Method and equipment for manufacturing multi-axial basalt fiber composite corrugated board

Abstract

The application discloses a preparation method and a preparation equipment of a multi-axial basalt fiber reinforced polymer (BFRP) corrugated plate. The preparation method comprises the following steps: preparing continuous fiber cloth and chopped fiber felt according to the required BFRP corrugated plate layer; stitching the chopped fiber felt and the continuous fiber cloth with different laying directions to prepare chopped-continuous fiber combination cloth with different laying directions; adjusting the length of the fiber cloth and the fiber felt according to the length of the corrugated plate; laying the chopped-continuous fiber combination cloth according to the set laying direction of each layer; fully soaking the laid multi-layer chopped-continuous fiber combination cloth in resin to prepare impregnated cloth; shaping the impregnated cloth through a corrugated mold to prepare a BFRP corrugated plate; and heating and curing the BFRP corrugated plate to obtain a multi-axial sandwich BFRP corrugated plate. The application can realize the integrated forming preparation of the multi-axial FRP corrugated plate.

Description

Technical Field

[0001] This invention relates to a multiaxial basalt fiber composite corrugated plate preparation technology, which relates to the field of composite material technology, and particularly to a method for preparing a multiaxial continuous-short-cut FRP composite profile. Background Technology

[0002] Corrugated sheets are widely used in civil engineering maintenance structures due to their excellent mechanical properties. Compared to ordinary flat plates, corrugated sheets offer significantly improved bending stiffness and strength. Based on the production materials, corrugated sheets can be categorized into corrugated steel sheets, corrugated aluminum sheets, and composite material (FRP) corrugated sheets. Metal corrugated sheets are bulky and inconvenient to install; some metals have high electrical conductivity and magnetism, making them unsuitable for specific requirements. FRP corrugated sheets are lightweight, high-strength, and corrosion-resistant, with basalt FRP corrugated sheets exhibiting superior electrical insulation properties and a wider range of applications. However, traditionally pultruded FRP corrugated sheets exhibit excellent unidirectional mechanical properties but poor mechanical properties in other directions, weak bonding performance, and are prone to brittle fracture, failing to effectively utilize the material's strength. Therefore, it is necessary to propose a technology for the continuous production of FRP corrugated sheets with excellent multidirectional mechanical properties to improve material utilization, increase structural safety, and further enhance the applicability of FRP corrugated sheets. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of existing FRP corrugated sheet production processes by proposing a manufacturing technology for producing multi-axial sandwich FRP corrugated sheets. This technology is simple, quick, and convenient to operate, enabling the integrated molding and manufacturing of multi-axial FRP corrugated sheets.

[0004] The technical solution of the present invention to solve the above-mentioned technical problems is:

[0005] A method for preparing a multiaxial sandwich basalt fiber composite corrugated plate includes:

[0006] Step 1: Prepare continuous fiber cloth and chopped strand mat according to the required BFRP corrugated board layup;

[0007] Step 2: Sew together the chopped fiber mat and the continuous fiber cloth with different laying directions to make chopped-continuous fiber composite cloth with different laying directions. Adjust the length of the fiber cloth and fiber mat according to the length of the corrugated board.

[0008] Step 3: Lay the chopped strand-continuous fiber composite fabric according to the set laying direction of each layer; fully impregnate the laid multi-layer chopped strand-continuous fiber composite fabric with resin to become a resin-impregnated fabric;

[0009] Step 4: The impregnated fabric is shaped using a corrugated mold to form a BFRP corrugated board;

[0010] Step 5: Heat and cure the BFRP corrugated material to obtain a multiaxial sandwich basalt fiber composite corrugated plate.

[0011] Preferably, the fiber cloth in the layup design includes, but is not limited to, basalt fiber cloth, as well as other types of fiber cloth and hybrid fiber cloth.

[0012] Preferably, the basalt fiber composite fabric is placed in the middle layer, and the upper and lower surfaces are made of continuous basalt fiber fabric.

[0013] To prevent the seam from breaking during the stretching process.

[0014] Preferably, the fiber content in the multiaxial basalt fiber composite corrugated plate is not less than 60%.

[0015] Preferably, the resin includes, but is not limited to, epoxy resin, vinyl resin, or phenolic resin.

