the composite board is more than 4.5 MPa;
iv) the composite board has a flat pull strength of 5.5MPa or more;
v) the bending strength of the composite plate is above 40 MPa.
13. A rail transit floor, comprising:
A composite panel according to any one of claims 1 to 12;
And the frame is arranged on at least one side surface of the core layer in a bonding way, and the frame is made of metal or fiber reinforced thermoplastic resin.
14. The rail transit floor of claim 13, wherein the frame is made of an aluminum alloy, and an oxide layer is formed on a surface of the frame.
15. The rail transit floor of claim 13, wherein the material of the frame is a short glass fiber reinforced polyethylene terephthalate resin and the material of the honeycomb structure is a polyethylene terephthalate resin.
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| CN202323490701.1U CN222080300U (en) | 2023-12-19 | 2023-12-19 | Composite board and rail transit floor |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202323490701.1U CN222080300U (en) | 2023-12-19 | 2023-12-19 | Composite board and rail transit floor |
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