A marine low-density high-strength non-metallic composite floor

Abstract

This invention discloses a low-density, high-strength non-metallic composite floor for marine applications, comprising a plastic frame, an upper surface layer, and a lower grid structure. The grid structure of the plastic frame is filled with foamed concrete or foamed aluminum, and the surface layer of the plastic frame is coated with a wear-resistant layer. The plastic frame is lightweight and high-strength; its asymmetrical design provides high-strength surface support with the upper surface layer and reduces weight with the lower grid structure; the cavities of the grid structure are filled with foamed concrete or foamed aluminum to increase flame retardancy and enhance the grid's support strength; the surface layer filled with foamed concrete is coated with a wear-resistant layer to enhance the wear resistance of the floor surface. This invention solves the problem of balancing weight and strength in flooring materials through a multi-heterogeneous material coupling technology; it is particularly suitable for applications where ship hulls and cabin decks have high requirements for the density, strength, and flame retardancy of the flooring materials.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of general-purpose non-metallic composite materials, and particularly relates to a low-density and high-strength non-metallic composite material plate, which is mainly used for deck paving in heavy-load occasions of a ship and realizes low-density and high-load general-purpose floor engineering application. BACKGROUND

[0002] At present, in order to realize general-purpose storage, the floor of a warehouse inside a ship is required to have general-purpose support and fixation functions for storage objects, so the floor is no longer made of simple steel plate components and is often designed as a functional floor. If the functional floor is simply made of steel materials, the weight of the ship structure will be greatly increased, which will cause serious waste of the overall index of the ship and resource consumption. Therefore, lightweight design of the functional floor becomes a problem to be solved. Because the marine environment is harsh and complex, the working temperature range is-55-60 DEG C, the ship is long-term in a salt spray environment, and there is a requirement for flame retardation, so the common lightweight floor material cannot meet the requirements. The typical functional floor material on the current ship adopts a lightweight polymer concrete base material, which has a certain bearing capacity, but the density is still high, and the material is brittle and easy to crack, even partially falls off, cannot adapt to the deformation working condition of the ship body, and has the problems of complex paving process and difficult maintenance, and the density and strength indexes cannot be considered, so a new material needs to be sought to optimize and replace.

[0003] A metal composite floor disclosed in Chinese Patent No. CN202017325U is a composite board material formed by pressing a metal composite board and a wooden board, which solves the problem of insufficient strength of the wooden board material, but the wooden board material is a flammable material and cannot be applied to a ship.

[0004] Chinese Patent No. CN110273530A discloses a double-layer pressure-resistant acrylic floor, which enhances the strength of the acrylic board material through a special structure of buckling two acrylic boards, but the acrylic board material itself does not have flame retardation ability, and the material itself is hard and brittle, which cannot adapt to the deformation and heavy-load impact working condition of the ship body, so it cannot be applied to a ship. SUMMARY

[0005] In view of the problem that the existing floor materials cannot be used for the deck and cabin deck of a ship and cannot consider the weight and strength of the material, the present application provides a ship low-density and high-strength non-metallic composite floor, which can meet the application scene of low-density and high-strength, especially the urgent practical demand of ship low-density and high-strength general-purpose floor paving, and solves the technical problem that the specific gravity and strength of the current similar materials cannot be considered.

[0006] The purpose of the present application is achieved in the following manner:

[0007] The application discloses a low-density high-strength non-metal composite floor for ships, which comprises a plastic framework, wherein the plastic framework comprises an upper surface layer and a lower grid structure, the grid structure of the plastic framework is filled with foamed concrete or foamed aluminum, and the surface layer of the plastic framework is coated with a wear-resistant layer.

[0008] The wear-resistant layer is a polyurethane layer.

[0009] The surface layer of the plastic framework is integrally formed with the grid structure.

[0010] The material of the plastic framework is modified polyphenyl ether.

[0011] The inner surface of the grid structure of the plastic framework is brushed with polyurethane glue.

