Basalt fiber reinforced composite material and method for manufacturing the same

Abstract

The application discloses a basalt fiber reinforced composite material and a preparation method thereof. The basalt fiber reinforced composite material is composed of a metal framework, filling materials and a basalt fiber reinforced surface layer. The inner and outer layers of the metal framework are respectively glued with the basalt fiber reinforced surface layer. The hollow part and the outer periphery of the metal framework are respectively filled with the filling materials of the impregnated resin composition. The basalt fiber reinforced surface layer is prepared by the following method: basalt fiber cloth is cut according to the length and width of the metal framework, the fiber cloth is laid flat in a mold after cutting, and a total of 5 layers of basalt fiber cloth are laid. After laying one layer of basalt fiber cloth, the resin composition is added, and the bubbles in the impregnated basalt fiber cloth are completely removed by using a plastic scraper. After solidification, the basalt fiber reinforced composite material prepared by the application has the advantages of light self-weight, low cost, flame-retardant effect, avoidance of warping of the plate during use, influence on the regulation of the air pressure in the air shaft and the airway, and suitability for being used for a mine air door leaf.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of mine air door leaf, in particular to a basalt fiber reinforced composite material and a preparation method thereof. BACKGROUND

[0002] According to statistics, when an accident occurs in a coal mine, only a small part of the direct casualties is caused by the accident, and most of the indirect casualties are caused by toxic and harmful gases in the airflow. Therefore, it is particularly important to ensure the physical and mental health of employees, ensure the safe operation of coal mines, and improve the construction environment by using a smooth and convenient door leaf plate.

[0003] Traditional mine door leaf plates are mostly made of metal or bamboo plywood (application number CN201920766813.X) plates.

[0004] Among them, the bamboo plywood is made of bamboo and wood, and has poor mechanical properties. It is easy to warp after long-term use, thereby reducing the service life. The metal plate is mostly a steel plate. Due to the material properties of the metal itself, the weight of the plate is large, the cost is high, and it brings great difficulty to the on-site transportation, installation and fixing work. The patent CN214697915U (application number 202120349225.3) discloses a corrugated mine air door leaf, which improves the structure of the steel door leaf and reduces the weight of the metal door leaf. However, due to the characteristics of the metal material itself, there is still room for improvement in the weight.

[0005] Therefore, it is urgent to develop a door leaf plate with light weight, mechanical properties meeting the requirements, and size adjustable according to actual working conditions, which is used for adjusting the air flow quality of the mine air door leaf material. SUMMARY

[0006] To solve the above technical problems, the present application provides a basalt fiber reinforced composite material, which is light in weight, flame-retardant, and not easy to warp at the other end of the door shaft, and is suitable for the plate of the mine air door leaf.

[0007] It is necessary to also provide a preparation method of the above-mentioned basalt fiber reinforced composite material.

[0008] A basalt fiber reinforced composite material,

[0009] which is composed of a metal framework, a filling material and a basalt fiber reinforced surface layer;

[0010] The inner and outer layers of the metal framework are respectively glued to the basalt fiber reinforced surface layer.

[0011] The hollow part and the outer periphery of the metal framework are respectively filled with a filling material impregnated with a resin composition.

[0012] The basalt fiber reinforced surface layer is prepared by the following method:

[0013] According to the metal skeleton length and width of basalt fiber cloth, after cutting, the fiber cloth is laid flat in the mold, and a total of 5 layers of basalt fiber cloth are laid;

[0014] After laying each layer of basalt fiber cloth, add the resin composition, and the amount of resin composition added ensures that the basalt fiber cloth is completely soaked, and use a plastic scraper to completely remove the bubbles in the soaked basalt fiber cloth;

[0015] Wait for complete curing at room temperature.

[0016] The resin composition includes the following components by weight:

[0017] Unsaturated resin 200;

[0018] Curing agent 1.8-2;

[0019] Flame retardant 10-12.

[0020] The unsaturated resin is a bisphenol A type unsaturated resin.

[0021] The curing agent is selected from one of m-phenylenediamine, aryl ether ester diarylamine, or diethylamine propylamine DEAPA; and the flame retardant is selected from aluminum hydroxide powder or tris(1,3-dichloropropyl) phosphate.

[0022] The basalt fiber cloth is plain weave basalt fiber cloth, 300g / m 2 .

[0023] The metal skeleton is welded from square steel, the welding method is two-way welding, and the square steel material is Q235B.

[0024] The inner and outer layers of the metal skeleton are glued with plant glue, and the thickness of the plant glue is 1cm.

