A multi-layer coated profile and a method for producing the same

Abstract

The application provides a multi-layer cladding profile, which comprises at least one skin layer and at least one core material, and the skin layer is closed-loop or semi-closed-loop wrapped around the core material in the cross section of the profile. The profile can comprise multiple skin layers and core materials, the multiple skin layers and core materials can be alternately wrapped, and the same skin side can also be internally provided with multiple core materials. The material of the skin layer and the core material is diversified, and according to the specific requirements of the building profile, a material with certain bearing capacity or certain functionality or both bearing capacity and functionality is selected as the core material. The surface of the skin layer is smooth and beautiful, has certain strength, corrosion resistance and thermoplasticity, and can be once-molded to form a skin layer structure, and then the core material is filled; or according to the specific shape of the core material, targeted outer wrapping can be carried out, and finally a profile with certain external shape is formed, and the overall structural performance meets the actual requirement.

Description

Technical Field

[0001] This invention belongs to the field of composite building profile technology, specifically relating to a multi-layer coated profile and its preparation method. Background Technology

[0002] Thermoplastic resins possess advantages such as corrosion resistance, impact resistance, recyclability, good hot processing performance, and high design freedom. In structures with high load-bearing requirements, thermoplastic resins can be composited with high-performance fibers. Their superior performance in terms of lightweight and high strength is further highlighted when combined with high-performance fiber reinforcements, enabling the low-cost and rapid preparation of high-performance materials and meeting the critical needs of building engineering for high efficiency, rapid construction, and long-term maintenance-free operation. Currently, the basic form of fiber-reinforced thermoplastic resin-based composites is usually prepreg, primarily used in aerospace vehicles. The manufacturing process typically involves layering and bonding prepregs together to form specific structural forms.

[0003] Limited by the single planar structure of prepreg, it cannot meet the needs of the construction, transportation, energy and other fields for profiles with a certain spatial structure and both load-bearing capacity and functionality.

[0004] Patent CN201610764666.3 provides a lightweight, low-cost, impact-resistant prepreg composite board. The composite board is a sandwich structure composed of a prepreg upper skin, a functional core material, and a prepreg lower skin. The functional core material is one or more of the following: chopped glass fiber reinforced thermoplastic resin prepreg, unidirectional long fiber prepreg, mesh fiberglass cloth, and woven fiber prepreg. The upper and lower skins of the prepreg are multilayer composite materials of chopped glass fiber reinforced thermoplastic resin, and the layers are stacked in the same or opposite directions.

[0005] Patent CN201610526251.2 discloses a foamed sandwich material, its manufacturing method, and its application. The foamed sandwich material is a three-layer sandwich structure composed of a foamed thermoplastic resin core layer and a fiber-reinforced thermoplastic resin composite skin layer, wherein the thermoplastic resin used in both the core and skin layers is the same type. The manufacturing method of the foamed sandwich material employs hot lamination and cold pressing to bond the core and skin layers, avoiding the use of adhesive materials. This further ensures the foamed sandwich material has a single material composition, facilitating easier and more convenient recycling.

[0006] Currently, thermoplastic resins and thermoplastic resin-based composite materials are mainly used in panel composite profiles. The types of materials for the internal core material are limited, the functionality is limited, and the stress is mainly considered in the unidirectional stress along the length of the panel. The overall profile is not resistant to bending, has low compressive strength, and has a narrow range of applications. The multi-layer flat-laying method is relatively complex, and it is prone to delamination and detachment after long-term use. At present, the main composite profiles cannot meet the requirements of other types of building profiles with better coupling effects in terms of multi-dimensional dimensions, strength, toughness, and stress functionality. Summary of the Invention

[0007] To address the aforementioned problems, the present invention provides a multi-layer coated profile, the profile comprising at least one skin layer and at least one core material, wherein the skin layer covers the core material in a closed-loop or semi-closed-loop manner on the cross-section of the profile, the material of the skin layer is selected from thermoplastic resin or thermoplastic resin-based composite materials, and the core material is a functional core material.

[0008] In the cross-section of the profile, the skin layer covers the core material 360 degrees, that is, the skin layer covers the inner core material in a closed loop, or the skin layer covers the core material in a semi-closed loop, that is, it has openings and covers three sides or two adjacent sides of the core material. Traditional multi-layer composite building profiles often adopt a sandwich-like structure, only covering the top and bottom sides of the inner core material, leaving the left and right sides of the core material exposed, and they are mostly plate-shaped profiles. This most common structure has the disadvantage of weak bonding between layers, which makes it easy to delaminate and fall off after long-term use. The skin layer of the profile described in this invention will uniformly cover all four sides of the inner core material circumferentially. In cross-section, the skin layer covers the core material in a closed loop 360 degrees, or covers three sides or two adjacent sides of the core material. This structure makes the bonding between the skin layer and the core material tighter, and it is less likely to cause structural failure and detachment during actual long-term use under stress.

