Thermoplastic honeycomb panel and method of making and use thereof

Abstract

The application discloses a thermoplastic honeycomb plate and a preparation method and application thereof, and belongs to the technical field of high polymer materials. The thermoplastic honeycomb plate comprises a honeycomb core and a surface layer completely wrapping the outer surface of the honeycomb core, wherein the surface layer comprises an upper surface layer, a lower surface layer and a side surface layer; the upper surface layer, the lower surface layer and the side surface layer each independently comprise a continuous fiber reinforced thermoplastic composite sheet and a modified resin film; the application can effectively edge the honeycomb core by arranging the surface layer on the outer surface of the honeycomb core, the edge is beautiful and has good sealing performance and is not easy to collapse; meanwhile, the upper surface layer, the lower surface layer and the side surface layer are made of the same material, the honeycomb core can be effectively protected, the sealing effect is improved, the honeycomb plate has the functions of flame retardation, aging resistance and waterproofing, and the compression and bending strength of the honeycomb plate is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of polymer materials technology, specifically to a thermoplastic honeycomb panel, its preparation method, and its application. Background Technology

[0002] Thermoplastic composite honeycomb panels have been widely used in various fields such as rail transportation, logistics, building materials, and electronics due to their lightweight, high rigidity, impact resistance, moisture resistance, and recyclability. However, due to the special processing technology of the honeycomb core, it has a hollow structure, making it difficult to meet requirements such as flame retardancy, aging resistance, and uniform appearance.

[0003] CN107379726A describes a sealing method that involves creating a sealing area outside the product's outline. Within this area, a high-temperature component is inserted between the upper and lower skins of the edge to melt and remove honeycomb-like structures and soften the skins. The skins are then folded inwards to achieve edge sealing. This method results in full, firm edges, increasing edge strength and solving the problem of sealing the edges of PPHC materials, aiming to promote the application of PPHC in spare tire covers. However, this processing method, where the hot-melt component removes honeycomb, can easily lead to resin adhesion, resulting in poor appearance and making it unsuitable for mass production.

[0004] Patent CN113844111A discloses a honeycomb panel with edge sealing and its preparation method. The honeycomb panel has upper and lower skins made of continuous fiber reinforced thermoplastic composite material. The upper skin surface has a coating and a protective film. The middle structure is a polypropylene honeycomb core. Polypropylene edge sealing strips are set on both sides of the honeycomb core. The edge sealing strips are interlocking, which can solve the problem of gaps between the two edge sealing materials during the final lamination process. A preparation method is also provided: the upper and lower surfaces are made of continuous fiber reinforced thermoplastic material, and the upper and lower surfaces are laminated with the honeycomb core through a thermal lamination process to form a honeycomb panel. Edge sealing material is cyclically laid on both sides of the honeycomb core, so that the edge of each honeycomb core is adhered to the edge sealing material. The working parameters of the laminating machine are set, the equipment is heated and kept at a fixed temperature for a fixed time, and the honeycomb panels with edge sealing material are fed into the laminating machine by a conveyor belt for thermoplastic lamination to obtain the honeycomb panel with edge sealing. The edge-sealed honeycomb panel produced by this method only has edge sealing material on two sides.

[0005] Therefore, how to edge the honeycomb core has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a thermoplastic honeycomb panel, its preparation method and application. The thermoplastic honeycomb core can effectively wrap the honeycomb core, resulting in a beautiful edge wrap, good sealing performance, and resistance to edge chipping. It also has excellent mechanical properties and bonding strength.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A thermoplastic honeycomb panel includes a honeycomb core and a surface layer that completely covers the outer surface of the honeycomb core, the surface layer including a top layer, a bottom layer, and a side layer;

[0009] The top layer, bottom layer, and side layer each independently comprise a continuous fiber-reinforced thermoplastic composite sheet and a modified resin film;

[0010] The continuous fiber reinforced thermoplastic composite sheet comprises continuous fibers and a matrix resin;

[0011] The matrix resin comprises the following components in parts by weight: 76-91 parts polypropylene resin, 4.5-10.5 parts toughening agent, 4.5-10.5 parts compatibilizer, 0.28-0.82 parts antioxidant, and 0.18-0.82 parts lubricant;

[0012] The honeycomb core includes multiple honeycomb cells arranged in an array, and each honeycomb cell includes a resin layer and an adhesive layer arranged sequentially from the inside to the outside.