[0025] The filling material is processed by 3D weaving process according to the weight ratio of 4:1 of glass fiber and basalt fiber.

[0026] A preparation method of a basalt fiber reinforced composite material as described above, comprising the following steps:

[0027] (1) Preparation of basalt fiber reinforced surface layer:

[0028] According to the metal skeleton length and width of basalt fiber cloth, after cutting, the fiber cloth is laid flat in the mold, and a total of 5 layers of basalt fiber cloth are laid;

[0029] After each layer of basalt fiber cloth is laid, a resin composition is added, and the amount of resin composition added is ensured to fully soak the basalt fiber cloth, and plastic scrapers are used to remove all air bubbles from the soaked basalt fiber cloth;

[0030] (2) Preparation of the metal framework:

[0031] The square steel is welded into a metal framework, and the welding method is two-way welding, and the square steel is made of Q235B;

[0032] (3) Manufacture of the plate mold. The length and width of the mold are adjusted according to the size of the metal framework, the gap between the inner wall of the mold and the metal framework is 5 mm, and the height of the mold is the same as the height of the metal framework;

[0033] (4) Apply a steel bar glue with an average thickness of 1 mm to the side of the metal framework connected to the surface layer, place the metal framework into the mold, and fully contact the basalt fiber reinforced surface layer, and wait for complete solidification at room temperature;

[0034] (5) Metal framework filling

[0035] According to the size of the space to be filled, the filling material is cut, and after cutting, the filler is filled into the metal frame and the outer periphery of the metal framework, the resin composition is slowly poured into the mold, the filling material is fully soaked, and the complete solidification is waited at room temperature;

[0036] (6) Preparation of the basalt fiber reinforced surface layer:

[0037] After complete solidification, the basalt fiber surface layer is prepared again, which is the same as step (1), and after the preparation of the basalt fiber reinforced surface layer is completed, the basalt fiber reinforced surface layer is placed in a press with a pressure level of 5 MPa and pressed for 10 min, and the excess resin and air bubbles are squeezed out, to ensure that the basalt fiber reinforced surface layer is fully combined with the filling material and the metal framework;

[0038] (7) After the preparation is completed, the surface of the sample is polished.

[0039] Compared with the prior art, the basalt fiber reinforced composite material disclosed by the application is composed of a metal framework, a filling material and a basalt fiber reinforced surface layer; the inner and outer two layers of the metal framework are respectively glued to the basalt fiber reinforced surface layer; and the hollow part and the outer periphery of the metal framework are respectively filled with the filling material soaked with the resin composition. The basalt fiber reinforced composite material prepared by the application has the advantages of light weight, low cost, flame retardant effect, avoidance of warping during use of the plate, and adjustment of the air door well and roadway air flow, and is suitable for use in mine air door leaves. BRIEF DESCRIPTION OF DRAWINGS

[0040] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required by the embodiments or prior art description. Obviously, the drawings in the following description only represent some of the embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor.

[0041] Figure 1 The structure diagram of the basalt fiber reinforced composite material of the present application. DETAILED DESCRIPTION

[0042] In order to make the skilled in the art better understand the technical solutions in the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below. Obviously, the described embodiments are only some of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0043] It should be noted that the structures, proportions, sizes, etc. shown in the drawings of the present specification are only used to cooperate with the content disclosed in the specification, to enable those skilled in the art to understand and read, and are not used to limit the conditions that can be implemented by the present application, so they do not have technical significance. Any modification of structure, change of proportion relationship or adjustment of size, which does not affect the effects and purposes that can be achieved by the present application, should still fall within the scope of the technical content disclosed by the present application.

[0044] The materials used in the embodiments of the present application are as follows:

[0045] Bisphenol A type unsaturated resin: Huibaxincai GE-7119A / GE-7122B, available on the market.

[0046] Aluminum hydroxide powder: available on the market, Al(OH)3≥99.6 (%).

[0047] Tris(1,3-dichloropropyl) phosphate: TDCPP, available on the market, content 99%.

[0048] M-phenylenediamine: available on the market.

[0049] Diethylamino propylamine: DEAPA, available on the market.

[0050] Aryl ether ester diarylamine: available on the market.

[0051] Adhesive for anchorage: RE100-HC (580ML) type of the brand of Xide.

[0052] The specification of the basalt fiber cloth is plain weave basalt fiber cloth, 300g / m2 .

[0053] Square steel material: Q235B.

