Porous cellular board and three-dimensional weaving process and application thereof

Abstract

The invention discloses a porous cellular board and a three-dimensional weaving process and application thereof. The weaving process comprises the following steps: (1) firstly, mixing a thermoplastic material with weaving yarns to form prefabricated yarns; (2) arranging the prefabricated yarns on a three-dimensional weaving base according to m rows and n columns, and performing three-dimensional weaving according to a four-step method to form a honeycomb structure; and (3) heating and curing the honeycomb structure to form the honeycomb plate. According to the method, the thermoplastic material and the weaving yarn are mixed to form the prefabricated yarn, so that after the honeycomb structure is formed by weaving the prefabricated yarn, the honeycomb structure is heated, the thermoplastic material on the weaving yarn can be molten, and then the role transformation of the thermoplastic material is realized through curing, so that the thermoplastic material becomes a base body; the base body enables the weaving yarns to be mutually bonded to form the complete cellular board, and the cellular board is of a porous structure, light in weight, high in strength and rigidity, capable of being cut into different lengths and widths according to needs, few in broken ends, small in mechanical property loss and capable of being widely applied to the fields of aviation, spaceflight and the like.

Description

Technical Field

[0001] The invention belongs to the field of weaving technology, and specifically relates to a porous honeycomb panel and a three-dimensional weaving technology and application thereof. Background Art

[0002] Textile composites are advanced composite materials that are reinforced with textile fibers and their structures. Three-dimensional woven composites are an important branch of textile structural composites. They use three-dimensional weaving technology to weave the reinforcing fibers into a three-dimensional integral fabric, and then compound it with a matrix (including resin, carbon, silicon carbide, metal, etc.) to make a three-dimensional woven composite product.

[0003] The biggest feature of three-dimensional braided fabrics is that there is no concept of layers. Three-dimensional braided fabrics are formed in one piece, so three-dimensional braided composite materials are a completely integral structure. They have high specific strength and specific modulus and excellent mechanical properties. Therefore, it is possible to use three-dimensional braided composite materials to make main load-bearing structural parts and reinforcements of load-bearing structural parts.

[0004] At present, aerospace, aviation, medical and other fields are in urgent need of various high-performance and functional three-dimensional woven composite special-shaped parts, so further research on three-dimensional weaving technology and three-dimensional woven composite materials for special-shaped parts is of great significance to the development of the new materials field.

[0005] In view of this, the present invention is proposed. Summary of the invention

[0006] The purpose of the invention is to overcome the problems of poor mechanical properties and low strength of existing three-dimensional woven composite materials, and to provide a porous honeycomb panel and its three-dimensional weaving process and application, so that the three-dimensional woven porous honeycomb panel has excellent mechanical properties, simple process, low cost, and is suitable for industrial mass production.

[0007] In order to solve the above technical problems, the basic concept of the technical solution adopted by the present invention is:

[0008] A three-dimensional woven porous honeycomb panel process,

[0009] (1) firstly, a thermoplastic material is mixed with a braided yarn to form a prefabricated yarn;

[0010] (2) arranging the prefabricated yarns in m rows and n columns on a three-dimensional weaving base, and three-dimensionally weaving to form a honeycomb structure according to a four-step method;

[0011] (3) heating and curing the honeycomb structure to form a honeycomb panel.

[0012] Further, the step (1) comprises: making a thermoplastic material into a slurry, and impregnating the slurry into the interior of the braided yarn to form a prefabricated yarn;

[0013] And / or, the thermoplastic material is spun into thermoplastic fibers, and the thermoplastic fibers are mixed with the braiding yarns by one or more methods of blending, winding, and co-weaving to form the prefabricated yarn.

[0014] Furthermore, in the step (3), the heating temperature is higher than the melting temperature of the thermoplastic material.

[0015] Furthermore, in the step (3), the heating is followed by cooling to solidify the honeycomb panel.

[0016] Furthermore, the thermoplastic material includes polyamide.