[0013] Preferably, the weight ratio of the continuous fiber to the matrix resin is (4-7):(3-6).

[0014] Preferably, the upper layer extends downward to form a first bend, and the lower layer extends upward to form a second bend, the first bend and the second bend constituting the side layer.

[0015] Preferably, the upper layer is arranged parallel to the lower layer, and the upper layer is arranged perpendicular to the side layer.

[0016] Preferably, at least one of the following (a) to (c) is satisfied:

[0017] (a) The polypropylene resin in the matrix resin is copolymer polypropylene, and the melt index of the copolymer polypropylene at 230℃ / 2.16kg is 60~120g / 10min;

[0018] (b) The toughening agent is at least one of GMA grafted polyolefin resin thermoplastic elastomer and MAH grafted polyolefin resin thermoplastic elastomer, and the melt index of the toughening agent at 190℃ / 2.16kg is 1.5 to 15 g / 10min.

[0019] (c) The compatibilizer in the matrix resin is MAH-grafted polypropylene, wherein the grafting rate of MAH in the MAH-grafted polypropylene is 0.9-1.2%, and the melt index of the compatibilizer at 190℃ / 2.16kg is 80-120g / 10min.

[0020] The grafting rate of the MAH can be determined by infrared spectroscopy: Fourier transform infrared spectrometer is used to test the characteristic absorption peaks of the infrared spectrum of a sample with a fixed thickness, and the grafting rate of the MAH can be calculated by comparing the ratio of the absorption intensity of carbonyl and methylene groups.

[0021] Preferably, at least one of the following (1) to (3) is satisfied:

[0022] (1) The weight ratio of the resin layer to the adhesive layer is (5-10):1.

[0023] (2) The resin layer is a polyolefin resin, and the crystallinity of the polyolefin resin is 50-85%;

[0024] (3) The modified resin film comprises the following components in parts by weight: 75-90 parts polypropylene resin, 5-10 parts compatibilizer, 5-10 parts polyolefin resin thermoplastic elastomer, and 0.1-0.6 parts UV stabilizer.

[0025] Preferably, the thickness of the continuous fiber reinforced thermoplastic composite sheet is 0.3–1.2 mm;

[0026] The thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is (30-120):(2-15).

[0027] This invention also provides a method for preparing a thermoplastic honeycomb panel, comprising the following steps:

[0028] The top layer, honeycomb core and bottom layer are laid in sequence and composited at 120-250℃ to obtain a honeycomb panel;

[0029] The honeycomb panel is processed using Teflon tape, resulting in a static friction coefficient ≥0.8 and a dynamic friction coefficient ≥0.17 on the surface of the honeycomb panel.

[0030] The honeycomb panel is cut into semi-finished honeycomb panels. The sides of the semi-finished honeycomb panels are cut. The top layer is pressed down and the bottom layer is pressed up in sequence. The edge sealing area is baked. After the edge sealing area softens, the top and bottom edge sealing areas are folded towards the middle in sequence to form the side layer. After cooling and compaction, a thermoplastic honeycomb panel is obtained.

[0031] This invention also provides an application of thermoplastic honeycomb panels in rail transit, logistics transportation, building materials and construction, and electronics.

[0032] The beneficial effects of the present invention are as follows: (1) By setting a surface layer on the outer surface of the honeycomb core, the present invention can effectively wrap the honeycomb core, which is aesthetically pleasing, has good sealing performance, and is not prone to edge breakage. At the same time, the materials of the top layer, bottom layer and side layer are consistent, which can effectively protect the honeycomb core and improve its sealing effect, so that the honeycomb panel has flame retardant, anti-aging and waterproof functions, and at the same time, significantly improves the compressive and bending strength of the honeycomb panel. (2) By using a specific matrix resin as the material of the continuous fiber reinforced thermoplastic composite sheet in the top layer, bottom layer and side layer, the mechanical properties and bonding strength can be effectively improved. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the thermoplastic honeycomb panel of the present invention.