[0054] As Figure 1 shown, the basalt fiber reinforced composite material provided by the application is composed of a metal framework 3, a filling material 2 and a basalt fiber reinforced surface layer 1; the inner and outer two layers of the metal framework 3 are respectively glued with the basalt fiber reinforced surface layer 1; the hollow part and the outer periphery of the metal framework 3 are respectively filled with the filling material 2 impregnated with the resin composition.

[0055] The following provides several specific preparation method embodiments to further illustrate the technical solutions of the application.

[0056] Example 1

[0057] Preparation of basalt fiber reinforced composite material

[0058] (1) Preparation of basalt fiber reinforced surface layer:

[0059] According to the length and width of the metal framework, the basalt fiber cloth is cut, and after cutting, the fiber cloth is laid flat in the mold, and a total of 5 layers of basalt fiber cloth are laid;

[0060] After laying each layer of basalt fiber cloth, the resin composition is added, and the amount of resin composition added is ensured to completely impregnate the basalt fiber cloth, and the bubbles in the impregnated basalt fiber cloth are completely removed with a plastic scraper;

[0061] (2) Preparation of metal framework:

[0062] The square steel is welded into a metal framework, and the welding method is two-way welding;

[0063] (3) Make a plate mold. The length and width of the mold are adjusted according to the size of the metal framework, the gap between the inner wall of the mold and the metal framework is 5mm, and the height of the mold is the same as the height of the metal framework;

[0064] (4) Apply anchor glue to the side of the metal framework where the surface layer meets, with an average thickness of 1mm, place the metal framework into the mold, and fully contact with the basalt fiber reinforced surface layer, and wait for complete curing at room temperature;

[0065] (5) Metal framework filling

[0066] According to the size of the space to be filled, the filling material is cut, and after cutting, the filling material is filled into the metal framework and the outer periphery of the metal framework, and the resin composition is slowly poured into the mold to completely impregnate the filling material, and wait for complete curing at room temperature;

[0067] (6) Preparation of basalt fiber reinforced surface layer:

[0068] After curing, the basalt fiber surface layer is made again, and the basalt fiber reinforced surface layer is made in the same way as step (1). After the basalt fiber reinforced surface layer is made, it is placed in a press with a pressure level set to 5 MPa for 10 minutes to extrude excess resin and bubbles and ensure that the basalt fiber reinforced surface layer is fully combined with the filler material and the metal framework;

[0069] (7) After the sample is made, the surface is polished;

[0070] The resin composition in this embodiment is prepared by adding aryl ether ester diarylamine and aluminum hydroxide powder to bisphenol A type unsaturated resin. The weight ratio of bisphenol A type unsaturated resin, aryl ether ester diarylamine and aluminum hydroxide powder is 200:2:10;

[0071] The filler material is made of glass fiber and basalt fiber in a weight ratio of 4:1 by 3D weaving process.

[0072] Example 2

[0073] Preparation of basalt fiber reinforced composite material

[0074] (1) Preparation of basalt fiber reinforced surface layer:

[0075] Cut the basalt fiber cloth according to the length and width of the metal framework. After cutting, lay the fiber cloth flat in the mold. A total of 5 layers of basalt fiber cloth are laid;

[0076] After laying each layer of basalt fiber cloth, add resin composition. The amount of resin composition added should ensure that the basalt fiber cloth is completely soaked. Use a plastic spatula to remove all bubbles from the soaked basalt fiber cloth;

[0077] (2) Preparation of metal framework:

[0078] Weld the square steel into a metal framework. The welding method is two-way welding;

[0079] (3) Make the plate mold. The mold length and width are adjusted according to the size of the metal framework. The gap between the inner wall of the mold and the metal framework is 5 mm. The height of the mold is the same as the height of the metal framework;

[0080] (4) Apply anchor glue to the side of the metal framework where the surface layer meets. The average thickness of the anchor glue is 1 mm. Place the metal framework in the mold and make full contact with the basalt fiber reinforced surface layer. Wait for complete curing at room temperature;

[0081] (5) Metal framework filling

[0082] According to the size of the space to be filled, the filling material is cut, and after cutting, the filler is filled into the metal frame and the outer periphery of the metal skeleton, the resin composition is slowly poured into the mold, the filling material is completely infiltrated, and the complete curing is waited at room temperature;

[0083] (6) Preparation of basalt fiber reinforced surface layer:

[0084] After complete curing, the basalt fiber surface layer is prepared again, which is the same as step (1). After the preparation of the basalt fiber reinforced surface layer is completed, it is placed in a press with a pressure level of 5 MPa for 10 minutes to extrude excess resin and bubbles, ensuring that the basalt fiber reinforced surface layer is fully combined with the filling material and the metal skeleton;

[0085] (7) After the preparation is completed, the surface of the sample is polished;

[0086] The resin composition in this embodiment is prepared by adding m-phenylenediamine and tris(1,3-dichloropropyl) phosphate into bisphenol A type unsaturated resin, and the weight ratio of bisphenol A type unsaturated resin, m-phenylenediamine and tris(1,3-dichloropropyl) phosphate is 200:1.8:12,

[0087] The filling material is processed by 3D weaving process according to the weight ratio of 4:1 of glass fiber and basalt fiber.

