Honeycomb composite panel and method of manufacturing the same

Abstract

The application provides a kind of honeycomb composite board and its manufacturing method, the honeycomb composite board includes outer skin and honeycomb core, and the honeycomb core includes thermoplastic tube and first continuous fiber.The thermoplastic tube is hot melt connected to the outer skin.The first continuous fiber is at least partially distributed in the tube wall of the thermoplastic tube.The first continuous fiber extends out of the end surface of the thermoplastic tube along the axial direction of the thermoplastic tube and extends into the outer skin, and the outer skin hot melt bonds the first continuous fiber.According to the honeycomb composite board of the application, the combination of the honeycomb core and the outer skin is strengthened, and the overall performance of the honeycomb core composite board is improved.

Description

Technical Field

[0001] This application relates generally to the technical field of honeycomb composite panels, and more specifically to a honeycomb composite panel and its manufacturing method. Background Technology

[0002] Honeycomb panels are hollow, lightweight, plate-like materials with good thermal insulation properties. Their structure typically consists of upper and lower skins and a honeycomb core, and the material is generally resin. The processing of honeycomb panels involves pre-producing the upper and lower skins and the honeycomb core, followed by hot-pressing and bonding. This often results in poor bonding between the skins and the core, and the compressive strength of existing honeycomb panels needs improvement. Summary of the Invention

[0003] The summary section introduces a series of simplified concepts, which will be further explained in detail in the detailed description section. This summary section is not intended to limit the key features and essential technical features of the claimed technical solution, nor is it intended to determine the scope of protection of the claimed technical solution.

[0004] To at least partially solve the above problems, a first aspect of this application provides a honeycomb composite panel, the honeycomb composite panel comprising:

[0005] Outer skin; and

[0006] The honeycomb core includes:

[0007] A thermoplastic tube, the thermoplastic tube being heat-fused to the outer skin; and

[0008] A first continuous fiber is at least partially distributed within the wall of the thermoplastic tube. The first continuous fiber extends from the end face of the thermoplastic tube along the axial direction and extends into the outer skin. The outer skin is thermofused to bond the first continuous fiber.

[0009] According to the honeycomb composite panel of the first aspect of this application, a first continuous fiber is disposed inside the thermoplastic tube of the honeycomb core, and the first continuous fiber extends along the axial direction of the thermoplastic tube, which can improve the structural strength of the honeycomb core; in addition, the first continuous fiber extends out of the end face of the thermoplastic tube and extends into the outer skin, and the first continuous fiber is thermally fused with the outer skin, thereby strengthening the bonding between the honeycomb core and the outer skin and improving the overall performance of the honeycomb core composite panel.

[0010] Optionally, the first continuous fiber extends at least partially in a direction parallel to the surface of the outer skin.

[0011] Optionally, along the radial direction of the thermoplastic tube, the first continuous fiber extends to the outer side of the tube wall.

[0012] Optionally, the first continuous fiber extends to the inner side of the wall of the thermoplastic tube along the radial direction of the thermoplastic tube.

[0013] Optionally, an adhesive strip is provided on the outer side of the thermoplastic tube wall, so that the outer sides of the thermoplastic tube walls are heat-fused together.

[0014] Optionally, the outer skin has a recessed portion on the surface near the honeycomb core, and at least a portion of the recessed portion is provided corresponding to the axis of the honeycomb core.

[0015] Optionally, the prepreg tape includes multiple layers, each layer of which contains a second continuous fiber, and the second continuous fibers of the multiple layers of prepreg tape are arranged at an angle to each other.

[0016] Optionally, the first continuous fiber and the second continuous fiber are the same or different fibers.

[0017] Optionally, the honeycomb composite panel includes two layers of outer skin, and the honeycomb core is disposed between the two layers of outer skin.

[0018] A second aspect of this application provides a method for manufacturing a honeycomb composite panel, the method comprising:

[0019] Continuous fibers are impregnated with thermoplastic resin and then shaped to form prepreg tape;

[0020] The prepreg tape is bent and spliced ​​to form a honeycomb tube, which is then coated with glue and stacked, and finally hot-melt bonded to form a honeycomb core.

[0021] The multi-layered prepreg tape is hot-pressed together with the continuous fibers arranged at an angle to form an outer skin.

[0022] The honeycomb core and the outer skin are thermally melted together to form the honeycomb composite panel.

