Lightweight compass deck and material preparation method thereof

Abstract

The invention provides a lightweight compass deck and a material preparation method thereof, the lightweight compass deck comprises an upper skin layer, a core material and a lower skin layer, the upper skin layer, the core material and the lower skin layer are bonded from top to bottom, the upper skin layer and the lower skin layer are both made of fiber reinforced resin matrix composite materials, and the fiber reinforced resin matrix composite materials are made of fiber reinforced resin matrix composite materials. And the core material is a foam material. Compared with a traditional compass deck, the upper compass deck has the advantage of being light in weight.

Description

Technical Field

[0001] The present invention relates to the field of compass deck manufacturing, and in particular to a lightweight compass deck and a material preparation method thereof. Background Art

[0002] The compass deck of a container ship, located above the wheelhouse, is the highest open-air deck on the ship. It houses a variety of equipment, including a standard magnetic compass, radar antenna, GPS antenna, searchlight, and fire monitor. As a key location for vital navigational equipment, its performance directly impacts the ship's navigation accuracy and safety. However, traditional steel compass decks have gradually exposed limitations over extended periods of navigation, such as heavy weight, poor corrosion resistance, and high vibration and noise levels. Summary of the Invention

[0003] In view of the above-mentioned shortcomings of the related art, an object of the present invention is to provide a lightweight compass deck and a method for preparing the same.

[0004] To achieve the above-mentioned and other related purposes, the present invention provides a lightweight compass deck, comprising an upper skin layer, a core material, and a lower skin layer, wherein the upper skin layer, the core material, and the lower skin layer are bonded together in order from top to bottom, the upper skin layer and the lower skin layer are both made of a fiber-reinforced resin-based composite material, and the core material is a foam material.

[0005] Optionally, the upper skin layer, the core material and the lower skin layer are bonded together in order from top to bottom using a structural adhesive film, and the bonding strength is not less than 20 MPa.

[0006] Optionally, the fibers in the fiber-reinforced resin-based composite material are one or more of carbon fibers, glass fibers, basalt fibers, aramid fibers, polyimide fibers, and polybenzoxazole fibers.

[0007] Optionally, the resin material in the fiber-reinforced resin-based composite material is one or more of modified phenolic resin, modified epoxy resin, modified vinyl ester resin, modified silicon-containing aromatic acetylene resin, modified cyanate ester resin and modified furan resin.

[0008] Optionally, the core material has a thickness of 20 to 80 mm.

[0009] Optionally, the upper skin layer and the lower skin layer both include multiple fiber layers, and the multiple fiber layers are laid at different laying angles, and the laying angles of the skin layers are one or more of [0° / 45°], [0° / 90°], [0° / -45° / 0° / 45°], [0° / 45° / 90° / 0°] and [0° / 30° / 0° / 60°].

[0010] Optionally, the lower skin layer is provided with a reinforcement structure, and the structural cross-section of the reinforcement structure is one or more of T-shaped, J-shaped, I-shaped, groove-shaped (C-shaped), angle-shaped (L-shaped) and hat-shaped.

[0011] Optionally, the reinforcement structure includes multiple fiber layers, and the multiple fiber layers are laid at different laying angles. The laying angle of the reinforcement structure is [-45° / 45°] or [0° / -45° / 45° / 0°].

[0012] A method for preparing a compass deck material, the material being used as a resin matrix in the aforementioned lightweight compass deck, comprises adding 2-amino-5,6-dichlorobenzothiazole, 4-hydroxytetraimidazole, paraformaldehyde, and 1,4-dioxane into a flask, stirring uniformly, and reacting at 110°C for 16 hours; pouring the solution into deionized water, rapidly stirring to obtain a solid precipitate, filtering the solid precipitate, washing the solid precipitate multiple times with ethanol and deionized water, and drying the solid precipitate to obtain a flame-retardant benzoxazine resin; and melt-blending the benzoxazine resin and an epoxy resin in a mass ratio of (1-3):(9-7) to form a benzoxazine-modified epoxy resin.