[0088] Example 3

[0089] Preparation of basalt fiber reinforced composite material

[0090] (1) Preparation of basalt fiber reinforced surface layer:

[0091] According to the length and width of the metal skeleton, the basalt fiber cloth is cut, and after cutting, the fiber cloth is laid flat in the mold, a total of 5 layers of basalt fiber cloth are laid;

[0092] After laying each layer of basalt fiber cloth, resin composition is added, and the amount of resin composition added is sufficient to ensure that the basalt fiber cloth is completely infiltrated, and the bubbles in the infiltrated basalt fiber cloth are completely removed with a plastic spatula;

[0093] (2) Preparation of metal skeleton:

[0094] The square steel is welded into a metal skeleton, and the welding method is two-way welding;

[0095] (3) Manufacture of plate mold. The length and width of the mold are adjusted according to the size of the metal skeleton, the gap between the inner wall of the mold and the metal skeleton is 5 mm, and the height of the mold is the same as the height of the metal skeleton;

[0096] (4) On the side where the metal framework and the surface layer meet, apply anchoring glue with an average thickness of 1 mm, place the metal framework in the mold, and make full contact with the basalt fiber reinforced surface layer, and wait for complete curing at room temperature;

[0097] (5) Metal framework filling

[0098] According to the size of the space to be filled, cut the filling material, fill the filler into the metal frame and the outer periphery of the metal framework, slowly pour the resin composition into the mold, and make the filling material fully infiltrate, and wait for complete curing at room temperature;

[0099] (6) Preparation of basalt fiber reinforced surface layer:

[0100] After complete curing, the basalt fiber surface layer is prepared again, which is the same as step (1). After the preparation of the basalt fiber reinforced surface layer is completed, it is placed in a press with a pressure level set to 5 MPa for 10 minutes to extrude excess resin and bubbles, and to ensure that the basalt fiber reinforced surface layer is fully combined with the filling material and the metal framework;

[0101] (7) After the preparation is completed, the surface of the sample is polished;

[0102] The resin composition in this embodiment is prepared by adding diethylaminopropylamine and aluminum hydroxide powder to bisphenol A type unsaturated resin, and the weight ratio of bisphenol A type unsaturated resin, diethylaminopropylamine and aluminum hydroxide powder is 200:2:10,

[0103] The filling material is processed by 3D weaving process according to the weight ratio of 4:1 of glass fiber and basalt fiber.

[0104] Comparative Example 1

[0105] 1.8 m*2.1 m steel air door plate material commercially available from Shaanxi Hangtai Electrical Co., Ltd.

[0106] The materials prepared in Examples 1-3 and the sample in Comparative Example 1 were weighed, tested for flame retardant grade, and subjected to mechanical simulation analysis, respectively.

[0107] The electronic scale with a precision of 0.01 kg was used to weigh the examples and the comparative example. The mass of the three samples in the examples was 70.7 kg, 71.5 kg and 70.9 kg, respectively. The mass of the steel plate in the comparative example was 135 kg. Compared with the comparative example, the mass was reduced by 47% under the condition of meeting the use requirements, and the installation difficulty and material cost were significantly reduced.

[0108] The flame retardation is performed according to the standard GB / T 2408-2008-Plastics-Determination of the Burning Behavior by Horizontal and Vertical Method, the panel and the filling material are processed into 125mm*13mm*3mm samples, each group has 28 samples, the horizontal and vertical burning test device is used to measure, the flammable grade of the three groups of samples in the examples is V0, which meets the use conditions of the products in the coal mine.

[0109] According to the 2940MPa negative pressure load requirement in the national standard GB / T 50215-2005 Coal Industry Mine Design Specification, the sample panel in the examples and the comparative examples is fixed on the side, and the 2940MPa uniform load is applied on the panel, the analysis shows that the maximum Mises stress in the examples is 175MPa, and the maximum deformation of the door frame is less than 6.2mm, which is less than the yield stress of the internal metal skeleton, and meets the use requirements of the coal mine air door, and the warping degree is small, which better guarantees the sealing effect of the air door; the deformation of the steel material in the comparative examples is 27mm, and the warping degree is large, and the use effect is worse than that of the examples.