[0009] Preferably, the closed-loop coating of the core material by the skin layer can greatly improve the overall load-bearing capacity of the profile under multi-directional stress. For example, when the profile bears normal pressure, the force transmitted to the skin layer by the overall structure is transformed into a large circumferential internal stress, which effectively constrains the pressure-bearing structure of the core, thereby greatly improving the overall compressive strength of the profile. Therefore, it exhibits superior compressive performance compared to other non-circumferential coating materials. In addition, since the skin layer of the profile has strong tensile strength along the reinforcing fiber direction and has a uniform surface material, when designing the load-bearing capacity, considering the overall stress characteristics of the profile, strengthening the coverage of the skin layer in the weak stress areas of the core structure will greatly improve the overall structural load-bearing performance. The design and manufacturing methods are simple.

[0010] Preferably, the profile includes at least two skin layers and at least two core layers. Multiple core layers may be provided inside the same outer skin side, or the skin layers and core layers may alternately cover the material. For example, the profile includes three skin layers and three core layers, with the outer-to-inner covering sequence being first skin layer, first core layer, second skin layer, second core layer, third skin layer, and third core layer. Alternatively, the outer-to-inner covering sequence may be first skin layer, first core layer, second core layer, second skin layer, third skin layer, and third core layer.

[0011] The outer layer is made of one or more of the following materials: thermoplastic resin, thermoplastic resin-based fiber composite prepreg, thermoplastic resin-based chopped fiber composite, or thermoplastic resin-based composite. The outer layer has a smooth and aesthetically pleasing surface, possesses a certain strength, exhibits thermoplasticity, is highly designable, and allows for diverse and convenient processing. The outer layer material is suitable for bonding with the core material, can be granulated and recycled after crushing, and is environmentally friendly and pollution-free.

[0012] The thermoplastic resin is selected from one or more of polyetheretherketone, polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamide, polycarbonate, polyphenylene ether, polysulfone, polyethylene terephthalate, and rubber. The thermoplastic resin in the thermoplastic resin-based composite material is selected from the above-mentioned thermoplastic resins.

[0013] The core material is selected from one or more of the following: cement, metal, concrete, foamed plastic, foam, sponge, or honeycomb material. The core material is a functional core material with diverse materials; specifically, depending on the specific requirements of the building profile, materials with certain load-bearing capacity, certain functionality, or both load-bearing capacity and functionality are selected as the core material.

[0014] Due to the high plasticity of the skin layer, on the one hand, it can be used to coat the outer layer in a targeted manner according to the specific shape of the core material of the building profile, so that the profile has a certain external shape and the overall structural performance meets the actual requirements; on the other hand, according to the macroscopic structural requirements of the building profile, a multi-layer skin layer structure containing the skin layer can be prepared by first pressing a film, and then a core material with a fixed external shape and meeting the actual performance requirements can be obtained by core injection method to form the final profile.

[0015] The cross-section of the profile is selected from circles, rectangles, ellipses, triangles, trapezoids, and other irregular shapes. The surface of the profile is planar or curved along its length. The profile has various shapes to suit the needs of different building structures or shapes. For example, the profile is rectangular in shape, with both the skin and core material covered in rectangles, and can be used as a brick profile; the profile is cylindrical in shape, with both the skin and core material covered in circles, and can be used as a column profile; the outer surface of the profile is curved, and the overall shape is wavy, with both the skin and core material adapted to wavy covering, and can be used as a support and decorative profile.

[0016] Preferably, the profile has an internal partition, which is perpendicular to the inner surface of the profile's skin layer.

[0017] Preferably, the partition is supported between the inner surface of the skin and the adjacent core material.

[0018] The partition can be a short-point support plate. The main function of the partition is to reinforce the internal structure of the profile, prevent deformation of the internal structure, promote the mutual transmission of stress in the multi-layered stress structure within the profile, so as to coordinate and enhance the overall stress performance, while strengthening the external support.

[0019] Preferably, the profile has a connecting rod inside, and the connecting rod is parallel to the cross-section of the profile.

[0020] Preferably, one end of the connecting rod is located inside the innermost core material, and the other end is located on the inner surface of the outermost skin layer of the profile. More preferably, one end of the connecting rod is located at the center of the innermost core material. The connecting rod serves to provide an effective and reliable connection between the skin layer and the core material, between skin layers, and between core materials, ensuring the overall structural stability of the multi-layered skin and core materials, as well as the reliable connection between the multiple layers.