[0012] The low-density high-strength non-metal composite floor for ships comprises a plastic framework, wherein the plastic framework comprises an upper surface layer and a lower grid structure, the grid structure of the plastic framework is filled with foamed concrete or foamed aluminum, and the surface layer of the plastic framework is coated with a wear-resistant layer. The plastic framework has the characteristics of light weight and high strength; the plastic framework is asymmetrically designed in the up-down direction, the upper surface layer provides high-strength surface support, and the lower grid structure is used for weight reduction; the cavities in the grid structure are filled with foamed concrete or foamed aluminum, so that the flame retardancy is improved, and the supporting force of the grid structure is improved; the surface layer filled with foamed concrete is coated with a wear-resistant layer, so that the wear resistance of the surface of the board is enhanced; the application solves the problem of the compromise between weight and strength of the paving material by means of a multi-element heterogeneous material coupling technology; the application is especially suitable for occasions where the paving material has high requirements on density, strength and flame retardancy, such as the deck of a ship body and a cabin (such as a general storage cabin), the grid structure filled with foamed concrete or foamed aluminum is not easy to crack and will not have a local shedding phenomenon, and can well adapt to the deformation working condition of the ship body, has good paving process and wear resistance, and well solves the above engineering problems, and is also suitable for other similar application occasions. BRIEF DESCRIPTION OF DRAWINGS

[0013] Fig. 1 Fig. 3 is a three-view drawing of the plastic framework.

[0014] Fig. 2 Fig. 4 is a three-view drawing of the grid structure of the plastic framework filled with foamed concrete or foamed aluminum.

[0015] Fig. 3 Fig. 5 is a schematic diagram of the overall structure of the application.

[0016] In the figure, 1 represents the plastic framework, 11 represents the surface layer, 12 represents the grid structure, 2 represents foamed concrete or foamed aluminum, and 3 represents the wear-resistant layer. DETAILED DESCRIPTION

[0017] As Figs. 1-3As shown, a marine-grade low-density, high-strength non-metallic composite floor includes a plastic frame 1, which is lightweight and high-strength. The plastic frame 1 includes an upper surface layer 11 and a lower grid structure 12. The plastic frame has an asymmetrical design, with the upper surface layer 11 providing high-strength surface support and the lower grid structure 12 used for weight reduction. The grid structure 12 of the plastic frame is filled with foamed concrete or foamed aluminum 2 to increase flame retardancy and improve the supporting force of the grid structure. Before filling with foamed concrete or foamed aluminum, polyurethane adhesive is applied to the inner surface of the grid structure of the plastic frame to enhance the bonding force between the grid structure of the plastic frame and the foamed concrete or foamed aluminum. The surface layer of the plastic frame 1 is coated with a wear-resistant layer 3 to enhance the wear resistance of the non-metallic composite floor surface. The wear-resistant layer 3 can be a polyurethane layer.

[0018] The surface layer of the plastic skeleton is integrally molded with the grid structure.

[0019] The engineering plastic is modified polyphenylene ether, and the density of the modified polyphenylene ether is 1.06 g / cm³. 3 It has a flame retardancy rating of V0 (UL94), a tensile strength of 63 MPa (10 KN, 20 mm / min), a flexural strength of 82 MPa (3 KN, 20 mm / min), and a simply supported beam impact strength of 27 (2 J, 2.9 m / s).

[0020] This invention solves the problem of balancing weight and strength in paving materials through a multi-heterogeneous material coupling technology. It is particularly suitable for situations where the density, strength, and flame retardancy of paving materials are required for ship hulls and cabin decks (such as general-purpose storage cabins). It is also applicable to other similar applications. It can adapt well to ship deformation conditions and has good paving processability and wear resistance. It effectively solves the problems of existing materials being brittle and prone to cracking, and even localized detachment.

[0021] Manufacturing process of marine low-density high-strength non-metallic composite floor

[0022] The polyphenylene oxide plastic skeleton 1 is injection molded according to the existing design drawings, and foamed concrete or foamed aluminum 2 is filled in its lower grid structure 12. The specific steps are as follows:

[0023] a) Before construction, use a brush to apply a layer of flame-retardant polyurethane adhesive to the entire interior of the polyphenylene ether grid structure 12 to improve the adhesion between the polyphenylene ether material and the foamed concrete. The interior of the polyphenylene ether grid structure 12 is the part where the grid structure contacts the filler. After the coating is applied, let it stand and dry for 24 hours before proceeding with subsequent construction.

[0024] b) Mix and foam the raw materials such as cement, fly ash, and foaming agent according to the set proportions required by the project, and make foamed concrete 2.

