A carbon fiber reinforced steel plate composite laminate and a method of manufacturing the same

Abstract

The application discloses a kind of carbon fiber reinforced steel plate composite laminated board and preparation method thereof, belong to carbon fiber composite material technical field.The carbon fiber reinforced steel plate composite laminated board disclosed in the application is connected by mixed connection mode of adhesive connection and mechanical connection between steel plate and carbon fiber cloth, and then carbon fiber reinforced steel plate composite laminated board is obtained by moulding technology.The application can fully exert the mechanical properties and lightweight characteristics of high-strength carbon fiber by the new mixed connection mode of mechanical connection and adhesive connection of carbon fiber cloth and steel plate, significantly improves the strength, reliability and stability of steel plate, and increases the heat resistance and corrosion resistance of laminated board, which can effectively reduce the influence of complex geological conditions on the quality of ultra-deep well drill pipe.The laminated board effectively reduces the weight compared with the same thickness steel plate, and greatly reduces the cost compared with pure carbon fiber composite material.

Description

Technical Field

[0001] This invention belongs to the field of carbon fiber composite material technology, specifically relating to a carbon fiber reinforced steel plate composite laminate and its preparation method. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] Ultra-deep well drilling technology is crucial for deep oil and gas resource exploration, and the materials used for drill pipes are critical. Currently, several new materials are used for drill pipes with relatively good performance, such as titanium alloy, aluminum alloy, and carbon fiber composite materials. However, their high cost prevents widespread adoption. Steel drill pipes remain the most cost-effective and widely used in China, but their performance is far inferior to that of carbon fiber composite materials. Therefore, there is an urgent need to develop new drill pipe materials to reduce costs and improve the performance of ordinary steel drill pipes. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a carbon fiber reinforced steel plate composite laminate for ultra-deep well drilling technology and its preparation method. The present invention effectively increases the mechanical properties of the laminate by mixing and connecting steel plates with carbon fiber cloth, giving full play to the high strength mechanical properties, excellent heat resistance, and corrosion resistance of carbon fiber cloth.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows:

[0006] In a first aspect, the present invention provides a carbon fiber reinforced steel plate composite laminate, comprising, from top to bottom: a top laminate layer, a first leveling layer, a first connecting layer, a first steel plate layer, a second connecting layer, a second steel plate layer, a second leveling layer, and a bottom laminate layer;

[0007] The first steel plate layer includes a first perforated steel plate and a first non-perforated carbon fiber cloth, and the first connecting layer includes a first non-perforated steel plate and a first carbon fiber connecting cloth; the first perforated steel plate and the first carbon fiber connecting cloth are staggered, the first non-perforated carbon fiber cloth is bonded to the lower surface of the first carbon fiber connecting cloth at a position flush with the first perforated steel plate, and the first non-perforated steel plate is bonded to the upper surface of the first perforated steel plate at a position flush with the first carbon fiber connecting cloth.

[0008] The second steel plate layer includes a second perforated steel plate and a second non-perforated carbon fiber cloth, and the second connecting layer includes a second non-perforated steel plate and a second carbon fiber connecting cloth; the second perforated steel plate and the second carbon fiber connecting cloth are staggered, the second non-perforated carbon fiber cloth is bonded to the lower surface of the second carbon fiber connecting layer cloth at a position flush with the second perforated steel plate, and the second non-perforated steel plate is bonded to the upper surface of the second perforated steel plate at a position flush with the second carbon fiber connecting cloth.

[0009] The first perforated steel plate has holes according to a set rule, and the second perforated steel plate also has holes at corresponding positions; a portion of the first carbon fiber connecting cloth passes through some holes in the first perforated steel plate in an S-shaped weave, and a portion of the second carbon fiber connecting cloth passes through some holes in the second perforated steel plate in an S-shaped weave; the other portion of the first carbon fiber connecting cloth and the other portion of the second carbon fiber connecting cloth are combined and then pass through the remaining holes in the first and second perforated steel plates in an S-shaped weave.

[0010] The carbon fiber reinforced steel plate composite laminate provided by this invention fully meets the requirements for drill pipe materials in ultra-deep well drilling technology, exhibiting advantages such as light weight, good tensile properties, and heat and corrosion resistance, making it suitable for use as a drill pipe material. In this invention, one end of the carbon fiber reinforced steel plate composite laminate is flush with a non-perforated steel plate, while the other end is flush with carbon fiber cloth. This approach effectively saves costs, and because drill pipe joints typically use steel male-female threads, using the flush end of the non-perforated steel plate allows for direct welding of the non-perforated steel plate into a male-female thread later, facilitating the connection between the drill pipe and the drill bit.

[0011] In some embodiments of the present invention, the dimensions of the first perforated steel plate and the second perforated steel plate are both 160 mm*25 mm to 200 mm*40 mm; the dimensions of the first non-perforated steel plate, the second non-perforated steel plate, the third non-perforated steel plate, and the fourth non-perforated steel plate are all 30 mm*25 mm to 50 mm*40 mm.

[0012] In some embodiments of the present invention, the holes are rectangular holes, the width of the holes is the thickness of the carbon fiber connecting cloth, the length is 2 mm to 4 mm, and the spacing between adjacent holes in each area is 10 mm to 20 mm.