[0023] The method for manufacturing a honeycomb composite panel according to the second aspect of this application produces a honeycomb composite panel with good bonding and high structural strength.

[0024] Optionally, the end portions of the continuous fibers are not impregnated with thermoplastic resin for shaping, thereby forming the prepreg tape for making the honeycomb core.

[0025] Optionally, the continuous fibers are fully impregnated with a thermoplastic resin and then shaped to form the prepreg tape used to make the outer skin.

[0026] Optionally, the prepreg tape is bent, and two prepreg tapes are spliced ​​together and extruded to a smaller diameter to form the honeycomb tube.

[0027] Optionally, the two prepreg tapes are extruded and compressed using a trapezoidal temperature curve formed by three temperature sections: the preheating section, the isothermal section, and the cooling section.

[0028] Optionally, a heat insulation section is provided between the constant temperature section and the heating section, and / or

[0029] A heat insulation section is provided between the constant temperature section and the cooling section. Attached Figure Description

[0030] The following drawings, which illustrate embodiments of this application, are incorporated herein by reference and are used to understand this application. The drawings depict embodiments of this application and their descriptions, serving to explain the principles of this application. In the drawings,

[0031] Figure 1 This is a side-section schematic diagram of a honeycomb composite panel according to a preferred embodiment of this application;

[0032] Figure 2 A top view of the honeycomb core; and

[0033] Figure 3 This is a schematic diagram illustrating the steps of a preferred embodiment of the manufacturing method of a honeycomb composite panel according to this application.

[0034] Explanation of reference numerals in the attached figures

[0035] 100: Honeycomb composite panel; 110: Honeycomb core

[0036] 111: Thermoplastic tube / sleeve 112: Tube wall

[0037] 113: First continuous fiber; 114: Adhesive strip

[0038] 120: Outer skin; 121: Depression

[0039] D: Axial direction Detailed Implementation

[0040] In the following description, numerous specific details are set forth to provide a more thorough understanding of this application. However, it will be apparent to those skilled in the art that embodiments of this application may be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described to avoid confusion with embodiments of this application.

[0041] In this document, ordinal numbers such as “first” and “second” used in this application are merely identifiers and do not have any other meaning, such as a specific order. Moreover, for example, the term “first component” does not imply the existence of a “second component”, and the term “second component” does not imply the existence of a “first component”.

[0042] In this article, terms such as "up," "down," "front," "back," "left," and "right" are used only to indicate the relative positional relationship between related parts, rather than to define the absolute position of these related parts.

[0043] In this document, terms such as “equal” and “same” are not strict mathematical and / or geometric limitations, but also include errors that are understandable to those skilled in the art and permissible in manufacturing or use.

[0044] Unless otherwise stated, the numerical ranges in this document include not only the entire range within its two endpoints, but also the subranges contained therein.

[0045] Figure 1 and Figure 2 A honeycomb composite panel 100 according to this application is shown. The honeycomb composite panel 100 includes an outer skin 120 and a honeycomb core 110. The honeycomb core 110 includes a thermoplastic tube 111 and a first continuous fiber 113. The thermoplastic tube 111 is heat-fused to the outer skin 120. The first continuous fiber 113 is at least partially distributed within the tube wall 112 of the thermoplastic tube 111. The first continuous fiber 113 extends from the end face of the thermoplastic tube 111 along the axial direction D of the thermoplastic tube 111 and extends into the outer skin 120, where the outer skin 120 is heat-fused to bond the first continuous fiber 113.

[0046] According to the honeycomb composite panel 100 of this application, a first continuous fiber 113 is disposed inside the thermoplastic tube 111 of the honeycomb core 110, and the first continuous fiber 113 extends along the axial direction D of the thermoplastic tube 111, which can improve the structural strength of the honeycomb core 110. In addition, the first continuous fiber 113 extends out of the end face of the thermoplastic tube 111 and extends into the outer skin 120, and the outer skin 120 is thermally bonded to the first continuous fiber 113, thereby strengthening the bonding between the honeycomb core 110 and the outer skin 120 and improving the overall performance of the honeycomb core 110 composite panel.

[0047] Reference Figure 1 The honeycomb composite panel 100 includes two outer skins 120, and the honeycomb core 110 is disposed between the two outer skins 120, so that both sides of the honeycomb core 110 are protected by the outer skin, which also makes the structural strength of the honeycomb composite panel 100 higher.