[0110] The above description of the disclosed examples enables those skilled in the art to carry out or use the present application. Various modifications to these examples will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other examples without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to these examples shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A basalt fiber reinforced composite material for mine air door door leaf, characterized in that: it is composed of a metal framework, a filling material and a basalt fiber reinforced surface layer; the inner and outer layers of the metal framework are respectively glued with the basalt fiber reinforced surface layer; the hollow part and the outer periphery of the metal framework are respectively filled with the filling material; and the filling material is specifically a woven body formed by 3D weaving process according to a weight ratio of 4:1 of glass fiber and basalt fiber.

2. The basalt fiber reinforced composite material according to claim 1, characterized in that: the basalt fiber reinforced surface layer is prepared by the following method: basalt fiber cloth is cut according to the length and width of the metal framework, and after cutting, the fiber cloth is laid flat in the mold, and a total of 5 layers of basalt fiber cloth are laid; after laying each layer of basalt fiber cloth, a resin composition is added, and the amount of resin composition added is ensured to make the basalt fiber cloth completely soaked, and plastic spatula is used to completely remove the bubbles in the soaked basalt fiber cloth; and normal temperature is waited for complete curing.

3. The basalt fiber reinforced composite material according to claim 1 or 2, characterized in that: the resin composition includes the following components by weight: unsaturated resin 200; curing agent 1.8-2; and flame retardant 10-12.

4. The basalt fiber reinforced composite material according to claim 3, characterized in that: the unsaturated resin is a bisphenol A type unsaturated resin.

5. The basalt fiber reinforced composite material according to claim 3, characterized in that: the curing agent is selected from one of m-phenylenediamine, aryl ether ester diarylamine or diethylamine propylamine DEAPA; and the flame retardant is selected from aluminum hydroxide powder or tris (1, 3-dichloropropyl) phosphate.

6. The basalt fiber reinforced composite material according to claim 1 or 2, characterized in that:

7. The basalt fiber reinforced composite material according to claim 1, characterized in that: the metal framework is welded by square steel.

8. The basalt fiber reinforced composite material according to claim 1, characterized in that: the inner and outer layers of the metal framework are respectively glued with the basalt fiber reinforced surface layer by using a plant bar glue, and the thickness of the plant bar glue is 1 cm. including the following steps: (1) Preparation of the basalt fiber reinforced surface layer: basalt fiber cloth is cut according to the length and width of the metal framework, and after cutting, the fiber cloth is laid flat in the mold, and a total of 5 layers of basalt fiber cloth are laid; after laying each layer of basalt fiber cloth, a resin composition is added, and the amount of resin composition added is ensured to make the basalt fiber cloth completely soaked, and plastic spatula is used to completely remove the bubbles in the soaked basalt fiber cloth; (2) Preparation of the metal framework: square steel is welded into a metal framework; (3) Preparation of the plate mold: the mold length and width are adjusted according to the size of the metal framework, the gap between the inner wall of the mold and the metal framework is 5 mm, and the height of the mold is the same as the height of the metal framework; (4) On the side where the metal framework and the surface layer meet, plant bar glue is applied, the average thickness of the plant bar glue is 1 mm, the metal framework is placed in the mold, and the metal framework is in full contact with the basalt fiber reinforced surface layer, and normal temperature is waited for complete curing; (5) Metal framework filling ​ ​ ​ ​ ​ ​ The basalt fiber cloth specification is plain weave basalt fiber cloth, 300g / m 2 . ​ ​ ​ ​ 9. A process for the production of a basalt fiber reinforced composite material according to any one of claims 1 to 8, characterized in that ​ ​ ​ ​ ​ ​ ​ ​ ​ According to the size of the space to be filled, the filling material is cut, and after cutting, the filler is filled into the metal frame and the outer periphery of the metal skeleton, the resin composition is slowly poured into the mold, and the filling material is completely infiltrated, and completely solidified at room temperature; (6) Preparation of basalt fiber reinforced surface layer: After curing, the basalt fiber surface layer is prepared again, which is the same as step (1). After the preparation of the basalt fiber reinforced surface layer is completed, it is placed in a press with a pressure level of 5MPa for 10min to extrude excess resin and bubbles, ensuring that the basalt fiber reinforced surface layer is fully combined with the filling material and the metal skeleton; (7) After the preparation is completed, the surface of the sample is polished.

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