[0013] In some embodiments of the present invention, the first perforated steel plate is divided into four identical parallel zones, each zone having a row of holes; the first carbon fiber connecting fabric includes four carbon fiber braided strips and the carbon fiber connecting fabric; wherein, two carbon fiber braided strips each pass through all the holes in a zone sequentially in an S-shaped perforation manner; the second perforated steel plate is divided into four identical parallel zones, each zone having a row of holes, the second perforated steel plate has the same structure as the first perforated steel plate, and in the carbon fiber laminate, the hole positions of the first perforated steel plate coincide with the hole positions of the first perforated steel plate. The second carbon fiber connecting fabric includes four carbon fiber braided strips and a carbon fiber connecting fabric. Two carbon fiber braided strips pass through all the holes in a zone in an S-shaped perforation pattern. The remaining two braided strips of the first carbon fiber connecting fabric pass through the first perforated steel plate and the second perforated steel plate, respectively, and are then combined with the remaining two braided strips of the second carbon fiber connecting fabric to obtain two double-layer braided strips. Each double-layer braided strip passes through all the holes in the same zone of the first perforated steel plate and the second perforated steel plate in an S-shaped braiding pattern, thus weaving the first perforated steel plate and the first perforated steel plate into a whole.

[0014] In some embodiments of the present invention, the carbon fiber laminate further includes pins with a diameter of 1.5 mm to 2.0 mm, which are driven into the carbon fiber laminate to fix the steel plate and carbon fiber.

[0015] In some embodiments of the present invention, the dimensions of the first and second non-perforated carbon fiber cloths are 30 mm * 25 mm to 50 mm * 40 mm. The use of non-perforated carbon fiber cloth in this invention is not only for weight reduction but also to more fully utilize the superior properties of carbon fiber compared to steel (lightweight, high tensile strength, heat resistance, and high temperature resistance). Furthermore, the carbon fiber cloth has the same thickness as the steel plate, facilitating flush alignment.

[0016] A second aspect of the present invention provides a method for preparing a carbon fiber reinforced steel plate composite laminate as described above, comprising the following steps:

[0017] (1) Making holes in the steel plate: Divide the steel plate into 4 identical areas in parallel. The opening areas are 1, 2, 3 and 4 from the outside to the inside. Make a row of holes in each area to obtain the first and second opening steel plates with the same structure.

[0018] (2) Apply epoxy resin evenly to the surface of the second carbon fiber connecting cloth and the second perforated steel plate. Insert the two carbon fiber braided strips of the second carbon fiber connecting cloth into any different row of holes in the second perforated steel plate in an S-shaped braiding method. Insert the remaining two carbon fiber braided strips into the first hole of any different row of holes from top to bottom and then turn them down for later use. Press the surface of the remaining carbon fiber connecting cloth with a scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin.

[0019] (3) Use steel plate adhesive to bond the second non-perforated steel plate to the upper surface of the second perforated steel plate at the position flush with the second carbon fiber connecting cloth, and use epoxy resin adhesive to bond the second non-perforated carbon fiber cloth to the lower surface of the second carbon fiber connecting cloth at the position flush with the second perforated steel plate, to obtain the G1 steel plate carbon fiber cloth connector.

[0020] (4) Apply epoxy resin evenly to the surface of the first carbon fiber connecting cloth and the first perforated steel plate. Insert the two carbon fiber braided strips of the first carbon fiber connecting cloth into any different row of holes in the first perforated steel plate in an S-shaped braiding method. Insert the remaining two carbon fiber braided strips into the first hole of any different row of holes from top to bottom and then turn them down for later use. Press the surface of the remaining carbon fiber connecting cloth with a scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin.

[0021] (5) Use steel plate adhesive to bond the first non-perforated steel plate to the upper surface of the first perforated steel plate at the position flush with the first carbon fiber connecting cloth, and use epoxy resin adhesive to bond the first non-perforated carbon fiber cloth to the lower surface of the first carbon fiber connecting cloth at the position flush with the first perforated steel plate, to obtain the G2 steel plate carbon fiber cloth connector.

[0022] (6) Apply epoxy resin to the upper surface of the second carbon fiber connecting cloth and the second non-perforated steel plate and the lower surface of the first perforated steel plate and the first non-perforated carbon fiber cloth, and use epoxy resin to bond the two connectors G1 and G2; wherein, after the two carbon fiber braided strips in the G1 steel plate carbon fiber cloth connector are folded down and ready for use, they are passed through the corresponding holes in the first perforated steel plate and combined with the two carbon fiber braided strips in the G2 steel plate carbon fiber cloth connector to obtain two double-layer carbon fiber braided strips;

[0023] (7) Pass the two double-layer carbon fiber braided strips through all the holes in any of the remaining different rows of the first and second perforated steel plates in an S-shaped braiding method, and fix the first and second perforated steel plates into a whole; then use a scraper to press the remaining double-layer carbon fiber braided strip that has passed through the last hole and remove the air between it and the steel plate, so that it is tightly attached to the steel plate.

[0024] (8) Use carbon fiber cloth to fill the gap left after the braided strip above the first perforated steel plate is woven to form the first leveling layer; use carbon fiber cloth and non-perforated steel plate to fill the thickness of the braided strip after the second perforated steel plate is woven to form the second leveling layer; use epoxy resin adhesive to bond the steel plate and the carbon fiber cloth, and use steel plate adhesive to bond the steel plates together.

[0025] (9) Use carbon fiber cloth of appropriate size and non-perforated steel plate to bond flush with the top of the laminate to form the top layer of the laminate; use carbon fiber cloth of appropriate size and non-perforated steel plate to bond flush with the bottom of the laminate to form the bottom layer of the laminate; so that the top and bottom layers of the laminate are pressed into a plane.

