A multi-axial basalt fiber composite corrugated board and a preparation method thereof

Abstract

The application discloses a multi-axial basalt fiber composite corrugated plate and a preparation method thereof. The basalt fiber composite corrugated plate (referred to as BFRP corrugated plate) is formed by molding a plurality of layers of fiber cloths with different axial directions and chopped fibers. The layer direction of the screw hole position of the BFRP corrugated plate is flexibly designed according to the stress working condition; the fiber content along the main stress direction accounts for 60% to 70% of the total fiber content of the corrugated plate; the upper and lower surfaces of the BFRP corrugated plate are continuous fibers, and the inside of the BFRP corrugated plate except the screw hole is chopped basalt fiber. The longitudinal direction of the BFRP corrugated plate adopts a corrugated cover plate, a fastening bolt and an epoxy resin connection, and the transverse direction adopts a U-shaped clamp and a fastening bolt connection. The multi-axial basalt fiber composite corrugated plate is a light-weight, high-strength and corrosion-resistant multi-axial BFRP corrugated plate, which makes up for the large difference in mechanical properties of the traditional composite corrugated plate in different directions, and is reinforced for the joint part. Compared with the traditional multi-axial BFRP corrugated plate, the overall price is reduced, the application range is wider, and the designability is strong.

Description

Technical Field

[0001] The present invention relates to a basalt fiber composite corrugated plate in the field of composite materials, specifically a multi-axial BFRP corrugated plate that can be designed according to engineering requirements. The present invention has advantages such as strong designability and controllable multi-directional mechanical properties. Background Art

[0002] Compared with traditional flat plates, corrugated plates have a greater moment of inertia and stiffness, and are used in many fields. In the existing technology, my country uses corrugated steel plates and pultruded FRP profile plates for the enclosure and reinforcement of building structures. Corrugated steel plates have a large deadweight and are not easy to construct. In addition, corrugated steel plates have poor corrosion resistance and need to be sprayed with corrosion-resistant coatings. They have a short service life, are easily conductive, and are magnetic, making them less suitable for special structures that require electrical insulation. Pultruded FRP profile plates have a low density and excellent mechanical properties in one direction. However, the mechanical properties in other directions are poor, resulting in weak connection performance and a limited scope of use. Therefore, it is necessary to develop a lightweight, high-strength, corrosion-resistant, and electrically insulating composite corrugated plate. At the same time, the mechanical properties in different directions can be designed according to the operating conditions to further improve the applicability of the composite corrugated plate. Summary of the Invention

[0003] In response to the current problems of poor corrosion resistance and heavy weight of corrugated steel plates, as well as large differences in the multi-directional mechanical properties of pultruded FRP corrugated plates, the present invention proposes a basalt continuous-chopped fiber composite corrugated plate and a preparation method. This BFRP corrugated plate is made of multiple layers of basalt fiber cloth in different directions and chopped fibers, which are molded at high temperature. The mechanical properties in different directions and positions can be adjusted according to the operating conditions of the corrugated plate. It maintains the excellent properties of traditional pultruded FRP corrugated plates, such as light weight, high strength, corrosion resistance, and non-magnetic properties, while improving the connection performance of the FRP corrugated plate, reducing the cost of the BFRP corrugated plate, forming a design concept of strong nodes and weak components, facilitating connection, and improving the applicability of the basalt fiber composite corrugated plate.