[0016] Preferably, the impregnation tank is equipped with multiple sets of rollers; the inlet and outlet rollers of the impregnation tank are responsible for pulling the composite fabric into the impregnation tank and pulling the impregnated fabric out of the impregnation tank; the separating rollers of the impregnation tank separate each layer of the fiber fabric in the impregnation tank; the movable track rollers move up and down during the impregnation process of the fiber fabric, separating or pressing it up and down, so that the resin fully impregnates each layer of fiber fabric; the fixed track rollers squeeze the multiple layers of fiber fabric in the impregnation tank into one piece, squeezing out excess resin.

[0017] Preferably, the heating oven has multiple sets of traction devices, and the traction angle can be adjusted according to the design to produce straight or curved BFRP corrugated sheets.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1) This invention uses a pultrusion continuous production method to prepare integrated multiaxial BFRP corrugated sheets, which avoids the brittle splitting failure of traditional unidirectional FRP corrugated sheets and enhances the overall performance of FRP corrugated sheets.

[0020] 2) The multi-directional mechanical properties of BFRP corrugated sheets can be designed according to the working conditions, making good use of fibers in different directions to ensure uniform stress, coordinated deformation, and high ductility.

[0021] 3) The opening and closing movement of the movable rollers in the impregnation tank improves the impregnation effect between multiple layers of fiber cloth. The cooperation of multiple sets of rollers in the impregnation tank is more suitable for the production of pultruded profiles with greater thickness and more layers.

[0022] 4) The integrated production of continuous-chopped fiber composite BFRP corrugated board has higher strength and modulus of elasticity than traditional SMC boards, resulting in superior performance; it is also cheaper and offers better value for money than traditional PCM boards. It combines the advantages of both production processes. Attached Figure Description

[0023] Figure 1 This is a schematic diagram illustrating the preparation technology of a multi-axial sandwich basalt fiber composite corrugated plate according to the present invention.

[0024] Figure 2 This is a schematic diagram of the stitching of multiaxial fibers and chopped strand mat in the fiber composite fabric cutting area.

[0025] Figure 3 This is a schematic diagram of the impregnation of short-cut-continuous basalt fiber composite fabric.

[0026] Figure 4 A schematic diagram of the shaping of short-cut continuous basalt fiber composite fabric using a corrugated mold.

[0027] Figure 5 This is a schematic diagram of a corrugated FRP board being cured in a heated oven.

[0028] The diagram shows: 1. Fiber composite fabric feeding area; 2. Impregnation tank; 3. Corrugated mold; 4. Heating oven; 5. Basalt fiber composite fabric; 6. Multi-axial sandwich basalt fiber composite corrugated plate; 1-1. Horizontal fiber; 1-2. Chopped strand mat; 1-3. Oblique fiber; 1-4. Stitching thread; 2-1. Impregnated fabric; 2-2. Impregnation tank inlet and outlet rollers; 2-3. Impregnation tank separation rollers; 2-4. Mobile track rollers; 2-5. Fixed track rollers; 3-1. Corrugated FRP plate; 4-1. Traction device. Detailed Implementation

[0029] To further understand the present invention, preferred embodiments of the present invention are described below in conjunction with examples. However, it should be understood that these descriptions are only for further illustrating the features and advantages of the present invention, and not for limiting the scope of the claims of the present invention.

[0030] This invention provides a preparation technique for a multiaxial basalt fiber composite corrugated plate, comprising the following steps:

[0031] Prepare raw materials, including the quantity of basalt fiber cloth and chopped strand mat, according to the required size of the BFRP corrugated sheet.

[0032] Basalt fiber cloth and basalt fiber chopped mat are sewn together with fine thread to make chopped-continuous basalt fiber composite cloth. The length of the fiber cloth and fiber mat is adjusted according to the length of the corrugated board.

[0033] Short-cut continuous basalt fiber composite fabric is fully impregnated with resin in an impregnation tank to produce impregnated fabric;

[0034] Short-cut continuous basalt fiber composite fabric is shaped using a corrugated mold to produce BFRP corrugated sheets;

[0035] BFRP corrugated sheets are cured in a heated oven to obtain multiaxial sandwich basalt fiber composite corrugated sheets.

[0036] The surface of the BFRP corrugated sheet is treated, and bolt holes are drilled at the corresponding locations.

[0037] The fiber cloth in the layup design described in this invention includes, but is not limited to, basalt fiber cloth, as well as other types of fiber cloth and hybrid fiber cloth.