[0013] As described above, the lightweight compass deck and the method for preparing the same of the present invention have the following beneficial effects: the lightweight compass deck prepared by the present invention is made of a fiber-reinforced resin-based composite material, and has a structure in the form of upper and lower skin layers + core material, wherein the upper and lower skin layers play the role of maintaining rigidity and strength, and corrosion resistance, while the core material mainly increases rigidity. Compared with traditional compass decks, the lightweight compass deck is expected to be reduced in weight by approximately 20% to 50%, having an outstanding advantage in lightweight level. At the same time, the compass deck of the present invention is flame retardant. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Shown is a schematic cross-sectional view of a compass deck according to an embodiment of the present invention.

[0015] Figure 2 Shown is a schematic diagram of a three-dimensional compass deck according to an embodiment of the present invention.

[0016] Component number description

[0017] 1. Upper skin layer; 2. Core material; 3. Lower skin layer; 4. Reinforced structure. DETAILED DESCRIPTION

[0018] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention.

[0019] For example, when describing the embodiments of the present invention, cross-sectional views of device structures may be partially enlarged to scale for ease of explanation. Furthermore, these schematic views are merely illustrative and should not limit the scope of the present invention. Furthermore, in actual manufacturing, three-dimensional dimensions, including length, width, and depth, should be included.

[0020] For ease of description, spatially relative terms such as "under," "below," "below," "below," "above," and "on" may be used herein to describe the relationship of one element or feature to other elements or features shown in the drawings. It will be understood that these spatially relative terms are intended to encompass orientations of the device in use or operation in addition to the orientation depicted in the drawings. Additionally, when a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or one or more intervening layers may be present. As used herein, "between" is inclusive of both endpoints.

[0021] In the context of the present application, a structure described as a first feature being "above" a second feature may include embodiments where the first and second features are formed in direct contact, and may also include embodiments where an additional feature is formed between the first and second features, such that the first and second features may not be in direct contact.

[0022] It should be noted that the illustrations provided in this embodiment are only used to schematically illustrate the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component can be changed at will, and the component layout type may also be more complicated.

[0023] like Figure 1 As shown, this embodiment provides a lightweight compass deck comprising an upper skin layer 1, a core material 2, and a lower skin layer 3. The upper skin layer 1, core material 2, and lower skin layer 3 are bonded together from top to bottom using a structural adhesive film, with a bonding strength of no less than 20 MPa. Both the upper skin layer 1 and the lower skin layer 3 are made of a flame-retardant fiber-reinforced resin-based composite material. Fire-retardant coatings can also be applied to the surfaces of the upper skin layer 1 and the lower skin layer 3. The core material 2 is made of foam or other lightweight materials.

[0024] The fibers in the fiber-reinforced resin-based composite material may be one or more of carbon fiber, glass fiber, basalt fiber, aramid fiber, polyimide fiber, and polybenzoxazole fiber. The resin material may be one or more of modified phenolic resin, modified epoxy resin, modified vinyl ester resin, modified silicon-containing aromatic acetylene resin, modified cyanate ester resin, and modified furan resin. In this embodiment, both the upper skin layer 1 and the lower skin layer 3 utilize benzoxazine-modified epoxy resin.

[0025] The fire retardant coating on the upper skin layer 1 and the lower skin layer 3 is an intumescent fire retardant. Compared to non-intumescent fire retardants, intumescent fire retardants have higher flame retardancy. By spraying intumescent fire retardant coating on the upper skin layer 1 and the lower skin layer 3, safety is maximized.

[0026] The core material 2 is made of one or more of polyimide foam, polyurethane foam, polyvinyl chloride foam, polyisophthalamide (m-phenylene diamine) foam, polymethacrylimide foam, polystyrene foam, and polyethylene terephthalate foam.

[0027] In this embodiment, the thickness of the core material 2 is 20-80 mm.