[0004] The technical solution of the present invention is:

[0005] A multi-axial basalt fiber composite corrugated plate, comprising a corrugated plate body, a longitudinal node part at both ends of the corrugated plate body along the corrugated groove direction, and a transverse node part at both ends of the corrugated plate body perpendicular to the corrugated groove direction; the longitudinal node part is laid by multiple layers of continuous basalt fiber cloth, the laying proportion of the continuous basalt fiber cloth of the longitudinal node part along the direction perpendicular to the corrugated direction is 70%-85%, the laying proportion of the continuous basalt fiber cloth of the longitudinal node part along the ±45° direction is 10-15%, and the laying proportion of the continuous basalt fiber cloth of the longitudinal node part along the direction parallel to the corrugated direction is 5%-10%; the transverse node part is laid by multiple layers of continuous basalt fiber cloth, the laying proportion of the continuous basalt fiber cloth of the transverse node part along the direction parallel to the corrugated direction is 70%-85%, the laying proportion of the continuous basalt fiber cloth of the transverse node part along the ±45° direction is 10-15%, and the laying proportion of the continuous basalt fiber cloth of the transverse node part along the direction perpendicular to the corrugated direction is 5%-10%; the corrugated plate body is laid by an upper layer of continuous fiber cloth, a lower layer of continuous fiber cloth, and chopped fibers between the upper layer of continuous fiber cloth and the lower layer of continuous fiber cloth.

[0006] The laying direction of the BFRP corrugated plate is defined as 0° perpendicular to the corrugated direction, according to the stress form of the BFRP corrugated plate, multiple layers of fiber cloth including but not limited to fiber directions of 0°, 90° and ±45° are used for compounding, and the BFRP corrugated plate is integrally formed;

[0007] According to the designed laying angle and proportion, the same direction laying should not be arranged at adjacent positions, but should be dispersedly arranged; and the angle difference between adjacent layings should be minimum;

[0008] According to the above application, the design method of the BFRP corrugated plate is:

[0009] Step one: according to the engineering needs, the basic parameters such as the pitch, the wave height, the curvature radius and the thickness of the BFRP corrugated plate 1 are designed;

[0010] Step two: according to the engineering needs, the main stress direction of the corrugated plate is determined, so as to design the laying of the node part of the corrugated plate, the laying proportion of the node part along the main stress direction is not less than 70%, the laying proportion of the node part along the ±45° direction is not less than 20%, so as to ensure that no splitting damage occurs;

[0011] Step three: chopped basalt fibers are used for laying in the part other than the node;

[0012] Step three: the laying form designed in the previous step is laid and high-temperature molded;

[0013] The cross-sectional parameters of the BFRP corrugated plate, characterized in that, include: pitch, wave height, curvature radius and thickness; wherein the pitch ranges from 100 to 300 mm, the wave height ranges from 55 to 200 mm, the curvature radius is not less than 30 mm, and the thickness ranges from 8 to 20 mm.

[0014] Through the above-mentioned design and preparation technology, it can be seen that compared with the existing technology, the present invention provides a design and preparation technology for multi-axial basalt fiber composite corrugated plates, which has the following beneficial effects:

[0015] 1) The present invention is molded by using multiple layers of basalt fiber cloth with different axial directions and short-cut basalt fibers, which avoids the problems of easy conductivity and poor corrosion resistance of traditional corrugated steel plates, while reducing the weight of the corrugated plates.

[0016] 2) The multi-axial basalt composite corrugated plate avoids the disadvantage of the large difference in mechanical properties of the pultruded FRP corrugated plate in different directions, thereby improving the comprehensive performance and connection performance of the BFRP corrugated plate.

[0017] 3) Most of the middle part of the BFRP corrugated plate is composed of short-cut basalt fibers, which reduces the cost of the corrugated plate and forms a design concept of strong nodes and weak components, avoiding damage to important node parts.

[0018] 4) The mechanical properties of the BFRP corrugated plate can be designed according to the stress conditions of the BFRP corrugated plate under different working conditions, thereby improving the utilization rate of the material and avoiding the connection from being damaged before the BFRP corrugated plate itself. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic structural diagram of a multi-axial basalt fiber composite material corrugated plate of the present invention;

[0020] Figure 2 yes Figure 1 Schematic diagram of the cross section of the middle plate;

[0021] Figure 3 1 is a schematic cross-sectional view of the longitudinal node portion;

[0022] Figure 4 1 is a schematic cross-sectional view of the transverse node portion;

[0023] Figure 5 This is a longitudinal connection diagram of the multi-axial basalt fiber composite corrugated plate of the present invention.