[0017] Furthermore, in step (2), the honeycomb structure includes a connecting segment and a branch segment, a single side of each honeycomb forms the branch segment, single sides of two adjacent honeycombs are combined to form a connecting segment, and the connecting segment and the branch segment are woven in a controlled loop to form the honeycomb panel.

[0018] Furthermore, in the step (2), the connecting segment includes a first connecting segment and a second connecting segment, a branch segment is between the first connecting segment and the second connecting segment, and the honeycomb panel is formed by loop weaving in the order of first connecting segment-branch segment-second connecting segment-branch segment.

[0019] Furthermore, in step (2), among the n columns of prefabricated yarns, every k columns are used as the prefabricated yarns of the connecting segments, and the prefabricated yarns of the connecting segments include first and second prefabricated yarns of the connecting segments, and the first and second prefabricated yarns of the connecting segments are arranged at intervals;

[0020] Weaving the first connecting section includes: controlling the prefabricated yarn of the first connecting section to move only left and right during weaving, and not to move up and down;

[0021] The braiding branch section includes: controlling the prefabricated yarns of the first and second junction sections to move only left and right, and not up and down;

[0022] The method of weaving the second connecting section comprises: controlling the prefabricated yarn of the second connecting section to move only left and right but not up and down during weaving.

[0023] The present invention provides a three-dimensional woven porous honeycomb panel woven by using any of the weaving processes described in the above technical solutions.

[0024] The present invention also provides applications of the three-dimensional woven porous honeycomb panel in the fields of aviation, aerospace, energy, transportation, and sports.

[0025] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0026] In the present invention, the thermoplastic material is first mixed with the braided yarn to form a prefabricated yarn. When the prefabricated yarn is used to weave a honeycomb structure, the honeycomb structure is heated, and the thermoplastic material on the braided yarn is melted. Then, the thermoplastic material is solidified to achieve the role change of the thermoplastic material, so that the thermoplastic material becomes a matrix. The matrix bonds the braided yarns to each other to form a complete honeycomb panel. The honeycomb panel has a porous structure, is light in weight, high in strength, and high in rigidity. It can be cut into different lengths and widths according to needs, has less breakage, and has a small loss in mechanical properties. It can be widely used in aviation, aerospace, energy, transportation, sports and other fields to achieve the purpose of increasing strength and reducing weight.

[0027] The weaving process of the present application can realize continuous weaving on a common four-step three-dimensional weaving machine, and is suitable for industrial mass production. The porous honeycomb board made by the weaving process has high strength, and the thermoplastic material as the reinforcing material of the board can improve the mechanical properties of the board, especially the shearing performance.

[0028] The specific implementation modes of the present invention are further described in detail below in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings are part of the present invention and are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention, but do not constitute an improper limitation of the present invention. Obviously, the drawings described below are only some embodiments. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. In the accompanying drawings:

[0030] Figure 1 It is a schematic diagram of the structure of the honeycomb panel of the present invention;

[0031] Figure 2 It is a schematic diagram of the yarn arrangement of the prefabricated yarn of the present invention.

[0032] in:

[0033] 1. Honeycomb panel; 11. First connecting section; 12. Branch section; 13. Second connecting section; 14. Prefabricated yarn of the first connecting section; 15. Prefabricated yarn of the second connecting section.

[0034] It should be noted that these drawings and textual descriptions are not intended to limit the conceptual scope of the present invention in any way, but are intended to illustrate the concept of the present invention for those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0036] In the description of the present invention, it should be noted that the terms "inside", "outside", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0037] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "contacted", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0038] Embodiment 1

[0039] The three-dimensional woven porous honeycomb panel process includes:

[0040] (1) firstly mixing a thermoplastic material with a braided yarn to form a prefabricated yarn; wherein the thermoplastic material comprises polyamide;

[0041] (2) arranging the prefabricated yarns in m rows and n columns on a three-dimensional weaving base, and three-dimensionally weaving to form a honeycomb structure according to a four-step method;

[0042] (3) heating and curing the honeycomb structure to form a honeycomb plate; wherein the heating temperature is higher than the melting point of the thermoplastic material; and the curing method is cooling curing.