[0026] (10) After the laminate is made, in order to make the braided strip and the steel plate more tightly connected, pins are punched in the reserved positions on the braided strip to fix the position of the braided strip and the steel plate.

[0027] (11) The bonded laminate is hot-pressed to obtain a carbon fiber reinforced steel composite laminate.

[0028] In some embodiments of the present invention, the hot pressing process includes the following steps:

[0029] Apply a release agent to the mold surface beforehand, place the mold in a molding press and heat it to 35℃~40℃ for preheating treatment; when the mold temperature reaches 35℃~40℃, place the bonded laminate into the mold and then close the mold; raise the temperature of the hot press to 120℃~130℃, control the pressure at 0.4 MPa~0.5 MPa, and the heating rate at 2℃ / min~3℃ / min, and maintain it for 1 h~2 h; after stopping the heating, slowly cool it for about 6 h until the temperature drops to the mold opening temperature, open the mold and take out the carbon fiber reinforced steel plate composite laminate.

[0030] In some embodiments of the present invention, the steel plate needs to be pre-treated before the hole is made in the steel plate;

[0031] The pretreatment includes the following steps: removing rust from the surface of the steel plate and wiping it clean with acetone, and using a high-pressure blower to remove dust from the plate surface and holes before connection.

[0032] In some embodiments of the present invention, the epoxy resin adhesive is a two-component modified epoxy adhesive consisting of components A and B. Components A and B are mixed in a mass ratio of 2:1. After mixing, the components A and B are stirred at a uniform speed using an electric stirrer to ensure that they are fully and evenly mixed.

[0033] The steel plate adhesive is a two-component adhesive consisting of components A and B. Components A and B are mixed in a 1:1 mass ratio. After mixing, the components are stirred at a constant speed using an electric stirrer to ensure that components A and B are fully and evenly mixed.

[0034] The beneficial effects of this invention are as follows:

[0035] This invention discloses a carbon fiber reinforced steel plate composite laminate, which can be used as a material for ultra-deep well drill pipes. The steel plate and carbon fiber cloth are joined using a hybrid method combining adhesive and mechanical bonding. The combined steel plate / carbon fiber composite material is then molded to obtain the carbon fiber reinforced steel plate composite laminate. This invention, through a novel hybrid bonding method combining mechanical and adhesive bonding of carbon fiber cloth and steel plate, fully utilizes the high strength and lightweight characteristics of carbon fiber, significantly improving the strength, reliability, and stability of the steel plate, and increasing the heat resistance and corrosion resistance of the laminate. This effectively reduces the impact of complex geological conditions on the quality of ultra-deep well drill pipes. Furthermore, the composite laminate obtained by this invention effectively reduces weight compared to steel plates of the same thickness and significantly lowers costs compared to pure carbon fiber composites. Attached Figure Description

[0036] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0037] Figure 1 This is a schematic diagram of the carbon fiber reinforced steel plate composite laminate structure of the present invention;

[0038] Figure 2 for Figure 1 Enlarged view of a portion of position A in the middle;

[0039] Figure 3 for Figure 1 A magnified view of a portion of position B in the middle;

[0040] Figure 4 This is a schematic diagram of the steel plate structure in the embodiment;

[0041] Figure 5 This is a schematic diagram of the carbon fiber braided strip structure in the embodiment;

[0042] Figure 6 This is a schematic diagram of the G1 steel plate carbon fiber cloth connector structure in the embodiment;

[0043] Figure 7 This is a schematic diagram of the G2 steel plate carbon fiber cloth connector structure in the embodiment;

[0044] Figure 8 This is a schematic diagram of the bonding method of G1 and G2 in the embodiment;

[0045] Figure 9 This is a schematic diagram illustrating the weaving method of the double-layer carbon fiber braided strips ab1 and ab3 in the embodiment;

[0046] Figure 10 This is a schematic diagram of the installation of the leveling layer, top layer, and bottom layer in the embodiment;

[0047] Figure 11 This is a schematic diagram of the pin installation position in the embodiment.

[0048] Among them, 1- Third non-perforated steel plate, 2- H2 carbon fiber cloth, 3- H1 carbon fiber cloth, 4- First non-perforated steel plate, 5- First carbon fiber connecting cloth, 6- First perforated steel plate, 7- First non-perforated carbon fiber cloth, 8- Second non-perforated steel plate, 9- Second carbon fiber connecting cloth, 10- Second perforated steel plate, 11- Second non-perforated carbon fiber cloth, 12- Fourth non-perforated steel plate, 13- h1 carbon fiber cloth, 14- Fifth non-perforated steel plate, 15- h2 carbon fiber cloth; 501- Carbon fiber braided strip b1, 502- Carbon fiber braided strip b2, 503- Carbon fiber braided strip b3, 504- Carbon fiber braided strip b4; 901- Carbon fiber braided strip a1, 902- Carbon fiber braided strip a2, 903- Carbon fiber braided strip a3, 904- Carbon fiber braided strip a4; 16- Double-layer carbon fiber braided strip ab1, 17- Double-layer carbon fiber braided strip ab3, and pin 18. Detailed Implementation

[0049] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to specific embodiments.

[0050] Example 1

[0051] A method for preparing a carbon fiber reinforced steel composite laminate includes the following steps:

[0052] (1) Pretreatment of steel plates:

[0053] Remove rust from the steel plate surface with a steel brush and wipe it clean with acetone. Use a high-pressure blower to remove dust from the plate surface and holes before making connections. The steel plate dimensions are 150 mm * 40 mm, and the thickness is 0.12 mm.

