Composite pultrusion floor and manufacturing method thereof

Abstract

The invention relates to the technical field of composite floors, in particular to a composite pultrusion floor and a manufacturing method thereof.The composite pultrusion floor comprises a plurality of plates evenly arranged in the width direction, first composite layers wrapping the plates, second composite layers wrapping the first composite layers, and third composite layers wrapping the second composite layers; the first composite layer between two adjacent plates is integrally formed into a pultrusion rib through a pultrusion process, and the first composite layer is made of a composite material. According to the invention, the first composite layer is coated outside the board, so that the bending strength and the overall rigidity of the floor are improved, and meanwhile, the self weight of the floor is reduced; the first composite layer forms an integrally-formed pultrusion rib structure between the adjacent plates, the overall strength and bearing capacity are enhanced, meanwhile, the problem of loosening or falling possibly existing in traditional assembly type connection is solved, and the stability and durability of the structure are improved; and the first composite layer made of the composite material also has excellent corrosion resistance and weather resistance, and can meet the long-term use requirement of a humid, high-salinity or chemical environment.

Description

Technical Field

[0001] The invention relates to the technical field of composite flooring, and in particular to a composite pultruded flooring and a manufacturing method thereof. Background Art

[0002] Pultrusion technology is an advanced processing technology that stretches plastics, composite materials and other raw materials through a mold at high temperature. It is widely used in manufacturing industrial products with specific shapes and performance requirements, such as pipes, profiles and floors. Composite pultruded floors are made by compounding reinforcing fibers with a resin matrix and using a pultrusion process. While maintaining high strength, it can effectively reduce weight and provide good durability and corrosion resistance.

[0003] At present, there are many composite floor products based on pultrusion technology on the market. These floors usually use a glass fiber or carbon fiber reinforced resin matrix, have strong durability and weather resistance, and are suitable for a variety of harsh environments. However, the existing pultruded composite floor still has certain shortcomings, mainly manifested in the balance between strength and weight. In some special applications, the floor is required to have high strength while maintaining a low dead weight to adapt to more demanding conditions of use.

[0004] Therefore, there is an urgent need for a new type of composite pultruded floor and a manufacturing method thereof, which can further reduce the weight of the floor without sacrificing strength. Summary of the invention

[0005] In view of at least one of the above technical problems, the present invention provides a composite pultruded floor and a method for manufacturing the same, which combines a composite material with a plate material to reduce weight while improving strength.

[0006] According to a first aspect of the present invention, there is provided a composite pultruded floor, comprising: A plurality of plates are evenly arranged in the width direction, a first composite layer is coated on the outside of each plate, the first composite layer between two adjacent plates is integrally formed into pultruded ribs through a pultrusion process, and the first composite layer is a composite material.

[0007] In some embodiments of the present invention, the board material is a wooden board.

[0008] In some embodiments of the present invention, there are further installation parts arranged on both sides of the pultruded floor, and the installation parts are recessed toward the inside of the board.

[0009] In some embodiments of the present invention, the mounting portion includes a mounting section parallel to the surface of the plate, a first bending section connected to the mounting section at one end and connected to the surface of the plate at the other end, and a second bending section connected to the mounting section at one end and connected to the side of the plate at the other end.

[0010] In some embodiments of the present invention, there is further provided a second composite layer coated outside the plurality of first composite layers, and the second composite layer is a composite material.

[0011] In some embodiments of the present invention, the second composite layer is a whole piece of composite material.

[0012] In some embodiments of the present invention, the first composite layer and the second composite layer have different wrapping angles.

[0013] In some embodiments of the present invention, the composite material is made of carbon fiber yarn, fabric and felt.

[0014] According to a second aspect of the present invention, there is also provided a method for manufacturing a composite pultruded floor, comprising the following steps: Set the number of panels according to the specifications of the pultruded floor; Wrapping the first composite layer on each plate respectively; splicing the plates coated with the first composite layer; Covering the second composite layer on the outer periphery of the spliced ​​plates; The first composite layer, the second composite layer and the plate are solidified by a pultrusion process.

[0015] In some embodiments of the present invention, the splicing of the plate material coated with the first composite layer further comprises curing the first composite layer and the plate material by a pultrusion process.

[0016] The beneficial effects of the present invention are as follows: the present invention improves the bending strength and overall rigidity of the floor while reducing the dead weight of the floor by coating the first composite layer on the outside of the board; the first composite layer forms an integrally formed pultruded rib structure between adjacent boards, thereby enhancing the overall strength and bearing capacity, while avoiding the loosening or falling off problems that may exist in traditional assembled connections, and improving the stability and durability of the structure; the first composite layer made of composite material also has excellent corrosion resistance and weather resistance, and can adapt to long-term use requirements in humid, high-salt or chemical environments; at the same time, the pultrusion process is used to achieve the two properties of weight reduction and strength enhancement of the composite material pultruded floor. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 This is a schematic diagram of the structure of a composite pultruded floor in an embodiment of the present invention; Figure 2 In the embodiment of the present invention Figure 1 A schematic diagram of the structure enlargement at the center A; Figure 3 A partial structural side view of a composite pultruded floor in an embodiment of the present invention; Figure 4 It is a schematic structural diagram of the first composite layer covering plate material in the method for manufacturing a composite pultruded floor in an embodiment of the present invention; Figure 5 It is a schematic diagram of the structure of the splicing of the coated first composite layer board in the method for manufacturing the composite pultruded floor in an embodiment of the present invention; Figure 6 It is a schematic diagram of the structure of coating the second composite layer in the method for manufacturing a composite pultruded floor in an embodiment of the present invention; Figure 7 In the embodiment of the present invention Figure 4 A schematic diagram of the structure enlarged at B in the middle; Figure 8 It is a step diagram of the method for manufacturing a composite pultruded floor in an embodiment of the present invention.