[0024] Figure 6 This is a transverse connection diagram of the multi-axial basalt fiber composite corrugated plate of the present invention.

[0025] Figure 7 This is a schematic diagram of the bidirectional assembly of the multi-axial basalt fiber composite material corrugated plate of the present invention.

[0026] Figure 8 The shear bearing capacity comparison between the multi-axial basalt fiber composite plate of the present invention and the traditional pultruded BFRP plate is shown.

[0027] Figure 9The bolt connection performance comparison between the multi-axial basalt fiber composite plate of the present invention and the traditional pultruded BFRP plate is shown.

[0028] The figure includes: 1. multi-axial basalt fiber composite corrugated plate; 11. corrugated plate body; 111. upper continuous fiber cloth; 112. chopped fiber; 113. lower continuous fiber cloth; 12. longitudinal node; 13. transverse node; 2. fastening bolts; 3. cover plate; 4. U-shaped clamp. DETAILED DESCRIPTION

[0029] The specific embodiments of the present invention are further explained in detail below in conjunction with the accompanying drawings. It should be understood that these embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. After reading the present invention, modifications of various equivalent forms of the present invention by those skilled in the art all fall within the scope defined by the claims attached to this application.

[0030] The present invention aims to overcome the drawbacks of existing tensile-type BFRP corrugated sheets, which can only bear unidirectional forces, are difficult to connect and anchor, and have low material utilization. A multi-axial basalt fiber composite corrugated sheet is proposed, whose mechanical properties can be tailored to the specific operating conditions, expanding the application range and improving its applicability.

[0031] The invention will be further described below with reference to the accompanying drawings.

[0032] like Figure 1 As shown, the present invention provides a multi-axial basalt fiber composite corrugated plate, comprising a corrugated plate body 11, longitudinal node portions 12 located at both ends of the corrugated plate body along the corrugation groove direction, and transverse node portions 13 located at both ends of the corrugated plate body perpendicular to the corrugation groove direction.

[0033] The corrugated plate body 11 is composed of an upper continuous fiber cloth 111, a lower continuous fiber cloth 113 and short-cut fibers 112 between the upper continuous fiber cloth and the lower continuous fiber cloth. Figure 2 .

[0034] The longitudinal node portion 12 is made of multiple layers of continuous basalt fiber cloth, see Figure 3 The ply ratio of the continuous basalt fiber cloth in the longitudinal node part perpendicular to the corrugation direction is 70% to 85%, the ply ratio in the ±45° direction is 10% to 15%, and the ply ratio parallel to the corrugation direction is 5% to 15%.

[0035] The transverse node 3 is made of multiple layers of continuous basalt fiber cloth, see Figure 4The ply ratio of the continuous basalt fiber cloth in the transverse node portion 13 parallel to the corrugation direction is 70% to 85%, the ply ratio in the ±45° direction is 10% to 15%, and the ply ratio perpendicular to the corrugation direction is 5% to 15%.

[0036] Connect adjacent BFRP corrugated plates longitudinally using cover plates 3 and fastening bolts 2. Figure 5 ;

[0037] The adjacent BFRP corrugated plates are connected horizontally using U-shaped clamps 4 and fastening bolts 2. Figure 6 .

[0038] In one embodiment, the wave pitch range of the multi-axial basalt fiber composite corrugated plate 1 is 100-300 mm, the wave height range is 55-200 mm, the curvature radius at the crest and trough is 30-50 mm, and the corrugated plate thickness is 8-20 mm, so that the molded BFRP corrugated plate has better mechanical properties.

[0039] In one embodiment, the BFRP corrugated plate is formed by high temperature and high pressure molding including but not prior to 0° fiber cloth, ±45° fiber cloth and 90° fiber cloth; the fiber cloths are dispersedly laid in the same direction, and the angle difference between adjacent layers of fiber cloth is kept as minimum as possible.