[0028] The surface of the lower skin layer 3 is provided with a reinforcing structure 4, which serves to enhance the compass deck's strength. The cross-sectional shape of the reinforcing structure 4 can be one or more of a T-shape, a J-shape, an I-shape, a channel (C-shape), an angle (L-shape), and a cap shape. The reinforcing ribs are connected to the compass deck via bolts. Specifically, the bolts are pre-embedded in the compass deck. When installing the reinforcing structure 4, the bolts are inserted through the corresponding holes in the reinforcing structure 4, and then nuts are installed on the bolts for tightening.

[0029] The reinforcement structure 4 is composed of multiple fiber layers, each of which is one or more of carbon fiber, glass fiber, basalt fiber, aramid fiber, polyimide fiber, and polybenzoxazole fiber. Each fiber is uniformly coated with a benzoxazine-modified epoxy resin by impregnation. Each fiber layer is laid at a different layup angle, and the layup angles between two layers are different. The layup angles of the reinforcement structure 4 can be [-45° / 45°] or [0° / -45° / 45° / 0°], preferably [-45° / 45°]. Taking the layup angle of [-45° / 45°] as an example, the fibers in the first fiber layer are laid at a -45° angle, and the second fiber layer is laid on the first layer with the fibers in the second layer laid at a 45° angle. The fibers are then laid alternately to form the reinforcement structure 4. In this embodiment, the thickness of a single fiber layer of each reinforcement structure 4 is 0.1 to 0.5 mm, and the overall thickness is 2 to 6 mm.

[0030] This embodiment also discloses a method for preparing a compass deck material. The material used for the compass deck is benzoxazine-modified epoxy resin, which is used as a resin matrix in the upper skin layer 1 and the lower skin layer 3. The specific steps include:

[0031] Step 1: Add 2-amino-5,6-dichlorobenzothiazole, 4-hydroxytetraimidazole, paraformaldehyde and 1,4-dioxane into a flask, stir evenly and react at 110°C for 16 hours; 2-amino-5,6-dichlorobenzothiazole and 4-hydroxytetraimidazole can improve the flame retardancy of the reaction product.

[0032] Step 2: Pour the solution in step 1 into deionized water, stir rapidly to obtain a solid precipitate, filter, and then wash with ethanol and deionized water multiple times, and dry to obtain a flame-retardant benzoxazine resin.

[0033] Step 3: melt-blending the benzoxazine resin and the epoxy resin in a mass ratio of (1-3): (9-7) to form a benzoxazine-modified epoxy resin, which has good flame retardancy.

[0034] The lightweight compass deck of the present invention achieves the flame retardant function requirement of the composite material compass deck by synthesizing a new benzoxazine resin containing hybrid structures such as thiazole and imidazole and halogen, and utilizing the new benzoxazine resin to modify the epoxy resin.

[0035] After obtaining the benzoxazine-modified epoxy resin, the upper skin layer 1 or the lower skin layer 3 can be made. The resin is first dissolved in a solvent to form a solution, and then the fiber is immersed in the solution so that the fiber surface is coated with a layer of benzoxazine-modified epoxy resin. Then, the fiber is pre-dried so that the fiber surface is in a semi-cured state. The fiber is then laid according to the skin layer laying angle, and then a molding process is used to form the upper skin layer 1 or the lower skin layer 3. Among them, the fiber is one or more of carbon fiber, glass fiber, basalt fiber, aramid fiber, polyimide fiber and polybenzoxazole fiber, the skin layer laying angle is one or more of [0° / 45°], [0° / 90°], [0° / -45° / 0° / 45°], [0° / 45° / 90° / 0°] and [0° / 30° / 0° / 60°], the thickness of each skin layer is 0.5~2mm, the thickness of the upper skin layer 1 or the lower skin layer 3 is 4~10mm, and [0° / -45° / 0° / 45°] or [0° / 30° / 0° / 60°] is preferred here.