[0021] The profile described in this invention has internal partitions or connecting rods, which are simple in structure and easy to use. It can improve the stress environment inside the profile and promote uniform stress distribution within the system. At the same time, it strengthens the connection between layers, stabilizes the structure, promotes effective collaboration between layers, and thus greatly improves the overall multi-directional load-bearing capacity.

[0022] The present invention also provides a method for manufacturing the profile, the method comprising the following steps:

[0023] (1) The innermost core material is formed on a prefabrication device having connecting rods and partitions;

[0024] (2) The innermost skin layer is hot-pressed onto the outside of the innermost core material;

[0025] (3) Repeat steps (1)-(2) to obtain the profile having multiple skin layers and core material.

[0026] The present invention also provides another method for manufacturing the profile, the method comprising the following steps:

[0027] (1) Molding forms the outermost skin layer;

[0028] (2) Molding to form the outermost skin layer;

[0029] (3) Place the second outermost layer of the dermis inside the outermost layer of the dermis, and position the two layers with a connecting rod.

[0030] (4) A partition is added between the second outermost dermal layer and the outermost dermal layer;

[0031] (5) Fill or cast the outermost core material between the two skin layers obtained in steps (1) and (2);

[0032] (6) Repeat steps (3)-(5) to obtain the profile having multiple skin layers and core material.

[0033] The advantages of the profile described in this invention are: (1) the skin layer has high strength, light weight, durability, environmental protection and recyclability; (2) the core material can not only bear certain mechanical performance requirements, but also meet functional requirements; (3) it has strong designability, the multi-layer structure is flexible and versatile, and at the same time meets functional design and structural design; (4) it has high structural stability and fast and efficient processing. Attached Figure Description

[0034] Figure 1 This is a structural diagram of a multi-layered profile.

[0035] Figure 2 This is a structural diagram of another optional multi-layered cladding profile.

[0036] Figure 3 This is a structural diagram of another optional multi-layered cladding profile.

[0037] Figure 4 This is a structural diagram of another optional multi-layered cladding profile.

[0038] Figure 5 This is a structural diagram of another optional multi-layered cladding profile.

[0039] In the attached diagram, 1-cortex, 101-first cortex, 102-second cortex, 103-third cortex, 2-core material, 201-first core material, 202-second core material, 203-third core material, 3-first connecting rod, 301-second connecting rod, 4-first partition, 401-second partition. Detailed Implementation

[0040] Example 1

[0041] The structure of the multi-layer covered profile in this embodiment is as follows: Figure 1 As shown, it includes a skin layer 1 and a core material 2. On the cross-section of the profile, the skin layer 1 covers the core material 2 in a closed loop. The material of the skin layer 1 is polypropylene resin, and the material of the core material 2 is polyethylene foam. The cross-section of the multi-layered profile is circular, and the whole is cylindrical.

[0042] The preparation method of the multi-layer coated profile in this embodiment is as follows: (1) the skin layer 1 is molded in one step; (2) the core material 2 is filled inside the molded skin layer 1.

[0043] Table 1 Mechanical properties of Example 1

[0044]

[0045] Example 2

[0046] The structure of the multi-layer covered profile in this embodiment is as follows: Figure 2 As shown, the profile includes two skin layers and two core layers, which are arranged from the outside to the inside as a first skin layer 101, a first core material 201, a second skin layer 102, and a second core material 202. In the cross-section of the profile, the second skin layer 102 covers the second core material 202 in a closed loop, and the first skin layer 101 covers the first core material 201 in a closed loop. Both skin layers are made of polypropylene-based chopped glass fiber composite material. The first core material 201 is a sponge, and the second core material 202 is a polypropylene plastic honeycomb material. The cross-section of the second core material 202 is elliptical, and the cross-section of the first core material 201 is rectangular. The overall profile is a cuboid.

[0047] The profile contains internal partitions and connecting rods. Both partitions are perpendicular to the outer surface of the profile. The first partition 4 extends from the first skin layer 101 into the first core material 201, and the second partition 401 extends from the outside of the second skin layer 102 into the first core material 201. The partitions facilitate stress transfer within the multi-layered load-bearing structure of the profile, coordinating and enhancing overall load-bearing performance while strengthening external support. The first connecting rod 3 and the second connecting rod 301 are parallel to the cross-section of the profile and penetrate its cross-section but do not protrude beyond the outer surface. The first connecting rod 3 and the second connecting rod 301 intersect each other at an angle of 120 degrees. These two connecting rods effectively connect the two skin layers and the two core materials, ensuring structural stability and reliable connection between the skin layers and core materials, while also enhancing the strength of the profile.

[0048] The method for preparing the profile in this embodiment is as follows: (1) molding to form a first skin layer; (2) molding to form a second skin layer; (3) placing the second skin layer inside the first skin layer and positioning the two layers with two connecting rods; (4) adding two partitions between the second skin layer and the first skin layer; (5) filling the first core material between the first skin layer and the second skin layer, and filling the second core material inside the second skin layer.

