Continuous fiber reinforced resin matrix composite honeycomb core material and manufacturing method thereof

Abstract

The invention discloses a continuous fiber reinforced resin matrix composite honeycomb core material and a manufacturing method thereof, and relates to the technical field of honeycomb core materials. Laying a honeycomb core raw material on the surface of the female die; a core rod is placed in the groove; repeating the steps until the required height is reached; closing the male die, and applying pressure on the male die; the mold is pushed into a curing oven to be heated and cured; opening the mold after the resin is cured, and drawing out the core rod to obtain a composite material honeycomb core block material; and cutting the block material into a sheet material with a certain thickness to obtain the composite material honeycomb core material. The preparation method is simple and feasible, the preparation process is simple and convenient, the energy consumption in the production process is low, and the manufacturing cost is low. The honeycomb sandwich material prepared by the method disclosed by the invention has higher compressive strength and flexural rigidity under the same volume weight; and under the same bearing capacity, the weight is lighter, and the cost is lower.

Description

Technical Field

[0001] The invention relates to the technical field of honeycomb core materials, and in particular to a continuous fiber reinforced resin-based composite honeycomb core material and a manufacturing method thereof. Background Art

[0002] Honeycomb core material, referred to as honeycomb core, mainly bears shear stress and compressive stress in the sandwich structure, so that the sandwich structure has higher bending stiffness and compressive strength while reducing weight. It is widely used in aviation, shipbuilding, construction, automobiles, trains and other fields.

[0003] At present, honeycomb core materials are mainly made of single materials such as metal (such as aluminum honeycomb) or non-metal (such as aramid, polypropylene, etc.). Aluminum honeycomb has good mechanical properties and simple manufacturing process, but poor fatigue resistance and impact resistance; aramid honeycomb has light bulk density, high specific strength and stiffness, excellent impact resistance, fatigue resistance, and corrosion resistance, but complex manufacturing process, low shear modulus, and high cost; polypropylene honeycomb has low bulk density, simple preparation process, and low cost, but poor mechanical properties and is easy to deform at high temperatures. The above reasons are mainly determined by the performance of the single material itself, which limits the further promotion and application of honeycomb structures.

[0004] Therefore, a continuous fiber reinforced resin-based composite honeycomb core material and a manufacturing method thereof have become issues that need to be urgently addressed. Summary of the invention

[0005] The technical problem to be solved by the present invention is to make full use of the characteristics of continuous fiber reinforced resin-based composite materials such as light weight, high strength and designable performance, and provide a honeycomb core material with excellent comprehensive performance and a low-cost manufacturing method thereof.

[0006] In order to solve the above technical problems, the present invention provides a technical solution: a continuous fiber reinforced resin-based composite honeycomb core material, comprising the following raw materials in the following mass proportions:

[0007] Continuous fiber 15%~85%, polymer resin 85%~15%;

[0008] The polymer resin is a thermosetting resin.

[0009] Furthermore, the continuous fibers are composited with one or more of glass fibers, carbon fibers, basalt fibers, aramid fibers, and ultra-high molecular weight polyethylene fibers.

[0010] Furthermore, the continuous fibers are in the form of unidirectional fabric, multi-axial fabric, woven fabric or felt.

[0011] Furthermore, the polymer resin is unsaturated polyester resin, epoxy resin, vinyl resin or phenolic resin.

[0012] Furthermore, the continuous fibers are used as reinforcements, and the polymer resin is used as a matrix to form a honeycomb core material.

[0013] Furthermore, the cross-section of a single through hole of the honeycomb core material is hexagonal, quadrilateral or circular.

[0014] Furthermore, the wall thickness of the honeycomb core material is between 0.1 mm and 5 mm.

[0015] The present invention also provides a method for preparing a continuous fiber reinforced resin-based composite honeycomb core material, comprising the following steps:

[0016] S1. Laying honeycomb core material on the surface of the female mold;

[0017] S2, placing a mandrel in the groove;

[0018] S3, repeat steps S1-S2 until the required height is reached;

[0019] S4, close the male mold and apply pressure on it;

[0020] S5, pushing the mold into a curing furnace for heating and curing;

[0021] S6, after the resin is solidified, the mold is opened, and the core rod is pulled out to obtain a composite honeycomb core block;

[0022] S7, cutting the block material into sheets with a certain thickness to obtain a composite honeycomb core material.

[0023] Furthermore, in step S1, a layer of resin matrix and continuous fiber cloth is hand-coated on the surface of the female mold.