[0036] For example, the lightweight compass deck is reinforced with a T-shaped stiffening structure 4, where the upper skin layer 1 and the lower skin layer 3 are made of carbon fiber reinforced modified epoxy resin composite materials, the core material 2 is polyethylene foam with a thickness of 50 mm, the single layer thickness of the upper skin layer 1 and the lower skin layer 3 is 0.2 mm, a total of 25 layers are laid, the total thickness is 5 mm, and the lay-up angle is [0° / 45°]; the stiffening structure 4 is 2 mm thick, with a total of 10 layers, and the lay-up angle is [-45° / 45°]. By changing only the layup angles in the upper skin layer 1 and the lower skin layer 3 while keeping other conditions unchanged, a variety of compass decks with different layup forms can be designed. Simulated stress analysis is then performed on each of the different compass decks. By analyzing the maximum displacement and maximum stress of the compass deck, the compass deck with the [0° / 30° / 0° / 60°] layup design exhibits the smallest maximum displacement and maximum stress. This layup design can effectively disperse stress, making the composite material more uniform and less concentrated when subjected to stress, thereby improving the overall bending performance and shear strength of the deck.

[0037] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A lightweight compass deck, characterized in that: It includes an upper skin layer, a core material and a lower skin layer, wherein the upper skin layer, the core material and the lower skin layer are bonded in order from top to bottom, the upper skin layer and the lower skin layer are both made of fiber-reinforced resin-based composite materials, and the core material is a foam material.

2. The lightweight compass deck according to claim 1, characterized in that: The upper skin layer, the core material and the lower skin layer are bonded together in order from top to bottom by a structural adhesive film, and the bonding strength is not less than 20 MPa.

3. The lightweight compass deck according to claim 1, characterized in that: The fibers in the fiber-reinforced resin-based composite material are one or more of carbon fibers, glass fibers, basalt fibers, aramid fibers, polyimide fibers and polybenzoxazole fibers.

4. The lightweight compass deck according to claim 1, characterized in that: The resin material in the fiber-reinforced resin-based composite material is one or more of modified phenolic resin, modified epoxy resin, modified vinyl ester resin, modified silicon-containing aromatic acetylene resin, modified cyanate ester resin and modified furan resin.

5. The lightweight compass deck according to claim 1, characterized in that: The thickness of the core material is 20 to 80 mm.

6. The lightweight compass deck according to claim 1, characterized in that: The upper skin layer and the lower skin layer both include multiple fiber layers, which are laid at different laying angles. The laying angles of the skin layers are one or more of [0° / 45°], [0° / 90°], [0° / -45° / 0° / 45°], [0° / 45° / 90° / 0°] and [0° / 30° / 0° / 60°].

7. The lightweight compass deck according to claim 1, characterized in that: The ply thickness of each fiber layer in the upper skin layer or the lower skin layer is 0.5 to 2 mm, and the thickness of the upper skin layer or the lower skin layer is 4 to 10 mm.

8. The lightweight compass deck according to claim 1, characterized in that: The lower skin layer is provided with a reinforcement structure, and the structural cross-section of the reinforcement structure is one or more of T-shaped, J-shaped, I-shaped, groove-shaped (C-shaped), angle-shaped (L-shaped) and hat-shaped.

9. The lightweight compass deck according to claim 1, characterized in that: The reinforcement structure includes multiple fiber layers, and the multiple fiber layers are laid according to different laying angles. The laying angle of the reinforcement structure is [-45° / 45°] or [0° / -45° / 45° / 0°].

10. A method for preparing a compass deck material, wherein the material is used as the resin matrix of the lightweight compass deck according to claim 1, characterized in that: The specific steps include: 2-Amino-5,6-dichlorobenzothiazole, 4-hydroxytetraimidazole, paraformaldehyde and 1,4-dioxane were added to the flask, stirred evenly and reacted at 110°C for 16 hours; The solution in the above step is poured into deionized water, and the solid precipitate is obtained by rapid stirring, and then filtered, and then washed with ethanol and deionized water for multiple times, and dried to obtain a flame-retardant benzoxazine resin; The benzoxazine resin and the epoxy resin are melt-blended in a mass ratio of (1-3):(9-7) to form a benzoxazine-modified epoxy resin.

Images