[0034] Figure 2 This is another structural schematic diagram of the thermoplastic honeycomb panel of the present invention.

[0035] Figure 3 This is a schematic diagram showing the cutting of the side surface of the semi-finished honeycomb panel of the present invention. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0037] In this application, numerical ranges are referred to as continuous unless otherwise specified, and include the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Furthermore, when the range refers to integers, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be merged. In other words, unless otherwise specified, all ranges disclosed herein should be understood to include any and all subranges to which they are incorporated.

[0038] Unless otherwise specified, all components and raw materials used in the embodiments and comparative examples of this invention are commercially available, and the same type of components and raw materials are used in each parallel experiment.

[0039] Please see Figure 1 , Figure 2 The present invention provides a thermoplastic honeycomb panel, comprising a honeycomb core 1 and a surface layer that completely covers the outer surface of the honeycomb core 1, wherein the surface layer comprises an upper layer 2, a lower layer 3, and a side layer 4;

[0040] The top layer, bottom layer, and side layer each independently comprise a continuous fiber-reinforced thermoplastic composite sheet and a modified resin film;

[0041] The continuous fiber reinforced thermoplastic composite sheet comprises continuous fibers and a matrix resin;

[0042] The matrix resin comprises the following components in parts by weight: 76-91 parts polypropylene resin, 4.5-10.5 parts toughening agent, 4.5-10.5 parts compatibilizer, 0.28-0.82 parts antioxidant, and 0.18-0.82 parts lubricant;

[0043] The honeycomb core includes multiple honeycomb cells arranged in an array, and each honeycomb cell includes a resin layer and an adhesive layer arranged sequentially from the inside to the outside.

[0044] This invention provides an effective edge wrapping for the honeycomb core by setting a surface layer on the outer surface of the honeycomb core. The edge wrapping is aesthetically pleasing, has good sealing performance, and is not prone to edge chipping. At the same time, the materials of the top layer, bottom layer, and side layer are consistent, which can effectively protect the honeycomb core and improve its sealing effect. This gives the honeycomb panel flame-retardant, anti-aging, and waterproof properties, while significantly improving the compressive and bending strength of the honeycomb panel.

[0045] By using the aforementioned specific matrix resin as the material for continuous fiber-reinforced thermoplastic composite sheets in the top, bottom, and side layers, mechanical properties and bond strength can be effectively improved.

[0046] In one embodiment, the weight ratio of the continuous fiber to the matrix resin is (4-7):(3-6).

[0047] In one embodiment, the upper layer extends downward to form a first bend 101, and the lower layer extends upward to form a second bend 102, the first bend and the second bend constituting the side layer.

[0048] In one embodiment, the upper layer is arranged parallel to the lower layer, and the upper layer is arranged perpendicular to the side layer.

[0049] In one embodiment, the matrix resin comprises the following components in parts by weight: 80-90 parts polypropylene resin, 5-10 parts toughening agent, 5-10 parts compatibilizer, 0.3-0.8 parts antioxidant, and 0.2-0.8 parts lubricant.

[0050] In one embodiment, the matrix resin comprises the following components in parts by weight: 85-89.5 parts polypropylene resin, 5-8 parts toughening agent, 5-6 parts compatibilizer, 0.3-0.5 parts antioxidant, and 0.2-0.5 parts lubricant.

[0051] In one embodiment, the weight ratio of the continuous fiber to the matrix resin is (4-7):(3-6), for example, it can be 4:6, 5:5, 6:7, 7:3 or any two of these weight ratios.

[0052] In one embodiment, at least one of (a) to (c) is satisfied:

[0053] (a) The polypropylene resin in the matrix resin is a copolymer polypropylene, and the melt index of the copolymer polypropylene at 230℃ / 2.16kg is 60 to 120 g / 10min, for example, it can be 60 g / 10min, 70 g / 10min, 80 g / 10min, 90 g / 10min, 100 g / 10min, 110 g / 10min, 120 g / 10min or any two of these values.