[0043] In the present invention, the thermoplastic material is first mixed with the braided yarn to form a prefabricated yarn. When the prefabricated yarn is used to weave a honeycomb structure, the honeycomb structure is heated, and the thermoplastic material on the braided yarn is melted. Then, the thermoplastic material is solidified to achieve the role change of the thermoplastic material, so that the thermoplastic material becomes a matrix. The matrix bonds the braided yarns to each other to form a complete honeycomb panel. The honeycomb panel has a porous structure, is light in weight, high in strength, and high in rigidity. It can be cut into different lengths and widths according to needs, has less breakage, and has a small loss in mechanical properties. It can be widely used in aviation, aerospace, energy, transportation, sports and other fields to achieve the purpose of increasing strength and reducing weight.

[0044] Embodiment 2

[0045] This embodiment is a further supplementary explanation of step (1) in embodiment 1.

[0046] Method 1: The thermoplastic material is made into a slurry, and the slurry is impregnated into the inside of the braided yarn to form the prefabricated yarn. Specifically, polyamide is made into a slurry, and the polyamide slurry is impregnated into the inside of the braided yarn to form the prefabricated yarn. In this method, the method for preparing the prefabricated yarn is simple and suitable for mass production of prefabricated yarn.

[0047] Method 2: Spin thermoplastic materials into thermoplastic fibers, and mix the thermoplastic fibers with braided yarns by one or more methods of blending, winding, and co-weaving to form prefabricated yarns. For example: Make polyamide into fibers, and blend the polyamide fibers with braided yarns to form prefabricated yarns. In this method, the polyamide fibers can be evenly interwoven with the braided yarns, and after interweaving, they participate in the subsequent three-dimensional braiding process, so that the subsequent polyamide can be evenly dispersed on the braided yarns, thereby making the texture of the formed honeycomb panel uniform.

[0048] In this embodiment, method 1 and method 2 can be used selectively, or method 1 and method 2 can be used in combination according to strength requirements, so that polyamide can be used as a reinforcing material in the plate to greatly improve the mechanical properties of the plate, especially the shear strength of the plate.

[0049] Embodiment 3

[0050] like Figure 1 and Figure 2 As shown, this embodiment is a further supplementary explanation of step (2) in embodiment 1.

[0051] The honeycomb structure of the honeycomb panel 1 includes a connecting section and a branch section 12. A single side of each honeycomb forms the branch section 12. Single sides of two adjacent honeycombs are combined to form a connecting section. The connecting section and the branch section 12 are woven in a controlled loop to form the honeycomb panel.

[0052] Specifically, the connecting section includes a first connecting section 11 and a second connecting section 13, and a branch section 12 is between the first connecting section 11 and the second connecting section 13. The hexagonal honeycomb panel 1 is formed by circular weaving in the order of first connecting section 11-branch section 12-second connecting section 13-branch section 12.

[0053] More specifically, the following steps are included:

[0054] (1) The honeycomb structure of the honeycomb panel 1 includes a connecting section and a branch section 12. The connecting section is a collection of two branch sections 12, and its function is to combine the hexagons to form an integral honeycomb structure panel;

[0055] (2) Determine the total number of yarns: total number of yarns = number of braided structure rows × number of braided structure columns;

[0056] (3) Determine the weaving structure and initial state of the junction part, and determine whether the weaving yarns on both sides of this row of weaving yarns are jointly woven into a junction section or separately woven into a branch section 12 by moving the entire row of weaving yarns.

[0057] (4) The three-dimensional woven honeycomb panel fabric is realized by weaving in a loop in the order of the connecting section, the branch section 12, the connecting section, and the branch section 12.