[0054] (2) Opening:

[0055] A steel plate punching machine is used to make holes in the steel plate. The hole making is divided into zones 1, 2, 3, and 4, such as... Figure 1As shown, the first perforated steel plate 6 has perforated areas designated as A1, A2, A3, and A4, and the second perforated steel plate 10 has perforated areas designated as B1, B2, B3, and B4 (seven holes are drilled in areas 1 and 3, designated as A11-A17, B11-B17, A31-A37, and B31-B37 respectively; thirteen holes are drilled in areas 2 and 4, designated as A21-A214, B21-B214, A41-A414, and B41-B414 respectively). The perforation size is 0.12 mm * 4 mm. The spacing between perforations in areas 1 and 3 is 20 mm, and the spacing between perforations in areas 2 and 4 is 10 mm.

[0056] (3) Weaving:

[0057] Apply epoxy resin evenly to the surfaces of the second carbon fiber connecting fabric 9 and the second perforated steel plate 10. Insert the carbon fiber braided strip b2 902 of the second carbon fiber connecting fabric 9 from top to bottom into hole B21, and then sequentially into holes B22, B23...B213 using an S-shaped braiding method until the carbon fiber braided strip b2 902 emerges from hole B214. Similarly, insert the carbon fiber braided strip b4 904 of the second carbon fiber connecting fabric 9 from top to bottom into hole B41, and then sequentially into holes B42, B43...B413 using an S-shaped braiding method until the carbon fiber braided strip b4 904 emerges from hole B414. Insert the carbon fiber braided strips b1 901 and b3 903 from top to bottom into holes B11 and B31, and then fold them down for later use. Press the surface of the remaining part of the second carbon fiber connecting fabric 9 with a plastic scraper to bond the carbon fiber fabric and the steel plate together with epoxy resin. The second carbon fiber connecting cloth 9 has dimensions of 150 mm * 40 mm and a thickness of 0.12 mm. The width of the carbon fiber braided strips is 2 mm.

[0058] (4) Level:

[0059] The second non-perforated steel plate 8 is bonded to the upper surface of the second perforated steel plate 10, flush with the second carbon fiber connecting cloth 9, using steel plate adhesive. The first non-perforated carbon fiber cloth 11 is bonded to the lower surface of the second carbon fiber connecting cloth 9, flush with the second perforated steel plate 10, using epoxy resin adhesive, to obtain the G1 steel plate carbon fiber cloth connector. The second non-perforated steel plate 8 has dimensions of 50 mm * 40 mm and a thickness of 0.12 mm, and the first non-perforated carbon fiber cloth 11 has dimensions of 50 mm * 40 mm and a thickness of 0.12 mm.

[0060] (5) Weaving:

[0061] Apply epoxy resin evenly to the surfaces of the first carbon fiber connecting cloth 5 and the first perforated steel plate 6. Insert the carbon fiber braided strip a2 502 of the first carbon fiber connecting cloth 5 from top to bottom into hole A21, and then sequentially into holes A22, A23...A213 using an S-shaped braiding method until the carbon fiber braided strip a2 502 emerges from hole A214. Similarly, insert the carbon fiber braided strip a4 504 of the first carbon fiber connecting cloth 5 from top to bottom into hole A41, and then sequentially into holes A42, A43...A413 using an S-shaped braiding method until the carbon fiber braided strip a4 504 emerges from hole A414. Insert the carbon fiber braided strips a1 501 and a3 503 from top to bottom into holes A11 and A31, respectively, and then fold them down for later use. Press the surface of the remaining part of the first carbon fiber connecting cloth 5 with a plastic scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin. The first carbon fiber connecting cloth 5 has dimensions of 150 mm * 40 mm and a thickness of 0.12 mm. The width of the carbon fiber braided strips is 2 mm.

[0062] (6) Level:

[0063] A first non-perforated steel plate 4 is bonded to the upper surface of the first perforated steel plate 6, flush with the first carbon fiber connecting cloth 5, using steel plate adhesive. Similarly, a first non-perforated carbon fiber cloth 7 is bonded to the lower surface of the first carbon fiber connecting cloth 5, flush with the first perforated steel plate 6, using epoxy resin adhesive, to obtain the G2 steel plate carbon fiber cloth connector. The first non-perforated steel plate 4 has dimensions of 50 mm * 40 mm and a thickness of 0.12 mm, and the first non-perforated carbon fiber cloth also has dimensions of 50 mm * 40 mm and a thickness of 0.12 mm.

[0064] (7) Composite:

[0065] Epoxy resin is applied to the upper surface of the second carbon fiber connecting cloth 9 and the second non-perforated steel plate 8, and to the lower surface of the first perforated steel plate 6 and the first non-perforated carbon fiber cloth 7. Epoxy resin is then used to bond the two connectors G1 and G2. Carbon fiber braided strips a1 501 and a3 503 are then passed through B11 and B31 respectively. Epoxy resin is then used to bond carbon fiber braided strips b1 901 and a1 501 to form a double-layer carbon fiber braided strip ab1 16, and carbon fiber braided strips a3 503 and b3 903 to form a double-layer carbon fiber braided strip ab3 17.