[0025] c) Fill the foamed concrete 2 into the grid structure 12 of the polyphenylene ether plastic skeleton and smooth it;

[0026] d) After standing for 12 hours, perform moisturizing curing, with a curing time of not less than 24 hours, to form standard-sized polyphenylene ether-foamed concrete blocks, such as... Fig. 2 As shown;

[0027] e) The prepared polyphenylene ether-foam concrete block is sanded to roughen the surface layer 11, which enhances the adhesion strength between the polyurethane wear-resistant layer 3 and the surface layer 11 of the plastic skeleton 2. After sanding, a two-component polyurethane wear-resistant layer 3 is sprayed onto the upper and lower surfaces of the polyphenylene ether-foam concrete block to achieve full coverage. The thickness of the wear-resistant layer can be adjusted according to requirements. After spraying, wait 5-7 days for the wear-resistant layer to fully harden. Then, sand any uneven areas on the surface to finally produce a low-density, high-strength non-metallic composite flooring material.

[0028] The prepared non-metallic marine deck material has a density of less than 1.3 g / cm³. 3 The compressive strength index is greater than 15MPa, and under the condition of more than 5000 cycles of 6T load (4 wheels) rolling abrasion resistance test, there are no obvious abrasion marks on the surface of the composite floor.

[0029] Marine low-density high-strength non-metallic composite flooring as a laying process on ship decks

[0030] 1) Deck pretreatment

[0031] Clean the deck of debris and rust. Use an angle grinder to grind down heavily rusted areas, but do not grind them smooth. You can wash the deck with water, or use a blower or vacuum cleaner to clean it. As long as the deck surface is clean, you can carry out the work even if the deck surface is damp. However, there should be no water on the deck surface during the work. Use a sponge to absorb the water.

[0032] 2) Laying composite flooring

[0033] To ensure a firm bond between the hull or cabin deck surface and the composite flooring, the hull or cabin deck surface and the bottom surface of the composite flooring (the surface where the plastic frame grid structure is located) need to be cleaned to ensure the surface is clean and free of debris. Mix polyurethane adhesive and organic filler, apply evenly to the hull or cabin deck surface to achieve the required leveling thickness, and then lay the composite flooring on the hull or cabin deck surface and smooth it out.

[0034] 3) Filling seams

[0035] Due to the large area of ​​the ship's hull or cabin deck, and the small size of a single composite floor panel, multiple panels need to be laid sequentially. Gaps are left between adjacent panels, which are filled with a sealant that provides adhesion and elasticity. This ensures the flatness and integrity of the finished floor, reducing the risk of cracking or breakage due to hull deformation. To ensure a strong bond, after the laid composite floor panels have cured, the gaps between the panels must be clean and free of debris. The sealant is then squeezed into the gaps and smoothed with a trowel. The flooring is left to stand for 24 hours, and then fully cured for 7 days, completing the installation.

[0036] The completed deck has a smooth, flat surface. Its internal polyphenylene ether-foamed concrete composite material can withstand high stress without damage, while the surface polyurethane wear-resistant layer enhances the overall durability and abrasion resistance of the deck. The overall material is flame-retardant, low-toxicity, low-density, and high-strength. The material produced based on this technology has a density of 1.2 g / cm³. 3 Under the premise of [condition], the compressive strength index can reach more than 15 MPa.

[0037] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several changes and improvements without departing from the overall concept of the present invention, and these should also be considered within the scope of protection of the present invention.

Claims

1. A low density high strength non-metal composite floor for marine use, characterized in that: The plastic framework comprises an upper surface layer and a lower grid structure, the grid structure of the plastic framework is filled with foamed concrete or foamed aluminum, and the surface layer of the plastic framework is coated with a wear-resistant layer. The surface layer and the grid structure of the plastic framework are integrally formed, and the inner surface of the grid structure of the plastic framework is coated with polyurethane glue. The plastic framework is asymmetrically designed, the upper surface layer provides high-strength surface support, the lower grid structure is used for weight reduction, and the cavities of the grid structure are filled with foam concrete or foam aluminum to increase the fire resistance and improve the support of the grid structure; the density of the non-metallic marine deck material is less than 1.3 g / cm 3 , the compressive strength index is greater than 25 MPa, and the composite floor surface has no obvious wear marks under the condition of 4-wheel 6T load rolling wear resistance test more than 5000 times.

2. The low density high strength non-metal composite floor for ship as claimed in claim 1, wherein: The wear-resistant layer is a polyurethane layer.

3. The low density high strength non-metal composite floor for ship as claimed in claim 1, wherein: The material of the plastic framework is modified polyphenyl ether.

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