[0054] (b) The toughening agent is at least one of GMA-grafted polyolefin resin thermoplastic elastomer and MAH-grafted polyolefin resin thermoplastic elastomer, and the melt index of the toughening agent at 190°C / 2.16kg is 1.5 to 15 g / 10min, for example, it can be 1.5 g / 10min, 2 g / 10min, 4 g / 10min, 5 g / 10min, 6 g / 10min, 8 g / 10min, 10 g / 10min, 12 g / 10min, 15 g / 10min or any two of these values.

[0055] (c) The compatibilizer in the matrix resin is MAH-grafted polypropylene, wherein the grafting rate of MAH in the MAH-grafted polypropylene is 0.9-1.2%, and the melt index of the compatibilizer at 190℃ / 2.16kg is 80-120g / 10min, for example, it can be 80g / 10min, 90g / 10min, 100g / 10min, 110g / 10min, 120g / 10min or any two of these values.

[0056] In one embodiment, the antioxidant is at least one of hindered phenolic antioxidants, thioether antioxidants, polyaromatic amine antioxidants, hindered amine antioxidants, and phosphite antioxidants.

[0057] In one embodiment, the lubricant is at least one of pentaerythritol stearate, ethylene bis-stearamide, lignite wax, stearic acid, and hyperbranched polyester.

[0058] The inventors of this invention have discovered that by using the aforementioned specific copolymer polypropylene, toughening agent, and compatibilizer as the matrix resin material, the bonding strength and compressive strength of the honeycomb panel are effectively improved.

[0059] In one embodiment, the continuous fiber is at least one of E-glass fiber unidirectional yarn and E-glass fiber fabric; in the continuous fiber, the weight percentage of volatile matter is not greater than 0.1%, the weight percentage of film-forming agent is 0.15-0.45%, the weight percentage of compatibilizer is 0.05-0.15%, the weight percentage of coupling agent is 0.04-0.15%, and the weight percentage of additives is 0.01-0.05%.

[0060] In one embodiment, the film-forming agent includes at least one of amino-modified epoxy resin and cross-linked polyurethane, the compatibilizer includes a silane coupling agent, and the additive includes at least one of polypropylene wax and polyethylene wax.

[0061] In one embodiment, the weight ratio of the resin layer to the adhesive layer is (5 to 10):1, for example, it can be 5:1, 6:1, 7:1, 8:1, 9:1, 10:1 or any two of these weight ratios.

[0062] In one embodiment, the resin layer is a polyolefin resin, and the crystallinity of the polyolefin resin is 50-85%, for example, it can be 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85% or any two of these values.

[0063] In one embodiment, the crystallinity of the polyolefin resin is 60-80%.

[0064] In one embodiment, the crystallinity of the polyolefin resin is 60-70%.

[0065] In one embodiment, the polyolefin resin is at least one of polypropylene and modified polypropylene.

[0066] In one embodiment, the modified polypropylene comprises the following components in parts by weight: 99.6 to 99.8 parts polypropylene resin and 0.2 to 0.4 parts nucleating agent.

[0067] This invention improves the overall rigidity of the honeycomb panel by using highly crystalline polypropylene, thus significantly enhancing the heat-resistant compressive strength of the honeycomb panel.

[0068] In one embodiment, the adhesive layer is a polyolefin resin thermoplastic elastomer.

[0069] In one embodiment, the modified resin film comprises the following components in parts by weight: 78-90 parts polypropylene resin, 5-10 parts compatibilizer, 5-10 parts polyolefin resin thermoplastic elastomer, and 0.1-0.6 parts UV stabilizer.

[0070] It should be noted that the polyolefin resin thermoplastic elastomer (POE) mentioned in this article is a thermoplastic elastomer that enables in-situ polymerization of ethylene and α-olefins, wherein the α-olefins include at least one of the α-olefins with 4 to 8 carbon atoms.

[0071] In one embodiment, the α-olefin includes at least one selected from 1-butene, 1-hexene, and 1-octene.

[0072] Furthermore, the polyolefin elastomer is a thermoplastic elastomer polymerized in situ from ethylene and 1-octene.

[0073] The compatibilizer in the modified resin film is MAH-grafted polypropylene, the grafting rate of MAH in the MAH-grafted polypropylene is 0.9-1.2%, and the melt index of the compatibilizer at 190℃ / 2.16kg is 80-120g / 10min.