[0066] (8) Weaving:

[0067] Apply epoxy resin to the contact surfaces of double-layer carbon fiber braided strips ab1 16 and ab3 17 with the steel plate. Insert ab1 through B12 and out through A12, then use an S-shaped weaving method to insert through A13 and out through B13, then through B14 and out through A14, then through A15 and out through B15, then through B16 and out through A16, and finally through A17 and out through B17. Similarly, perform the same operation on ab3, inserting through B32 and out through A32, then using an S-shaped weaving method to insert through A33 and out through B33, then through B34 and out through A34, then through A35 and out through B35, then through B36 and out through A36, and finally through A37 and out through B37. Finally, use a plastic scraper to remove the remaining double-layer carbon fiber braided strip ab1 from B17. 16 and double-layer carbon fiber braided strips ab3 17 are pressed together and the air between them and the steel plate is removed, so that they are in close contact with the steel plate.

[0068] (9) Leveling:

[0069] Because the carbon fiber woven strips protrude beyond the steel plate after weaving, H1 layer carbon fiber cloth 3 is used to fill the gap left after the woven strips above the first perforated steel plate 6. H1 carbon fiber cloth 13 and the fourth non-perforated steel plate 12 are used to fill the gap left after the woven strips below the second perforated steel plate 10. The steel plate and carbon fiber cloth are bonded together with epoxy resin adhesive, and the steel plates are bonded together with steel plate adhesive. The thickness of H1 carbon fiber cloth 13 and the fourth non-perforated steel plate 12 is 0.12 mm.

[0070] (10) Capping:

[0071] The thickness of a single-layer woven strip is flush with the top surface of the laminate. Then, a suitably sized H2 layer of carbon fiber cloth 2 and a third non-perforated steel plate 1 are bonded flush with the top layer of the laminate. Similarly, a suitably sized h2 carbon fiber cloth 15 and a fifth non-perforated steel plate 14 are bonded flush with the bottom layer of the laminate, ensuring that both the top and bottom layers are pressed into a single plane. The thicknesses of the H2 layer of carbon fiber cloth 2, the third non-perforated steel plate 1, the h2 carbon fiber cloth 15, and the fifth non-perforated steel plate 14 are all 0.12 mm.

[0072] (11) Pin fixing:

[0073] like Figure 10 As shown, after the laminate is manufactured, in order to make the connection between the braided strip and the steel plate tighter, pins 18 are punched into the reserved positions on the braided strip to fix the position of the braided strip and the steel plate.

[0074] (12) Hot pressing:

[0075] Apply a release agent to the mold surface beforehand, place the mold in a molding press and heat it to 35°C for preheating treatment; when the mold temperature reaches 35°C, place the bonded laminate into the mold and then close the mold; raise the temperature of the hot press to 120°C, control the pressure at 0.4 MPa, and the heating rate at 2°C / min, and maintain for 2 hours; after stopping the heating, slowly cool for about 6 hours until the temperature drops to the mold opening temperature, open the mold and remove the carbon fiber reinforced steel plate composite laminate.

[0076] Example 2

[0077] A method for preparing a carbon fiber reinforced steel composite laminate includes the following steps:

[0078] (1) Pretreatment of steel plates:

[0079] Remove rust from the steel plate surface with a steel brush and wipe it clean with acetone. Use a high-pressure blower to remove dust from the plate surface and holes before making connections. The steel plate dimensions are 200 mm * 40 mm, and the thickness is 0.15 mm.

[0080] (2) Opening:

[0081] A steel plate punching machine is used to make holes in the steel plate. The hole making is divided into zones 1, 2, 3, and 4, such as... Figure 1 As shown, the first perforated steel plate 6 has perforated areas designated as A1, A2, A3, and A4, and the second perforated steel plate 10 has perforated areas designated as B1, B2, B3, and B4 (seven holes are drilled in areas 1 and 3, designated as A11-A17, B11-B17, A31-A37, and B31-B37 respectively; thirteen holes are drilled in areas 2 and 4, designated as A21-A214, B21-B214, A41-A414, and B41-B414 respectively). The perforation size is 0.15 mm * 4 mm. The spacing between perforations in areas 1 and 3 is 20 mm, and the spacing between perforations in areas 2 and 4 is 10 mm.

[0082] (3) Weaving:

[0083] Apply epoxy resin evenly to the surfaces of the second carbon fiber connecting fabric 9 and the second perforated steel plate 10. Insert the carbon fiber braided strip b2 902 of the second carbon fiber connecting fabric 9 from top to bottom into hole B21, and then sequentially into holes B22, B23...B213 using an S-shaped braiding method until the carbon fiber braided strip b2 902 emerges from hole B214. Similarly, insert the carbon fiber braided strip b4 904 of the second carbon fiber connecting fabric 9 from top to bottom into hole B41, and then sequentially into holes B42, B43...B413 using an S-shaped braiding method until the carbon fiber braided strip b4 904 emerges from hole B414. Insert the carbon fiber braided strips b1 901 and b3 903 from top to bottom into holes B11 and B31, and then fold them down for later use. Press the surface of the remaining part of the second carbon fiber connecting fabric 9 with a plastic scraper to bond the carbon fiber fabric and the steel plate together with epoxy resin. The second carbon fiber connecting cloth 9 has dimensions of 200 mm * 40 mm and a thickness of 0.15 mm. The width of the carbon fiber braided strips is 4 mm.

[0084] (4) Level:

[0085] The second non-perforated steel plate 8 is bonded to the upper surface of the second perforated steel plate 10, flush with the second carbon fiber connecting cloth 9, using steel plate adhesive. The first non-perforated carbon fiber cloth 11 is bonded to the lower surface of the second carbon fiber connecting cloth 9, flush with the second perforated steel plate 10, using epoxy resin adhesive, to obtain the G1 steel plate carbon fiber cloth connector. The second non-perforated steel plate 8 has dimensions of 50 mm * 40 mm and a thickness of 0.15 mm, and the first non-perforated carbon fiber cloth 11 has dimensions of 50 mm * 40 mm and a thickness of 0.15 mm.