[0040] In one embodiment, the proportion of fibers along the main stress direction of the BFRP corrugated plate is 60% to 70%.

[0041] In one embodiment, the longitudinal bolt holes of the BFRP corrugated plate are located at the crest or trough within a range of 40 to 70 mm from both ends; and the transverse bolt holes are located at 1 / 3 to 1 / 4 of the side wall of the BFRP corrugated plate.

[0042] In one embodiment, the cover plate is molded from multi-axial basalt fiber cloth, bonded to the BFRP corrugated plate by epoxy resin, and fixed by fastening bolts; the U-shaped clamp 4 is connected to the side wall of the BFRP corrugated plate 1 by fastening bolts.

[0043] The design and preparation steps of multi-axial basalt composite corrugated plates are as follows:

[0044] Step 1: Design the basic parameters of the BFRP corrugated plate 1, such as wave pitch, wave height, curvature radius, thickness, etc., according to the project requirements;

[0045] Step 2: Design the laying angle and corresponding number of layers of basalt fiber cloth according to the stress form;

[0046] Step 3: After impregnation with resin, high temperature and high pressure compression molding is performed to form a multi-axial basalt fiber composite corrugated plate 1;

[0047] Step 4: Align the BFRP corrugated plates longitudinally, use epoxy resin to bond the cover plate 3 to the surface of the ends of the two multi-axial basalt fiber composite corrugated plates 1, align the bolt holes, and use the fastening bolts 2 to limit the position;

[0048] Step 5: Align the multi-axial basalt fiber composite material corrugated plate 1 transversely, use the U-shaped clamp 4 to fix the bolt hole position, and use the fastening bolt 2 to limit the position to complete the assembly.

[0049] Example:

[0050] like Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 and Figure 7 shown.

[0051] The production and preparation method of multi-axial basalt composite corrugated plate is as follows:

[0052] According to the tunnel project, the width of the BFRP corrugated plate is determined to be 1000mm, the length is 3000mm, the corrugation pitch is 200mm, the wave height is 100mm, the curvature radius is 30mm, and the corrugated plate thickness is 10mm;

[0053] The transverse and longitudinal nodes of the corrugated plate are both made of 10 layers of fiber cloth. The fibers perpendicular to the corrugation direction of the node are 0° fibers, accounting for 80% of the total fiber content, 45° fibers account for 10%, and 90° fibers account for 10%. The ply design is: 0°-0°-0°-0°-90°-0°-45°-0°-0°-0°. For specific ply angles, see Figure 3 and Figure 4 .

[0054] The upper and lower surfaces of the designed matrix are respectively a layer of 0° fiber cloth, and the middle interior is randomly distributed short-cut fibers, accounting for 80% of the total fiber content;

[0055] After being impregnated with thermosetting resin, it is molded under high temperature and high pressure;

[0056] Align the BFRP corrugated sheets longitudinally and drill bolt holes at the wave crests 50 mm from the ends. Use epoxy resin to bond the cover plate to the ends of the two BFRP corrugated sheets and secure them in place with tightening bolts before the resin cures.

[0057] Align the BFRP corrugated sheets horizontally and drill bolt holes at 1 / 3 of the side sheet. Use U-shaped clamps to clamp the two BFRP corrugated sheets and secure the position of the U-shaped clamps with fastening bolts.

[0058] After the resin is cured, the splicing is completed.

[0059] According to experimental data, compared with traditional tensile BFRP laminates, the ultimate load of bolt nodes of multi-axial BFRP laminates is increased by 78% to 148%, and the shear strength is increased by 76% to 229%. The overall performance is significantly improved, and it shows a trend of ductile failure.

[0060] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein, but is to be embodied in the widest possible scope consistent with the principles and novel features disclosed herein.