[0074] The polypropylene resin in the modified resin film has a melt index of 9 to 160 g / 10 min at 230°C / 2.16 kg.

[0075] In one embodiment, the UV stabilizer is at least one of hydroxybenzophenones, hydroxybenzotriazoles, hydroxybenzotriazines, cyanoacrylates, and nanoscale inorganic materials (e.g., titanium dioxide, cerium oxide, and zinc oxide).

[0076] In one embodiment, the thickness of the continuous fiber reinforced thermoplastic composite sheet is 0.3 to 1.2 mm, for example, it can be 0.3 mm, 0.4 mm, 0.6 mm, 0.8 mm, 1 mm, 1.2 mm or any two of these values.

[0077] In one embodiment, the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is (30-120):(2-15).

[0078] In one embodiment, the thickness of the modified resin film is 20 to 150 μm, for example, it can be 20 μm, 40 μm, 60 μm, 80 μm, 100 μm, 120 μm, 150 μm or any two of these values.

[0079] In one embodiment, the thickness of the thermoplastic honeycomb panel is 5 to 30 mm, for example, it can be 5 mm, 6 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm or any two of these values.

[0080] In one embodiment, the present invention also provides a method for preparing a thermoplastic honeycomb panel, comprising the following steps:

[0081] A honeycomb panel is obtained by laminating a top layer comprising a continuous fiber reinforced thermoplastic composite sheet 21 and a modified resin film 22 and a bottom layer comprising a continuous fiber reinforced thermoplastic composite sheet 31 and a modified resin film 32 at 120–250°C.

[0082] The honeycomb panel is processed using Teflon tape, resulting in a static friction coefficient ≥0.8 and a dynamic friction coefficient ≥0.17 on the surface of the honeycomb panel.

[0083] Cut the honeycomb panel into semi-finished honeycomb panels, such as Figure 3 As shown, the sides of the semi-finished honeycomb panel are cut, the top layer is pressed down and the bottom layer is pressed up in sequence, the edge sealing area is baked, and after the edge sealing area softens, the top and bottom edge sealing areas are folded towards the middle in sequence to form the side layer. After cooling and compaction, a thermoplastic honeycomb panel is obtained.

[0084] The cutting width range is from the final product width + 1 / 2 product thickness to the final product width + product thickness; the cutting length range is from the final product length + 1 / 2 product thickness to the final product length + product thickness.

[0085] The honeycomb core is cut from the side, with a cutting depth of 1 / 2 to 1 / 2 of the product thickness. A pre-reserved thickness of 1 / 10 to 1 / 2 of the honeycomb core thickness is left on both the upper and lower surfaces. The milling cutter thickness can be changed according to the honeycomb core thickness to obtain grooves of different depths and cutting thicknesses.

[0086] In one embodiment, the present invention also provides an application of the aforementioned thermoplastic honeycomb panel in the fields of rail transit, logistics transportation, building materials and construction, and electronics.

[0087] The following embodiments are provided to facilitate understanding of the invention. These embodiments are not intended to limit the scope of the claims.

[0088] The raw materials used in the examples and comparative examples are described below:

[0089] Copolymer PP-1: Copolymer polypropylene, with a melt index of 80 g / 10 min at 230℃ / 2.16 kg, manufacturer: Yanshan Petrochemical, grade: K7780.

[0090] Copolymer PP-2: Copolymer polypropylene, with a melt index of 60 g / 10 min at 230℃ / 2.16 kg. Manufacturer: Yanshan Petrochemical, Grade: K7760H.

[0091] Copolymer PP-3: Copolymer polypropylene, with a melt index of 120g / 10min at 230℃ / 2.16kg. Manufacturer: SK Korea. Grade: BX3920 / BX3950 mixed in a 7:3 ratio.

[0092] Toughening agent-1: GMA grafted with POE, melt index of 1.5g / 10min at 190℃ / 2.16kg, manufacturer: Guangdong Chuanheng, grade: CH-904.

[0093] Toughening agent-2: GMA grafted with POE, melt index of 15g / 10min at 190℃ / 2.16kg, manufacturer: Mingyuan, grade: W5E.

[0094] Toughening agent-3: GMA grafted with POE, melt index of 5g / 10min at 190℃ / 2.16kg, manufacturer: Jia Yirong, grade: SOG-02.