[0049] Table 2 Mechanical properties of Example 2

[0050]

[0051]

[0052] Example 3

[0053] The structure of the multi-layer covered profile in this embodiment is as follows: Figure 3As shown, the profile comprises three skin layers and three core layers, arranged from the outside in as follows: first skin layer 101, first core material 201, second skin layer 102, second core material 202, third skin layer 103, and third skin layer 203. In the cross-section of the profile, the first skin layer 101 completely covers the first core material 201, the second skin layer 102 completely covers the second core material 202, and the third skin layer 103 completely covers the third core material 203. All three skin layers are made of polyphenylene sulfide resin prepreg tape. The first core material 201 is made of copper, the second core material 202 is made of polyethylene foam, and the third core material 203 is made of concrete. The profile has a rectangular cross-section and is an overall cuboid.

[0054] The method for preparing the profile in this embodiment is as follows: (1) molding to form a first skin layer; (2) molding to form a second skin layer; (3) molding to form a third skin layer; (4) filling a first core material between the first skin layer and the second skin layer; (5) filling a second core material between the second skin layer and the third skin layer; (6) casting a third core material inside the third skin layer.

[0055] Table 3 Mechanical properties of Example 3

[0056]

[0057] Example 4

[0058] The structure of the multi-layer covered profile in this embodiment is as follows: Figure 4 As shown, it includes a skin layer 1 and a core material 2. On the cross-section of the profile, the skin layer 1 covers the core material 2 in a closed loop. The material of the skin layer 1 is polyphenylene sulfide resin, and the material of the core material 2 is glass fiber reinforced honeycomb material. The cross-section of the profile is arched, and the whole is arched.

[0059] The method for preparing the profile in this embodiment is as follows: (1) the polyurethane honeycomb material is made into a core material shape; (2) a skin layer is hot-pressed onto the outside of the core material.

[0060] Table 4 Mechanical properties of Example 4

[0061]

[0062] Example 5

[0063] The structure of the multi-layer covered profile in this embodiment is as follows: Figure 5 As shown, it includes a skin layer 1 and a core material 2. On the cross-section of the profile, the skin layer 1 covers the core material 2 in a semi-closed loop, that is, the skin layer 1 covers the upper surface and two sides of the core material 2. The material of the skin layer 1 is glass fiber cloth polycarbonate composite tape, and the material of the core material 2 is polyurethane foam. The cross-section of the profile is rectangular, and the whole is a cuboid.

[0064] The method for preparing the profile in this embodiment is as follows: (1) making the polyurethane foam material into a core shape; (2) hot-pressing a skin layer on the outside of the core material.

[0065] Table 5 Mechanical properties of Example 5

[0066]

Claims

1. A method for the production of a multi-layer clad profile, characterized in that, The method comprises the following steps: (1) forming the outermost skin layer by molding; (2) forming the next outer skin layer by molding; (3) placing the next outer skin layer inside the outermost skin layer, and positioning the two layers by connecting rods; (4) adding a partition between the next outer skin layer and the outermost skin layer; (5) filling or pouring the outermost core material between the two skin layers obtained in steps (1) and (2); (6) repeating steps (3)-(5) to obtain the profile with multiple skin layers and core materials, The profile comprises at least two skin layers and at least two core materials, and in the cross-section of the profile, the skin layers are closed-loop or semi-closed-loop wrapped around the core materials, the material of the skin layer is selected from thermoplastic resin or thermoplastic resin-based composite material, and the core material is functional core material, The profile is provided with a partition inside, the partition is perpendicular to the inner surface of the skin layer of the profile, the partition is supported between the inner surface of the skin layer and the adjacent core material, the profile is provided with a connecting rod inside, the connecting rod is parallel to the cross-section of the profile, one end of the connecting rod is arranged in the innermost core material, and the other end of the connecting rod is arranged on the inner surface of the outermost skin layer of the profile.

2. The production method according to claim 1, characterized by, In the cross-section of the profile, the skin layers are closed-loop wrapped around the core materials.

3. The method of claim 1, wherein, The multiple skin layers and the multiple core materials are alternately wrapped.

4. The method of claim 1, wherein, The material of the skin layer is selected from one or more than two combinations of thermoplastic resin, thermoplastic resin-based fiber composite material prepreg, thermoplastic resin-based chopped fiber composite material, or thermoplastic resin-based composite material; The functional core material is selected from one or more than two combinations of cement, metal, concrete, foamed plastic, foam, sponge, or honeycomb material.

5. The preparation method according to claim 1, characterized in that, The cross-section of the profile is selected from circular, rectangular, oval, triangular, or trapezoidal, and the surface of the profile is planar or curved along the length direction.

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