[0019] Figure numerals: 1, plate; 2, first composite layer; 3, second composite layer; 4, pultruded ribs; 5, mounting portion; 51, first bending section; 52, second bending section. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0021] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only implementation method.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0023] like Figures 1 to 7 The composite pultruded floor shown includes: a plurality of plates 1 evenly arranged in the width direction, a first composite layer 2 coated on the outside of each plate 1, the first composite layer 2 between two adjacent plates 1 is integrally formed into pultruded ribs 4 by a pultrusion process, and the first composite layer 2 is a composite material. It should be pointed out here that the material of the plate 1 can be of many kinds, it can be a wooden board, a metal plate, a plastic board or plates 1 of other possible materials. It should also be pointed out that the pultruded ribs 4 are formed by curing the composite material by coating the first composite layer 2 on the plate 1 through a pultrusion process. It should also be pointed out that the coating of the first composite layer 2 and the plate 1 can be a winding wrapping, a covering wrapping, or other forms of wrapping.

[0024] The present invention improves the bending strength and overall rigidity of the floor while reducing the dead weight of the floor by coating the first composite layer 2 on the outside of the plate 1; the first composite layer 2 forms an integrally formed pultruded rib 4 structure between adjacent plates 1, thereby enhancing the overall strength and bearing capacity, while avoiding the loosening or falling off problems that may exist in traditional assembled connections, and improving the stability and durability of the structure; the first composite layer 2 made of composite material also has excellent corrosion resistance and weather resistance, and can adapt to long-term use requirements in humid, high-salt or chemical environments; at the same time, the pultrusion process is used to achieve the two properties of weight reduction and strength enhancement of the composite material pultruded floor.

[0025] In some embodiments of the present invention, the board 1 is a wooden board. The wooden board has a relatively light weight, and compared with traditional metal or other dense materials, it can significantly reduce the weight of the entire floor, which helps to achieve a lightweight design; the wooden board also has a certain natural strength and toughness, and forms a synergistic effect with the first composite layer 2 coated on the outside, which can effectively improve the bending resistance and overall rigidity of the floor; the wooden board as the core material, combined with the composite material coating layer, can enhance the structural stability of the floor.

[0026] The pultruded floor of the present invention can be installed in a container. In order to make the pultruded floor and the container more closely fit, Figure 2 , Figure 3 As shown, there are also mounting parts 5 arranged on both sides of the pultruded floor, and the mounting parts 5 are recessed toward the inside of the board 1. The design of the mounting parts 5 enables the floor to fit more closely with other components during installation, thereby improving the stability and firmness of the installation.

[0027] Continue to refer Figure 2 , Figure 3As shown, the mounting portion 5 includes a mounting section parallel to the surface of the plate 1, a first bending section 51 with one end connected to the mounting section and the other end connected to the surface of the plate 1, and a second bending section 52 with one end connected to the mounting section and the other end connected to the side of the plate 1. The structure in which the mounting section is parallel to the surface of the plate 1 provides a stable mounting reference surface, which facilitates the precise docking of the floor with other structural parts, and improves the firmness and accuracy of the installation. When the pultruded floor is installed in the container, the first bending section 51 and the second bending section 52 can, on the one hand, prevent the connection parts from being deformed due to long-term stress, and on the other hand, can play a guiding role during the installation process, so that the pultruded floor can be installed in the container more smoothly.

[0028] like Figures 1 to 3 , Figure 6 As shown, there is also a second composite layer 3 coated outside the plurality of first composite layers 2, and the second composite layer 3 is a composite material. As an additional protective layer, the second composite layer 3 not only further improves the overall strength and rigidity of the floor, but also effectively enhances its wear resistance and impact resistance. Through the synergistic effect of the first composite layer 2 and the second composite layer 3, the overall structure of the floor is more stable, the performance is more excellent, and the adaptability is stronger.

[0029] like Figure 1 , Figure 6 As shown, the second composite layer 3 is a whole piece of composite material. The plurality of panels 1 are coated with the first composite layer 2 after the pultrusion process. In order to make the pultruded floor stronger, in some embodiments of the present invention, a whole layer of composite material can be added outside the first composite layer 2, so that the first composite layer 2 and the second composite layer 3 work together to have a stronger strength.