[0058] For example: Figure 1 and Figure 2 For example, for the Figure 1 The specific weaving process of the honeycomb panel 1 shown is specifically described:

[0059] 1) The honeycomb structure of the honeycomb panel 1 includes a first connecting segment 11, a second connecting segment 13, and a branch segment 12, which are woven in a loop in the order of the first connecting segment 11-branch segment 12-second connecting segment 13-branch segment 12;

[0060] 2) The prefabricated yarns are arranged on a three-dimensional braiding base in 7 rows and 35 columns; wherein every 4 columns are used as a column of binding segment prefabricated yarns, and the first binding segment prefabricated yarns 14 and the second binding segment prefabricated yarns 15 of the prefabricated yarns are arranged alternately;

[0061] 3) First weave the first binding section 11: Determine the initial state as follows Figure 2 As shown, the first binding section prefabricated yarn 14 is controlled to move only left and right during weaving, and does not move up and down; in this way, the 4 columns on the left and the 4 columns on the right of each column of the first binding section prefabricated yarn 14 are woven to form left and right branch sections 12; there is a column of second binding section prefabricated yarn 15 between two adjacent columns of first binding section prefabricated yarn 14, and during the weaving process, the left and right branch sections 12 formed by the prefabricated yarns woven between the two adjacent columns of the first binding section prefabricated yarn 14 are connected under the movement of the second binding section prefabricated yarn 15 to form the first binding section 11;

[0062] Weaving the branch segment 12: Control the first connecting segment prefabricated yarn 14 and the second connecting segment prefabricated yarn 15 to move only left and right, without moving up and down; thus, the 4 columns on the left and the 4 columns on the right of each column of the first connecting segment prefabricated yarn 14 and the second connecting segment prefabricated yarn 15 are woven to form the left and right branch segments 12 respectively;

[0063] Weaving the second connecting segment 13 includes: controlling the second connecting segment prefabricated yarn 15 to move only left and right during weaving, and not to move up and down; in this way, the 4 columns on the left and the 4 columns on the right of each column of the second connecting segment prefabricated yarn 15 are woven to form left and right branch segments 12; there is a column of first connecting segment prefabricated yarn 14 between two adjacent columns of second connecting segment prefabricated yarn 15, and during the weaving process, the left and right branch segments 12 formed by the prefabricated yarns between the two adjacent columns of the second connecting segment prefabricated yarn 15 are woven together under the movement of the first connecting segment prefabricated yarn 14 to form the second connecting segment 13.

[0064] The above steps are repeated to weave a hexagonal honeycomb panel 1. In this embodiment, the number of cycles of the four-step weaving method can be increased or decreased according to design requirements, so as to obtain hexagons with different side lengths.

[0065] This embodiment can realize continuous weaving on a four-step three-dimensional weaving machine, has a simple process, low cost, and is suitable for industrial mass production.

[0066] Embodiment 4:

[0067] like Figure 1 As shown, the present invention provides a three-dimensional woven porous honeycomb panel 1 woven by the weaving process described in any one of the above technical solutions. The honeycomb structure of the honeycomb panel 1 includes a connecting section and a branch section 12, a single side of each honeycomb forms the branch section 12, and the single sides of two adjacent honeycombs are combined to form a connecting section, and the connecting section and the branch section are woven in a controlled cycle to form the honeycomb panel.

[0068] Specifically, the connecting section includes a first connecting section 11 and a second connecting section 13, and a branch section 12 is provided between the first connecting section 11 and the second connecting section 13. The hexagonal honeycomb panel 1 is formed by loop weaving in the order of the first connecting section 11-branch section 12-second connecting section 13-branch section 12. The honeycomb panel 1 is light in weight, high in strength and high in rigidity. Due to the presence of the holes, the honeycomb panel 1 has excellent sound absorption performance and good heat preservation and thermal insulation performance.

[0069] Embodiment 5

[0070] The present invention also provides applications of the three-dimensional woven porous honeycomb panel 1 in the fields of aviation, aerospace, energy, transportation, and sports. The honeycomb panel 1 is integrally formed and can be cut into different lengths and widths as required. After cutting, the fiber breakage is small and the mechanical property loss is small. Moreover, the present invention can realize continuous weaving on a four-step three-dimensional weaving machine, which is suitable for industrial mass production.