[0024] Furthermore, in step S1, continuous fiber reinforced composite material prepreg is laid on the surface of the female mold.

[0025] Compared with the prior art, the advantages of the present invention are: the present invention is simple and easy to implement, the preparation process is simple and convenient, the production process has low energy consumption, and the manufacturing cost is low. The honeycomb sandwich material prepared by the method of the present invention has higher compressive strength and bending stiffness at the same bulk density; when having the same bearing capacity, it is lighter and has lower cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a front view of a continuous fiber reinforced resin-based composite honeycomb core material of the present invention.

[0027] Figure 2 It is a structural schematic diagram of a continuous fiber reinforced resin-based composite honeycomb core material of the present invention.

[0028] Figure 3The present invention is a front view of a continuous fiber reinforced resin-based composite honeycomb core material and a production mold thereof.

[0029] Figure 4 The present invention is a structural schematic diagram of a continuous fiber reinforced resin-based composite honeycomb core material and a manufacturing mold thereof.

[0030] Figure 5 It is a schematic diagram of the structure of the mandrel. DETAILED DESCRIPTION

[0031] The following is a further detailed description of a continuous fiber reinforced resin-based composite honeycomb core material and a manufacturing method thereof according to the present invention in conjunction with the accompanying drawings.

[0032] Combined with Figure 1-5 , the present invention is introduced in detail.

[0033] The present invention first provides a continuous fiber reinforced resin-based composite honeycomb core material, which is made of continuous fiber reinforced resin-based composite material. The continuous fiber has high strength and high modulus, plays a major role in bearing, and the resin matrix consolidates the continuous fibers together to transfer the load. The continuous fiber is one of glass fiber, carbon fiber, basalt fiber, aramid fiber, and ultra-high molecular weight polyethylene fiber, and a composite of two or more of the above fibers can also be used; the above continuous fiber is unidirectional cloth, multi-axial cloth, gingham cloth or felt; the polymer resin matrix material is thermosetting resin such as unsaturated polyester resin, epoxy resin, vinyl resin, phenolic resin, etc.

[0034] The mass content of the continuous fibers is between 15% and 85%, and the corresponding mass content of the resin matrix is ​​between 85% and 15%. The structure of the honeycomb core material adopts a polygonal structure such as a hexagon or a quadrilateral, and can also adopt a circular structure. The wall thickness of the honeycomb core material is between 0.1 mm and 5 mm.

[0035] The present invention also provides a method for preparing the above-mentioned continuous fiber reinforced resin-based composite honeycomb core material, the steps of which are as follows:

[0036] S1: hand lay up a layer of resin matrix and continuous fiber cloth on the surface of the female mold;

[0037] S2: Place the mandrel at the groove;

[0038] S3: Repeat the above steps until the required height is reached;

[0039] S4: Close the male mold and apply a certain pressure on it;

[0040] S5: Push the mold into a curing furnace for heating and curing;

[0041] S6: After the resin is solidified, the mold is opened and the core rod is pulled out to obtain a composite honeycomb core block;

[0042] S7: Cut the block material into sheets with a certain thickness to obtain a composite honeycomb core material.

[0043] The method for preparing the above-mentioned continuous fiber reinforced resin-based composite honeycomb core material can also be prepared by using composite material prepreg, and the steps are as follows:

[0044] S1: Laying continuous fiber reinforced composite prepreg on the surface of the female mold;

[0045] S2: Place the mandrel at the groove;

[0046] S3: Repeat the above steps until the required height is reached;

[0047] S4: Close the male mold and apply a certain pressure on it;

[0048] S5: Push the mold into a curing furnace for heating and curing;

[0049] S6: After the resin is cured, the mold is opened and the core rod is pulled out to obtain a composite honeycomb core block;

[0050] S7: Cut the block material into sheets with a certain thickness to obtain a composite honeycomb core material.