[0030] In some embodiments of the present invention, the first composite layer 2 and the second composite layer 3 have different wrapping angles. By laying at different angles, the optimization of multi-directional mechanical properties can be achieved, so that the floor exhibits higher strength and rigidity when subjected to loads in different directions. The angle difference between the first composite layer 2 and the second composite layer 3 helps to disperse and evenly transfer external stress, avoid stress concentration, and improve the bending and shear resistance of the floor; the design of different wrapping angles can also enhance the anti-fatigue performance of the floor, making it more durable under long-term use or frequent load changes.

[0031] In some embodiments of the present invention, the composite material is a composite of carbon fiber yarn, fabric and felt. The carbon fiber yarn provides excellent tensile strength and rigidity, providing core support for the overall structure of the floor; the carbon fiber fabric is laid in multiple directions to enhance the bending and shear resistance of the floor; the carbon fiber felt effectively fills the gaps between the yarn and the fabric, improving the integrity and impact resistance of the material. The composite design of the three enables the floor to have excellent multi-directional mechanical properties while ensuring lightweight.

[0032] According to a second aspect of the present invention, a method for manufacturing a composite pultruded floor is also provided. Figure 8 As shown in , the following steps are included: S10: setting the number of panels 1 according to the specifications of the pultruded floor; S20: Covering the first composite layer 2 on each plate 1 respectively; S30: splicing the plate 1 coated with the first composite layer 2; S40: coating the second composite layer 3 on the outer periphery of the spliced ​​plate 1; S50: curing the first composite layer 2, the second composite layer 3 and the plate 1 through a pultrusion process.

[0033] During the production process of the pultruded floor in the present invention, the first composite layer 2 is firstly coated on the plate 1 separately, and then the plates are spliced ​​and coated with the second composite layer 3 on the overall periphery, so that the bonding between the layers of materials is tighter, thereby improving the overall strength and structural stability of the floor; after splicing, the second composite layer 3 is uniformly coated, which not only makes the floor surface smoother and more beautiful, but also effectively enhances its bending resistance, impact resistance and corrosion resistance; finally, the first composite layer 2, the second composite layer 3 and the plate 1 are solidified at one time through the pultrusion process, thereby realizing efficient industrialized production, greatly improving production efficiency and reducing manufacturing costs.

[0034] In some embodiments of the present invention, the plate 1 coated with the first composite layer 2 is spliced, and the first composite layer 2 and the plate 1 are solidified by a pultrusion process. In order to make the coating of the pultruded floor more compact, the first composite layer can be coated on the plate 1 first, and then spliced, and then the spliced ​​plate 1 is pultruded to form a pultrusion rib 4 between the two plates 1, and then the second composite layer 3 is coated on the periphery, and finally pultruded again, so that the entire pultruded floor forms a complete whole. The first composite layer 2 and the plate 1 are solidified as a whole by the pultrusion process, so that the spliced ​​plates 1 are more tightly connected, the rigidity and stability of the overall structure are enhanced, and the loosening or falling problems that may occur in the traditional splicing method are avoided. At the same time, the pultrusion process can firmly attach the first composite layer 2 to the surface of the plate 1, ensuring that the mechanical properties of the composite material are fully utilized, thereby improving the bending strength and shear resistance of the floor.

[0035] Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A composite pultruded floor, characterized in that: include: A plurality of plates are evenly arranged in the width direction, a first composite layer is coated on the outside of each plate, the first composite layer between two adjacent plates is integrally formed into pultruded ribs through a pultrusion process, and the first composite layer is a composite material.

2. The composite pultruded floor according to claim 1, characterized in that: The board is a wooden board.

3. The composite pultruded floor according to claim 1, characterized in that: The invention also has mounting parts arranged on both sides of the pultruded floor, and the mounting parts are recessed toward the inside of the plate.

4. The composite pultruded floor according to claim 3, characterized in that: The mounting portion includes a mounting section parallel to the surface of the plate, a first bending section with one end connected to the mounting section and the other end connected to the surface of the plate, and a second bending section with one end connected to the mounting section and the other end connected to the side of the plate.

5. The composite pultruded floor according to claim 1, characterized in that: The invention also comprises a second composite layer covering the outside of the plurality of the first composite layers, wherein the second composite layer is a composite material.

6. The composite pultruded floor according to claim 5, characterized in that: The second composite layer is a whole piece of composite material.

7. The composite pultruded floor according to claim 5, characterized in that: The first composite layer and the second composite layer have different covering angles.

8. The composite pultruded floor according to claim 5, characterized in that: The composite material is made of carbon fiber yarn, fabric and felt.

9. A method for manufacturing a composite pultruded floor, characterized in that: Using the composite pultruded floor as claimed in any one of claims 1 to 8 comprises the following steps: Set the number of panels according to the specifications of the pultruded floor; Wrapping the first composite layer on each plate respectively; splicing the plates coated with the first composite layer; Covering the second composite layer on the outer periphery of the spliced ​​plates; The first composite layer, the second composite layer and the plate are solidified by a pultrusion process.

10. The method for manufacturing a composite pultruded floor according to claim 9, characterized in that: The method of splicing the plate covered with the first composite layer also includes solidifying the first composite layer and the plate by a pultrusion process.

Images