[0071] The honeycomb panel 1 of the present invention has high strength. The thermoplastic material is used as a reinforcing material of the panel to improve the mechanical properties of the panel, especially the shearing properties. In particular, compared with the bonding process of the existing honeycomb, the hexagonal honeycomb joint of the present invention is an integral structure with high joint strength. The honeycomb panel 1 of the present invention can be widely used in the fields of national defense, medical treatment, energy, transportation, sports, etc. to achieve the purpose of increasing the strength of the panel and reducing the weight of the panel.

[0072] The above is only a preferred embodiment of the present invention, and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment, it is not used to limit the present invention. Any technician familiar with this patent can make some changes or modify the technical contents suggested above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the solution of the present invention.

Claims

1. A three-dimensional woven porous honeycomb panel process, characterized in that: (1) firstly, a thermoplastic material is mixed with a braided yarn to form a prefabricated yarn; (2) arranging the prefabricated yarns in m rows and n columns on a three-dimensional weaving base, and three-dimensionally weaving to form a honeycomb structure according to a four-step method; (3) heating and curing the honeycomb structure to form a honeycomb panel.

2. A three-dimensional woven porous honeycomb panel process according to claim 1, characterized in that: The step (1) comprises: preparing a thermoplastic material into a slurry, and impregnating the slurry into the interior of the braided yarn to form a prefabricated yarn; And / or, the thermoplastic material is spun into thermoplastic fibers, and the thermoplastic fibers are mixed with the braiding yarns by one or more methods of blending, winding, and co-weaving to form the prefabricated yarn.

3. A three-dimensional woven porous honeycomb panel process according to claim 1 or 2, characterized in that: In the step (3), the heating temperature is higher than the melting temperature of the thermoplastic material.

4. A three-dimensional woven porous honeycomb panel process according to claim 1 or 2, characterized in that: In the step (3), the heating is followed by cooling to solidify the honeycomb panel.

5. A three-dimensional woven porous honeycomb panel process according to claim 1 or 2, characterized in that: The thermoplastic material comprises polyamide.

6. A three-dimensional woven porous honeycomb panel process according to claim 1 or 2, characterized in that: In the step (2), the honeycomb structure includes a connecting segment and a branch segment, a single side of each honeycomb forms the branch segment, and the single sides of two adjacent honeycombs are combined to form a connecting segment, and the connecting segment and the branch segment are woven in a controlled loop to form the honeycomb panel.

7. A three-dimensional woven porous honeycomb panel process according to claim 6, characterized in that: In the step (2), the connecting segment includes a first connecting segment and a second connecting segment, a branch segment is between the first connecting segment and the second connecting segment, and the honeycomb panel is formed by loop weaving in the order of first connecting segment-branch segment-second connecting segment-branch segment.

8. A three-dimensional woven porous honeycomb panel process according to claim 7, characterized in that: In the step (2), among the n columns of prefabricated yarns, every k columns are used as the prefabricated yarns of the connecting segments, and the prefabricated yarns of the connecting segments include first and second prefabricated yarns of the connecting segments, and the first and second prefabricated yarns of the connecting segments are arranged at intervals; Weaving the first connecting section includes: controlling the prefabricated yarn of the first connecting section to move only left and right during weaving, and not to move up and down; The braiding branch section includes: controlling the prefabricated yarns of the first and second junction sections to move only left and right, and not up and down; The method of weaving the second connecting section comprises: controlling the prefabricated yarn of the second connecting section to move only left and right but not up and down during weaving.

9. A three-dimensional woven porous honeycomb panel woven by the weaving process described in any one of claims 1 to 8.

10. Application of the three-dimensional woven porous honeycomb panel according to claim 9 in the fields of aviation, aerospace, energy, transportation and sports.

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