[0095] Toughening agent-4: MAH grafted POE, melt index of 3.3 g / 10 min at 190℃ / 2.16 kg, manufacturer: Dow Chemical, grade: GR208.

[0096] Compatibilizer-1: MAH grafted polypropylene, with a MAH grafting rate of 1.0%, the melt index of the compatibilizer at 190℃ / 2.16kg is 100g / 10min, manufacturer: Ployram, brand: Bondyram1001.

[0097] Antioxidant: Manufacturer: Sanfeng Chemical, Brand: Sonox225G.

[0098] Lubricant: Manufacturer: Wuhan Chaozhi Chemical Co., Ltd., Brand: HBP-158.

[0099] Continuous fiber: Manufacturer: China Jushi Co., Ltd., Grade: EDR16-1200-362A(U).

[0100] PP-1: Modified homopolymer polypropylene (obtained by extrusion granulation of homopolymer polypropylene resin with 2% sodium benzoate nucleating agent): crystallinity 60%, homopolymer polypropylene resin manufacturer: Priman Japan, grade PP / J-700GP.

[0101] PP-2: Homopolymer polypropylene resin: 70% crystallinity, manufacturer: Hanwha, grade HJ730.

[0102] PP-3: Homopolymer polypropylene resin: Crystallinity 50%, Manufacturer: Primavista Japan, Grade PP / J-700GP.

[0103] PP-4: Modified homopolymer polypropylene (obtained by extrusion granulation of homopolymer polypropylene resin with 1% dimethylbenzyl sorbitol): crystallinity 85%, homopolymer polypropylene resin manufacturer: Hanwha, grade HJ730.

[0104] PP-5: Copolymer polypropylene resin: Melt index of 9 g / 10 min at 230℃ / 2.16 kg, Manufacturer: Sinopec Qilu Petrochemical Company, Grade: SP179.

[0105] PP-6: Copolymer polypropylene resin: Melt index of 160g / 10min at 230℃ / 2.16kg, Manufacturer: SK Korea, Grade: BX3950.

[0106] Nucleating agent: Manufacturer: Milliken, Brand: MILLAD3988.

[0107] POE: Manufacturer: Nantong Ruicheng, Grade: RC9030.

[0108] UV stabilizer: Manufacturer: Baoxu Chemical, Brand: UV-3808PP5.

[0109] Examples 1-8, Comparative Examples 1-4

[0110] The thermoplastic honeycomb panels of Examples 1-8 and Comparative Examples 1-4 include a honeycomb core and a surface layer that completely covers the outer surface of the honeycomb core. The surface layer includes a top layer, a bottom layer, and a side layer.

[0111] The top layer, bottom layer, and side layer each independently comprise a continuous fiber-reinforced thermoplastic composite sheet and a modified resin film.

[0112] The upper layer extends downward to form a first bend, and the lower layer extends upward to form a second bend, the first bend and the second bend constituting the side layer.

[0113] The upper layer is arranged parallel to the lower layer, and the upper layer is arranged perpendicular to the side layer.

[0114] The continuous fiber reinforced thermoplastic composite sheet comprises continuous fibers and matrix resin (the composition of the matrix resin is shown in Table 1); the weight ratio of the continuous fibers to the matrix resin is 6:4.

[0115] The honeycomb core includes multiple honeycomb cells arranged in an array. Each honeycomb cell includes a resin layer and an adhesive layer arranged sequentially from the inside to the outside, and the weight ratio of the resin layer to the adhesive layer is 8:1.

[0116] The resin layer comprises the following components in parts by weight: 99.7 parts PP-1 and 0.3 parts nucleating agent.

[0117] The adhesive layer is POE.

[0118] The modified resin film comprises the following components in parts by weight: 85.5 parts PP-5, 8 parts compatibilizer-1, 6 parts POE, and 0.5 parts UV stabilizer.

[0119] The thickness of the continuous fiber reinforced thermoplastic composite sheet is 0.3 mm; the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is 100:10; and the thickness of the thermoplastic honeycomb panel is 10 mm.