[0086] (5) Weaving:

[0087] Apply epoxy resin evenly to the surfaces of the first carbon fiber connecting cloth 5 and the first perforated steel plate 6. Insert the carbon fiber braided strip a2 502 of the first carbon fiber connecting cloth 5 from top to bottom into hole A21, and then sequentially into holes A22, A23...A213 using an S-shaped braiding method until the carbon fiber braided strip a2 502 emerges from hole A214. Similarly, insert the carbon fiber braided strip a4 504 of the first carbon fiber connecting cloth 5 from top to bottom into hole A41, and then sequentially into holes A42, A43...A413 using an S-shaped braiding method until the carbon fiber braided strip a4 504 emerges from hole A414. Insert the carbon fiber braided strips a1 501 and a3 503 from top to bottom into holes A11 and A31, respectively, and then fold them down for later use. Press the surface of the remaining part of the first carbon fiber connecting cloth 5 with a plastic scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin. The first carbon fiber connecting cloth 5 has dimensions of 200 mm * 40 mm and a thickness of 0.15 mm. The width of the carbon fiber braided strips is 4 mm.

[0088] (6) Level:

[0089] A first non-perforated steel plate 4 is bonded to the upper surface of the first perforated steel plate 6, flush with the first carbon fiber connecting cloth 5, using steel plate adhesive. A first non-perforated carbon fiber cloth 7 is bonded to the lower surface of the first carbon fiber connecting cloth 5, flush with the first perforated steel plate 6, using epoxy resin adhesive, to obtain the G2 steel plate carbon fiber cloth connector. The first non-perforated steel plate 4 has dimensions of 50 mm * 40 mm and a thickness of 0.15 mm. The first non-perforated carbon fiber cloth also has dimensions of 50 mm * 40 mm and a thickness of 0.15 mm.

[0090] (7) Composite:

[0091] Epoxy resin is applied to the upper surfaces of the second carbon fiber connecting cloth 9 and the second non-perforated steel plate 8, and to the lower surfaces of the first perforated steel plate 6 and the first non-perforated carbon fiber cloth 7. Epoxy resin is then used to bond the two connectors G1 and G2. Carbon fiber braided strips a1 501 and a3 503 are threaded through B11 and B31 respectively, and then epoxy resin is used to bond carbon fiber braided strips b1 901 and a1 501 to form a double-layer carbon fiber braided strip ab1 16, and carbon fiber braided strips a3 503 and b3 903 to form a double-layer carbon fiber braided strip ab3 17.

[0092] (8) Weaving:

[0093] Apply epoxy resin to the contact surfaces of double-layer carbon fiber braided strips ab1 16 and ab3 17 with the steel plate. Insert ab1 through B12 and out through A12, then use an S-shaped weaving method to insert through A13 and out through B13, then through B14 and out through A14, then through A15 and out through B15, then through B16 and out through A16, and finally through A17 and out through B17. Similarly, perform the same operation on ab3, inserting through B32 and out through A32, then using an S-shaped weaving method to insert through A33 and out through B33, then through B34 and out through A34, then through A35 and out through B35, then through B36 and out through A36, and finally through A37 and out through B37. Finally, use a plastic scraper to remove the remaining double-layer carbon fiber braided strip ab1 from B17. 16 and double-layer carbon fiber braided strips ab3 17 are pressed together and the air between them and the steel plate is removed, so that they are in close contact with the steel plate.

[0094] (9) Leveling:

[0095] Because the carbon fiber woven strips protrude beyond the steel plate after weaving, H1 layer carbon fiber cloth 3 is used to fill the gap left after the woven strips above the first perforated steel plate 6. H1 carbon fiber cloth 13 and the fourth non-perforated steel plate 12 are used to fill the gap left after the woven strips below the second perforated steel plate 10. The steel plate and carbon fiber cloth are bonded together with epoxy resin adhesive, and the steel plates are bonded together with steel plate adhesive. The thickness of both h1 carbon fiber cloth 13 and the fourth non-perforated steel plate 12 is 0.15 mm.

[0096] (10) Capping:

[0097] The thickness of the single-layer woven strip is flush with the top surface of the laminate. Then, a suitably sized H2 layer of carbon fiber cloth 2 and a third non-perforated steel plate 1 are bonded flush with the top layer of the laminate. Similarly, a suitably sized h2 carbon fiber cloth 15 and a fifth non-perforated steel plate 14 are bonded flush with the bottom layer of the laminate, ensuring that both the top and bottom layers are pressed into a single plane. The thickness of the H2 layer of carbon fiber cloth 2, the third non-perforated steel plate 1, the h2 carbon fiber cloth 15, and the fifth non-perforated steel plate 14 is 0.15 mm.

[0098] (11) Pin fixing:

[0099] like Figure 10 As shown, after the laminate is manufactured, in order to make the connection between the braided strip and the steel plate tighter, pins 18 are punched into the reserved positions on the braided strip to fix the position of the braided strip and the steel plate.