Claims

1. A multi-axial basalt fiber composite corrugated plate comprising a corrugated plate body, longitudinal node portions located at both ends of the corrugated plate body along the corrugation groove direction, and transverse node portions located at both ends of the corrugated plate body perpendicular to the corrugation groove direction; characterized in that: The longitudinal node portion is formed by laying multiple layers of continuous basalt fiber cloth, wherein the ply ratio of the continuous basalt fiber cloth in the longitudinal node portion is 70% to 85% in the direction perpendicular to the corrugation, the ply ratio in the ±45° direction is 10% to 15%, and the ply ratio parallel to the corrugation direction is 5% to 15%; the transverse node portion is formed by laying multiple layers of continuous basalt fiber cloth, wherein the ply ratio of the continuous basalt fiber cloth in the transverse node portion is 70% to 85% in the direction parallel to the corrugation, the ply ratio in the ±45° direction is 10% to 15%, and the ply ratio perpendicular to the corrugation direction is 5% to 15%; the corrugated plate body is formed by laying an upper layer of continuous fiber cloth, a lower layer of continuous fiber cloth, and chopped fibers located between the upper and lower layers of continuous fiber cloth.

2. The multi-axial basalt fiber composite corrugated plate according to claim 1, characterized in that: The longitudinal node portion has a ply ratio of 80% of the continuous basalt fiber cloth perpendicular to the corrugation direction, a ply ratio of 10% in the ±45° direction, and a ply ratio of 10% parallel to the corrugation direction; the transverse node portion is formed by laying multiple layers of continuous basalt fiber cloth, and the transverse node portion has a ply ratio of 80% of the continuous basalt fiber cloth parallel to the corrugation direction, a ply ratio of 10% in the ±45° direction, and a ply ratio of 10% perpendicular to the corrugation direction.

3. The multi-axial basalt fiber composite corrugated plate according to claim 1 or 2, characterized in that: The upper continuous fiber cloth and the lower continuous fiber cloth of the corrugated plate body are both laid with 0° fiber cloth, and both the upper continuous fiber cloth and the lower continuous fiber cloth include more than one layer of continuous fiber cloth.

4. The multi-axial basalt fiber composite corrugated plate according to claim 1 or 2, characterized in that: According to the designed ply angle and proportion, plies in the same direction should not be set in adjacent positions, but should be dispersed; and the angle difference between adjacent plies should be minimized.

5. The multi-axial basalt fiber composite corrugated plate according to claim 1 or 2, characterized in that: The wave pitch of BFRP corrugated sheets ranges from 100 to 300 mm, the wave height ranges from 55 to 200 mm, the curvature radius at the crest and trough is 30 to 50 mm, and the thickness of the corrugated sheets is 8 to 20 mm.

6. The multi-axial basalt fiber composite corrugated plate according to claim 5, characterized in that: Cover plates are used to connect two adjacent BFRP corrugated plates longitudinally.

7. The multi-axial basalt fiber composite corrugated plate according to claim 5, characterized in that: U-shaped clamps are used to connect two adjacent BFRP corrugated plates horizontally.

8. The method for preparing a multi-axial basalt fiber composite corrugated plate according to any one of claims 1 to 7, characterized in that: include: Determine the number of fiber layup layers; Determine the ply direction and proportion according to the number of plies; The fibers are laid and molded according to the determined number of layers, direction and proportion.

9. The method for preparing the multi-axial basalt fiber composite corrugated plate according to claim 8, characterized in that: The method to determine the number of fiber plies is: Determine the number of layers according to the required corrugated board thickness n , each layer is calculated as 0.8~1 mm thick; The number of plies is checked according to the maximum stress load in the main force direction of the corrugated plate, and the number of plies after verification is obtained. n’ ; like n’ > n , then the layer n Adjust to n’ ,like n’ < n , then the number of plies remains n； Number of layers n’ for: n’ = P / ( l × t ) in, n’ Round up; P is the maximum load per unit length, l is the wavelength per unit length, t It is the thickness of a single layer of fiber cloth.

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