[0120] The method for preparing the thermoplastic honeycomb panel includes the following steps:

[0121] The top layer, honeycomb core, and bottom layer are laid out in sequence and composited at 220℃ to obtain a honeycomb panel;

[0122] The honeycomb panel is processed using Teflon tape, resulting in a static friction coefficient of 0.88 and a dynamic friction coefficient of 0.17 on the surface of the honeycomb panel.

[0123] Cut the honeycomb panel into semi-finished honeycomb panel squares, such as Figure 3 As shown, the sides of the semi-finished honeycomb panel are then cut, with the milling cutter penetrating to a depth of 1 / 2 the thickness of the honeycomb panel to the product thickness. The top layer is then folded downwards and the bottom layer upwards in sequence. The edge sealing area is baked and softened. After the edge sealing area softens, the top and bottom edge sealing areas are folded towards the center in sequence to form the side layers. After cooling and compaction, the desired result is obtained as shown. Figure 1 The thermoplastic honeycomb panel shown.

[0124] Table 1

[0125]

[0126] Examples 9-11

[0127] The difference between Examples 9-11 and Example 1 is that the polypropylene in the resin layer is different, but everything else is the same.

[0128] The polypropylene in the resin layer of Example 9 is PP-2.

[0129] The polypropylene in the resin layer of Example 10 is PP-3.

[0130] The polypropylene in the resin layer of Example 11 is PP-4.

[0131] Examples 12-15

[0132] The difference between Examples 12-15 and Example 1 is that the thicknesses of the continuous fiber reinforced thermoplastic composite sheet and the modified resin film are different, while everything else is the same.

[0133] The thickness of the continuous fiber reinforced thermoplastic composite sheet described in Example 12 is 0.9 mm, and the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is 30:2.

[0134] The thickness of the continuous fiber reinforced thermoplastic composite sheet described in Example 13 is 1.2 mm, and the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is 120:15.

[0135] The thickness of the continuous fiber reinforced thermoplastic composite sheet described in Example 14 is 1.5 mm, and the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is 120:80.

[0136] The thickness of the continuous fiber reinforced thermoplastic composite sheet described in Example 15 is 0.6 mm, and the thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is 30:1.

[0137] Examples 16-18

[0138] The difference between Examples 16-18 and Example 1 is that the thickness of the thermoplastic honeycomb panel is different, but everything else is the same.

[0139] The thickness of the thermoplastic honeycomb panel in Example 16 is 5 mm.

[0140] The thickness of the thermoplastic honeycomb panel in Example 17 is 15 mm.

[0141] The thickness of the thermoplastic honeycomb panel in Example 18 is 20 mm.

[0142] Example 19

[0143] The difference between Example 19 and Example 1 is that the polypropylene used in the modified resin film is different.

[0144] The modified resin film of Example 19 is made of polypropylene PP-6.

[0145] Comparative Example 5

[0146] The difference between Comparative Example 5 and Example 1 is that Comparative Example 5 does not contain a side layer (i.e., Comparative Example 5 is not edge-wrapped), but otherwise they are the same.

[0147] Comparative Example 6

[0148] The difference between Comparative Example 6 and Example 1 is that the side layer of Comparative Example 6 is an adhesive strip (i.e., Comparative Example 6 uses an adhesive strip for edging), but everything else is the same.

[0149] Test case

[0150] Compression test: Refer to "GB / T 1453-2005 Test method for flat compression performance of sandwich structure or core", the speed is 0.5mm / min.

[0151] Bending test: The test was conducted according to GB / T 1456-2005 Test Method for Bending Performance of Sandwich Structures, at a speed of 5 mm / min.

[0152] Peel strength: Tested according to GB / T 1457-2005 "Test method for peel strength of sandwich structure roller".

[0153] Table 2

[0154]

[0155]

[0156] As can be seen from Table 2, the thermoplastic honeycomb panel of the present invention has excellent flexural strength, compressive strength and peel strength.

[0157] The thermoplastic honeycomb panel prepared by this invention has a compressive strength ≥1.45MPa at 23℃, a compressive strength ≥0.32MPa at 90℃, a peel strength ≥132 (N·mm) / mm, an edge compressive strength ≥1.76MPa, an edge bending strength ≥14.6MPa, and no abnormal bending deflection of 5mm.