[0100] (12) Hot pressing:

[0101] Apply a release agent to the mold surface beforehand, place the mold in a molding press and heat it to 40°C for preheating treatment; when the mold temperature reaches 40°C, place the bonded laminate into the mold and then close the mold; raise the temperature of the hot press to 130°C, control the pressure at 0.5MPa, and the heating rate at ~3°C / min, and maintain for 1 hour; after stopping the heating, slowly cool for about 6 hours until the temperature drops to the mold opening temperature, open the mold and remove the carbon fiber reinforced steel plate composite laminate.

[0102] Currently, most composite materials are made by bonding steel plates and carbon fibers using ordinary adhesives, which involves adding a suitable structural adhesive between the two for fixation. When used in ultra-deep well technology, the adhesive between the steel plate and carbon fiber is affected by temperature, tensile strength, and external corrosion, leading to failure and separation of the steel plate and carbon fiber fabric. To address this, this invention employs a hybrid bonding method combining adhesives and mechanical connections to composite the steel plate and carbon fiber into a suitable composite material. The presence of mechanical connections increases the friction between the carbon fiber and the steel plate, effectively preventing failure and significantly improving the composite material's peel resistance and mechanical properties. The carbon fiber reinforced steel plate composite laminate obtained by this invention is more suitable for ultra-deep well technology.

[0103] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A carbon fiber reinforced steel plate composite laminate, characterized in that, From top to bottom, it includes: top laminate layer, first leveling layer, first connecting layer, first steel plate layer, second connecting layer, second steel plate layer, second leveling layer, and bottom laminate layer; The first steel plate layer includes a first perforated steel plate and a first non-perforated carbon fiber cloth, and the first connecting layer includes a first non-perforated steel plate and a first carbon fiber connecting cloth; the first perforated steel plate and the first carbon fiber connecting cloth are staggered, the first non-perforated carbon fiber cloth is bonded to the lower surface of the first carbon fiber connecting cloth at a position flush with the first perforated steel plate, and the first non-perforated steel plate is bonded to the upper surface of the first perforated steel plate at a position flush with the first carbon fiber connecting cloth. The second steel plate layer includes a second perforated steel plate and a second non-perforated carbon fiber cloth, and the second connecting layer includes a second non-perforated steel plate and a second carbon fiber connecting cloth; the second perforated steel plate and the second carbon fiber connecting cloth are staggered, the second non-perforated carbon fiber cloth is bonded to the lower surface of the second carbon fiber connecting cloth at a position flush with the second perforated steel plate, and the second non-perforated steel plate is bonded to the upper surface of the second perforated steel plate at a position flush with the second carbon fiber connecting cloth. The first perforated steel plate is divided into four identical parallel sections, each with a row of holes; the second perforated steel plate is also divided into four identical parallel sections, each with a row of holes. The positions of the holes in the first and second perforated steel plates coincide, resulting in first and second perforated steel plates with identical structures. The first carbon fiber connecting fabric includes four carbon fiber braided strips and a carbon fiber connecting fabric. Two carbon fiber braided strips of the first carbon fiber connecting fabric are sequentially threaded into any different row of holes in the first perforated steel plate using an S-shaped braiding method. The remaining two carbon fiber braided strips of the first carbon fiber connecting fabric are then threaded from top to bottom into the first hole of any remaining different row of holes and folded down for later use. The second carbon fiber connecting fabric includes four carbon fiber braided strips and a carbon fiber connecting fabric. First, attach the two carbon fiber braided strips of the second carbon fiber connecting fabric and thread them sequentially through any row of holes in the second perforated steel plate using an S-shaped braiding method. Then, thread the remaining two carbon fiber braided strips of the second carbon fiber connecting fabric from top to bottom through the first hole of any remaining row of holes and fold them down for later use. Finally, thread the two carbon fiber braided strips of the first carbon fiber connecting fabric that have been folded down through the corresponding holes in the second perforated steel plate and combine them with the two carbon fiber braided strips of the second carbon fiber connecting fabric to obtain two double-layer carbon fiber braided strips. Then, thread the two double-layer carbon fiber braided strips sequentially through all the remaining holes in any row of holes in the first and second perforated steel plates using an S-shaped braiding method, thus weaving the first and second perforated steel plates into a whole.

2. The carbon fiber reinforced steel plate composite laminate as described in claim 1, characterized in that, The dimensions of the first perforated steel plate and the second perforated steel plate are both 160 mm × 25 mm to 200 mm × 40 mm; the dimensions of the first non-perforated steel plate and the second non-perforated steel plate are both 30 mm × 25 mm to 50 mm × 40 mm.

3. The carbon fiber reinforced steel plate composite laminate as described in claim 1, characterized in that, The holes are rectangular, with the width equal to the thickness of the carbon fiber connecting fabric and the length ranging from 2 mm to 4 mm. The spacing between adjacent holes in each area is 10 mm to 20 mm.

4. The carbon fiber reinforced steel plate composite laminate as described in claim 1, characterized in that, The carbon fiber reinforced steel plate composite laminate also includes pins with a diameter of 1.5 mm to 2.0 mm. The pins are driven into the carbon fiber reinforced steel plate composite laminate to fix the steel plate and carbon fiber.

5. The carbon fiber reinforced steel plate composite laminate as described in claim 1, characterized in that, The dimensions of both the first and second non-perforated carbon fiber cloths are 30 mm × 25 mm to 50 mm × 40 mm.