[0051] The specific implementation process of the continuous fiber reinforced resin-based composite honeycomb core material and the manufacturing method thereof of the present invention is as follows:

[0052] Example 1

[0053] Clean the mold (2.5m long, 1m wide), spray the mold release agent on the mold surface, apply a layer of hand-laid unsaturated polyester resin on the lower mold, then place a layer of 03 glass fiber lattice cloth, and roll the glass fiber cloth with a pressure roller to fully soak it and drive away the bubbles; then place a regular hexagonal stainless steel mandrel with a side length of 10mm coated with a demoulding machine in the concave part of the lower mold, and apply slight pressure to fix the mandrel; then apply a layer of hand-laid unsaturated polyester resin on the upper surface of the hexagonal mandrel, place a layer of 03 glass fiber lattice cloth, and roll the glass fiber cloth with a pressure roller to fully soak it and drive away the bubbles. Repeat the above steps until the height reaches 1.2m. Then cover the upper mold, and place 6 50kg pressing plates on the upper surface of the upper mold, then push the mold into the curing furnace, and after curing at 50℃ for 2h, open the mold, pull out the core rod, and then use a cutting saw to cut the block perpendicular to the direction of the honeycomb core hole to obtain a glass fiber cloth reinforced unsaturated polyester resin composite material hexagonal honeycomb core material with a width of 1.2m, a length of 2.5m, and a wall thickness of 0.3mm. The honeycomb has a bulk density of about 120kg / m3 and a compressive strength of more than 10MPa.

[0054] Example 2

[0055] Clean the mold (2.5m long, 1m wide), spray the mold release agent on the mold surface, lay a layer of epoxy cloth prepreg with a surface density of 400g / ㎡ and a glass fiber mass content of 68% on the lower mold, and use a pressure roller to press the prepreg to make it close to the mold surface; then place a regular hexagonal stainless steel mandrel with a side length of 10mm coated with a demoulding machine in the concave part of the lower mold, and apply slight pressure to fix the mandrel; then lay a layer of epoxy prepreg with a surface density of 400g / ㎡ on the upper surface of the hexagonal mandrel, and use a pressure roller to roll it again to make it fully fit with the hexagonal mandrel. Repeat the above steps until the height reaches 1.2m. Then, the upper mold is covered and six 50kg pressure plates are placed on the upper surface of the upper mold. Then, the mold is pushed into the curing furnace. After curing at 150°C for 4 hours, the mold is opened, the core rod is pulled out, and the block is cut with a cutting saw perpendicular to the direction of the honeycomb core hole to obtain a glass fiber cloth reinforced epoxy resin composite hexagonal honeycomb core material with a width of 1.2m, a length of 2.5m, and a wall thickness of 0.35mm. The honeycomb has a bulk density of about 150kg / m 3 , compressive strength is greater than 13MPa.

[0056] The present invention and its embodiments are described above, and such description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if ordinary technicians in the field are inspired by it, without departing from the purpose of the invention, they can design a structure and embodiment similar to the technical solution without creativity, which should belong to the protection scope of the present invention.

Claims

1. A continuous fiber reinforced resin-based composite honeycomb core material, characterized in that: Including the following raw materials in mass proportion, Continuous fiber 15%~85%, polymer resin 85%~15%; The polymer resin is a thermosetting resin.

2. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 1, characterized in that: The continuous fibers are composited with one or more of glass fibers, carbon fibers, basalt fibers, aramid fibers, and ultra-high molecular weight polyethylene fibers.

3. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 1, characterized in that: The continuous fibers are unidirectional cloth, multi-axial cloth, woven cloth or felt.

4. A continuous fiber reinforced resin-based composite honeycomb core material according to any one of claims 1 to 3, characterized in that: The polymer resin is unsaturated polyester resin, epoxy resin, vinyl resin or phenolic resin.

5. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 4, characterized in that: The continuous fibers are used as reinforcements, and the polymer resin is used as a matrix to form a honeycomb core material.

6. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 5, characterized in that: The cross section of a single through hole of the honeycomb core material is hexagonal, quadrilateral or circular.

7. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 6, characterized in that: The wall thickness of the honeycomb core material is between 0.1 mm and 5 mm.

8. A method for preparing a continuous fiber reinforced resin-based composite honeycomb core material, characterized in that: The following steps are included: S1. Laying honeycomb core material on the surface of the female mold; S2, placing a mandrel in the groove; S3, repeat steps S1-S2 until the required height is reached; S4, close the male mold and apply pressure on it; S5, pushing the mold into a curing furnace for heating and curing; S6, after the resin is solidified, the mold is opened, and the core rod is pulled out to obtain a composite honeycomb core block; S7, cutting the block material into sheets with a certain thickness to obtain a composite honeycomb core material.

9. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 8, characterized in that: In step S1, a layer of resin matrix and continuous fiber cloth is hand-laid on the surface of the female mold.

10. The continuous fiber reinforced resin-based composite honeycomb core material according to claim 8, characterized in that: In step S1, a continuous fiber reinforced composite material prepreg is laid on the surface of a female mold.

Images