[0038] In this invention, the basalt fiber composite fabric is preferably placed in the middle layer, and the upper and lower surfaces are made of continuous basalt fiber fabric to avoid breakage at the seams during the pultrusion process.

[0039] The fiber content in the multiaxial basalt fiber composite corrugated plate described in this invention is not less than 60%.

[0040] The resins described in this invention include, but are not limited to, epoxy resins, vinyl resins, or phenolic resins.

[0041] The impregnation tank described in this invention contains multiple sets of traction rollers. The inlet and outlet rollers of the impregnation tank are responsible for pulling the composite fabric into the impregnation tank and pulling the impregnated fabric out of the impregnation tank. The separating rollers of the impregnation tank separate each layer of the fiber fabric in the impregnation tank. The movable track rollers move up and down during the impregnation process of the fiber fabric, separating or pressing it up and down, so that the resin fully impregnates each layer of fiber fabric. The fixed track rollers squeeze the multiple layers of fiber fabric in the impregnation tank into one piece and squeeze out the excess resin.

[0042] The impregnation tank of the present invention can be equipped with multiple sets of movable track rollers at the same time, ensuring that each set of movable track rollers pulls at least one set of impregnation tank separation rollers in front and behind.

[0043] The heating oven described in this invention has multiple sets of traction devices, and the traction angle can be adjusted according to the design to produce straight or curved BFRP corrugated sheets.

[0044] Example 1

[0045] The BFRP corrugated sheet is designed with a cross-sectional width of 0.8m and a length of 3m; the cross-sectional wave pitch is 200mm, the wave height is 100mm, and the radius of curvature is 30mm. With the direction perpendicular to the corrugated cross-section defined as 0°, the basalt fiber cloth is arranged in a pattern of 90°, 0°, 45°, 0°, -45°, 0°, and 90°. Each layer is sewn to chopped strand mat, but layers are not sewn together. The outermost layer on the top and bottom surfaces is 0° fiber cloth, for a total of 37 layers. The middle layer (excluding the top and bottom layers) consists of a combination of 500cm continuous fibers and 2500cm chopped strand mat, continuously cycling in the direction of extension. Driven by the traction device, the composite fiber cloth enters the impregnation tank under the traction of the inlet roller. It is then separated into multiple layers by the impregnation separation roller. The cloth is fully impregnated with resin by the opening and closing action of the moving track rollers. Afterwards, the multiple layers are separated again by the action of the impregnation tank separation rollers. Finally, excess resin is squeezed out by the fixed track rollers, and the impregnated cloth is pulled out of the impregnation tank by the outlet roller. The resulting impregnated cloth is then shaped using a corrugated mold. After forming the BFRP corrugated sheet, it is placed in a heated oven for curing at a constant temperature of 120℃. Curing is completed by multiple sets of traction devices in an arc direction, with a curing time of 30 minutes, passing through each set of traction devices at a uniform speed. Finally, a drilling machine is used to drill bolt holes at the crests and troughs of the BFRP corrugated sheet.

[0046] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for the pultrusion manufacturing of a multi-axial basalt fiber composite corrugated panel, characterized in that, It comprises: Step 1: Prepare continuous fiber cloth and chopped fiber mat according to the required BFRP corrugated board layer; Step 2: Stitch the chopped fiber mat and continuous fiber cloth with different laying directions along the pultrusion direction to make chopped-continuous fiber combination cloth with different laying directions, and adjust the length of the fiber cloth and fiber mat according to the length of the corrugated board; Step 3: Lay the chopped-continuous fiber combination cloth according to the set laying direction of each layer; fully soak the laid multi-layer chopped-continuous fiber combination cloth in resin to become impregnated cloth; Step 4: Impregnated cloth is shaped through corrugated mold to make BFRP corrugated board; Step 5: Heat and cure the BFRP corrugated board to obtain multi-axial sandwich basalt fiber composite corrugated board.

2. The pultrusion manufacturing method according to claim 1, characterized in that, The laying proportion of the chopped-continuous fiber combination cloth perpendicular to the corrugated direction is 70%-85%, the laying proportion of the ±45° direction is 10-15%, and the laying proportion parallel to the corrugated direction is 5%-15%.

3. The pultrusion manufacturing method according to claim 1, characterized in that, The chopped-continuous fiber combination cloth is arranged in the middle layer, and continuous basalt fiber cloth is used on the upper and lower surfaces.

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