6. A method for preparing a carbon fiber reinforced steel plate composite laminate as described in any one of claims 1-5, characterized in that, Includes the following steps: (1) Making holes in the steel plate: Divide the steel plate into 4 identical areas in parallel. The opening areas are 1, 2, 3 and 4 from the outside to the inside. Make a row of holes in each area to obtain the first and second opening steel plates with the same structure. (2) Apply epoxy resin evenly to the surface of the second carbon fiber connecting cloth and the second perforated steel plate. Insert the two carbon fiber braided strips of the second carbon fiber connecting cloth into any different row of holes in the second perforated steel plate in an S-shaped braiding method. Insert the remaining two carbon fiber braided strips of the second carbon fiber connecting cloth into the first hole of any different row of holes from top to bottom and then turn them down for later use. Press the surface of the carbon fiber cloth with a scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin. (3) Use steel plate adhesive to bond the second non-perforated steel plate to the upper surface of the second perforated steel plate at the position flush with the second carbon fiber connecting cloth, and use epoxy resin adhesive to bond the second non-perforated carbon fiber cloth to the lower surface of the second carbon fiber connecting cloth at the position flush with the second perforated steel plate, to obtain the G1 steel plate carbon fiber cloth connector. (4) Apply epoxy resin evenly to the surface of the first carbon fiber connecting cloth and the first perforated steel plate. Insert the two carbon fiber braided strips of the first carbon fiber connecting cloth into any different row of holes in the first perforated steel plate in an S-shaped braiding method. Insert the remaining two carbon fiber braided strips of the first carbon fiber connecting cloth into the first hole of any different row of holes from top to bottom and then turn them down for later use. The remaining part of the first carbon fiber connecting cloth is pressed with a scraper to bond the carbon fiber cloth and the steel plate together with epoxy resin adhesive. (5) Use steel plate adhesive to bond the first non-perforated steel plate to the upper surface of the first perforated steel plate at the position flush with the first carbon fiber connecting cloth, and use epoxy resin adhesive to bond the first non-perforated carbon fiber cloth to the lower surface of the first carbon fiber connecting cloth at the position flush with the first perforated steel plate, to obtain the G2 steel plate carbon fiber cloth connector. (6) Apply epoxy resin to the upper surface of the second carbon fiber connecting cloth and the second non-perforated steel plate and the lower surface of the first perforated steel plate and the first non-perforated carbon fiber cloth, and use epoxy resin to bond the two connectors G1 and G2; wherein, after the two carbon fiber braided strips in the G2 steel plate carbon fiber cloth connector are turned down and ready for use, they are passed through the corresponding holes in the second perforated steel plate and combined with the two carbon fiber braided strips in the G1 steel plate carbon fiber cloth connector respectively to obtain two double-layer carbon fiber braided strips; (7) Pass the two double-layer carbon fiber braided strips through all the holes in any of the remaining different rows of the first and second perforated steel plates in an S-shaped braiding method, and fix the first and second perforated steel plates into a whole; then use a scraper to press the remaining double-layer carbon fiber braided strip that has passed through the last hole and remove the air between it and the steel plate, so that it is tightly attached to the steel plate. (8) Use carbon fiber cloth to fill the gap left after the braided strip above the first perforated steel plate is woven to form the first leveling layer; use carbon fiber cloth and non-perforated steel plate to fill the thickness of the braided strip after the second perforated steel plate is woven to form the second leveling layer; use epoxy resin adhesive to bond the steel plate and the carbon fiber cloth, and use steel plate adhesive to bond the steel plates together. (9) Use carbon fiber cloth of appropriate size and non-perforated steel plate to bond flush with the top of the laminate to form the top layer of the laminate; use carbon fiber cloth of appropriate size and non-perforated steel plate to bond flush with the bottom of the laminate to form the bottom layer of the laminate; so that the top and bottom layers of the laminate are pressed into a plane. (10) After the laminate is made, in order to make the braided strip and the steel plate more tightly connected, pins are punched in the reserved positions on the braided strip to fix the position of the braided strip and the steel plate. (11) The bonded laminate is hot-pressed to obtain a carbon fiber reinforced steel composite laminate.

7. The method for preparing a carbon fiber reinforced steel plate composite laminate as described in claim 6, characterized in that, The hot pressing process includes the following steps: Apply a release agent to the mold surface beforehand, place the mold in a molding press and heat it to 35℃~40℃ for preheating treatment; when the mold temperature reaches 35℃~40℃, place the bonded laminate into the mold and then close the mold; raise the temperature of the hot press to 120℃~130℃, control the pressure at 0.4 MPa~0.5 MPa, and the heating rate at 2℃ / min~3℃ / min, and maintain it for 1h~2h; after stopping the heating, slowly cool it for 6h until the temperature drops to the mold opening temperature, open the mold and take out the carbon fiber reinforced steel plate composite laminate.

8. The method for preparing a carbon fiber reinforced steel plate composite laminate as described in claim 6, characterized in that, Before drilling holes in a steel plate, the steel plate needs to be pre-treated. The pretreatment includes the following steps: removing rust from the surface of the steel plate and wiping it clean with acetone, and using a high-pressure blower to remove dust from the plate surface and holes before connection.

9. The method for preparing a carbon fiber reinforced steel plate composite laminate as described in claim 6, characterized in that, The epoxy resin adhesive is a two-component modified epoxy adhesive consisting of components A and B. Components A and B are mixed in a mass ratio of 2:

1. After mixing, the components A and B are stirred at a constant speed using an electric stirrer to ensure that they are fully and evenly mixed. The steel plate adhesive is a two-component adhesive consisting of components A and B. Components A and B are mixed in a 1:1 mass ratio. After mixing, the components are stirred at a constant speed using an electric stirrer to ensure that components A and B are fully and evenly mixed.

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