[0158] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A thermoplastic honeycomb panel, characterized in that, It includes a honeycomb core and a surface layer that completely covers the outer surface of the honeycomb core, the surface layer including a top layer, a bottom layer, and a side layer; The top layer, bottom layer, and side layer each independently comprise a continuous fiber-reinforced thermoplastic composite sheet and a modified resin film; The continuous fiber reinforced thermoplastic composite sheet comprises continuous fibers and a matrix resin; The matrix resin comprises the following components in parts by weight: 76-89.5 parts polypropylene resin, 5-10.5 parts toughening agent, 4.5-10.5 parts compatibilizer, 0.28-0.82 parts antioxidant, and 0.18-0.82 parts lubricant; The honeycomb core includes multiple honeycomb units arranged in an array, and each honeycomb unit includes a resin layer and an adhesive layer arranged sequentially from the inside to the outside; The thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is (30~120):(2~15); The modified resin film comprises the following components in parts by weight: 75-90 parts polypropylene resin, 5-10 parts compatibilizer, 5-10 parts polyolefin resin thermoplastic elastomer, and 0.1-0.6 parts UV stabilizer. The polypropylene resin in the matrix resin is copolymer polypropylene, and the melt index of the copolymer polypropylene at 230℃ / 2.16kg is 80~120g / 10min. The resin layer is a polyolefin resin, and the crystallinity of the polyolefin resin is 60-85%.

2. The thermoplastic honeycomb panel according to claim 1, characterized in that, The weight ratio of the continuous fiber to the matrix resin is (4~7):(3~6).

3. The thermoplastic honeycomb panel according to claim 1, characterized in that, The upper layer extends downward to form a first bend, and the lower layer extends upward to form a second bend, the first bend and the second bend constituting the side layer.

4. The thermoplastic honeycomb panel according to claim 1, characterized in that, The upper layer is arranged parallel to the lower layer, and the upper layer is arranged perpendicular to the side layer.

5. The thermoplastic honeycomb panel according to claim 1, characterized in that, Satisfy at least one of the following (a) to (b): (a) The toughening agent is at least one of GMA grafted polyolefin resin thermoplastic elastomer and MAH grafted polyolefin resin thermoplastic elastomer, and the melt index of the toughening agent at 190℃ / 2.16kg is 1.5~15g / 10min. (b) The compatibilizer in the matrix resin is MAH-grafted polypropylene, wherein the grafting rate of MAH in the MAH-grafted polypropylene is 0.9~1.2%, and the melt index of the compatibilizer at 190℃ / 2.16kg is 80~120 g / 10min.

6. The thermoplastic honeycomb panel according to claim 1, characterized in that, The weight ratio of the resin layer to the adhesive layer is (5~10):

1.

7. The thermoplastic honeycomb panel according to claim 1, characterized in that, The thickness of the continuous fiber reinforced thermoplastic composite sheet is 0.3~1.2 mm; The thickness ratio of the continuous fiber reinforced thermoplastic composite sheet to the modified resin film is (30~100):(2~10).

8. The thermoplastic honeycomb panel according to claim 1, characterized in that, The thickness of the thermoplastic honeycomb panel is 5~30mm.

9. A method for preparing the thermoplastic honeycomb panel according to any one of claims 1 to 8, characterized in that, Includes the following steps: The top layer, honeycomb core and bottom layer are laid in sequence and composited at 120~250℃ to obtain a honeycomb panel; The honeycomb panel is processed using Teflon tape, resulting in a static friction coefficient ≥0.8 and a dynamic friction coefficient ≥0.17 on the surface of the honeycomb panel. The honeycomb panel is cut into semi-finished honeycomb panels. The sides of the semi-finished honeycomb panels are cut. The top layer is pressed down and the bottom layer is pressed up in sequence. The edge sealing area is baked. After the edge sealing area softens, the top and bottom edge sealing areas are folded towards the middle in sequence to form the side layer. After cooling and compaction, a thermoplastic honeycomb panel is obtained.

10. The application of the thermoplastic honeycomb panel according to any one of claims 1 to 8 in the fields of rail transit, logistics transportation, building materials and construction, and electronics.

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