[0048] Optionally, the portion of the first continuous fiber 113 extending beyond the end face of the thermoplastic tube 111 extends within the outer skin 120 in a direction parallel to the surface of the outer skin 120, thereby increasing the extension length of the first continuous fiber 113 within the outer skin 120 and further improving the bonding between the honeycomb core 110 and the outer skin 120.

[0049] Reference Figure 1 The outer skin 120 has a recess 121 on its surface near the honeycomb core 110. The recess 121 is constructed as a concave hole in the outer skin 120 and is formed by deformation of the outer skin 120. At least a portion of the recess 121 is provided corresponding to the axis of the honeycomb core 110, so that the first continuous fiber 113 extending into the outer skin 120 has a certain curvature, which allows the outer skin 120 to connect longer first continuous fibers 113, further ensuring the bonding between the honeycomb core 110 and the outer skin 120, and making the structural strength of the honeycomb composite panel 100 higher.

[0050] Reference Figure 2 A rubber strip 114 is provided on the outer side of the tube wall 112 of the thermoplastic tube 111, so that the outer sides of the tube walls 112 of the thermoplastic tube 111 are heat-fused together. Multiple thermoplastic tubes 111 are connected together to form the main body of the honeycomb core 110, which has high structural strength and high compressive strength along the axial direction D. The multiple thermoplastic tubes 111 are all connected to the outer skin 120, which also ensures the overall connection strength of the honeycomb core 110.

[0051] Reference Figure 2 Along the radial direction of the thermoplastic tube 111, the first continuous fiber 113 extends to the outer side of the tube wall 112 of the thermoplastic tube 111. When adjacent thermoplastic tubes 111 are connected by an adhesive strip 114, if the portion of the first continuous fiber 113 extending to the outer side of the tube wall 112 of the thermoplastic tube 111 is located inside the adhesive strip 114, the bonding area of ​​the thermoplastic tubes 111 can be increased, thereby strengthening the connection strength between the thermoplastic tubes 111. In other words, the first continuous fiber 113 increases the roughness of the outer surface of the tube wall 112 of the thermoplastic tube 111, thereby enhancing the connection strength between the thermoplastic tubes 111.

[0052] Similarly, along the radial direction of the thermoplastic tube 111, the first continuous fiber 113 extends to the inner side of the tube wall 112 of the thermoplastic tube 111, so that it is not necessary to distinguish the front and back sides of the prepreg tape during the manufacturing process of the honeycomb core 110 (i.e., during the bending process of the prepreg tape of the thermoplastic tube 111), thereby simplifying the manufacturing process of the honeycomb core 110.

[0053] Optionally, the outer skin 120 includes multiple layers of prepreg tape, each layer of prepreg tape containing a second continuous fiber. The second continuous fibers of the multiple layers of prepreg tape are arranged at an angle, thereby enabling the outer skin 120 to have good strength in multiple directions parallel to the surface of the outer skin 120, thus improving the structural strength of the outer skin 120.

[0054] Optionally, the first continuous fiber 113 and the second continuous fiber are the same fiber, such as glass fiber or shale fiber.

[0055] Alternatively, the first continuous fiber 113 and the second continuous fiber can be different fibers. For example, the first continuous fiber 113 can be glass fiber and the second continuous fiber can be shale fiber; or the first continuous fiber 113 can be shale fiber and the second continuous fiber can be glass fiber.

[0056] This application also provides a method for manufacturing a honeycomb composite panel 100. The manufacturing method is used to manufacture the honeycomb composite panel 100 according to the above description, and the manufacturing method includes:

[0057] Continuous fibers (such as glass fibers) are impregnated with thermoplastic resin and then shaped to form prepreg tape;

[0058] The prepreg tape is bent and spliced ​​into a honeycomb tube, which is then coated with glue and stacked. Finally, it is hot-melt bonded to make a honeycomb core 110.

[0059] The outer skin 120 is made by hot-pressing multiple layers of prepreg tape with continuous fibers arranged at an angle.

[0060] The honeycomb core 110 and the outer skin 120 are hot-melted together to form a honeycomb composite panel 100.

[0061] The honeycomb composite panel 100 manufactured according to the method of this application has good bonding and high structural strength.

[0062] Optionally, the end portions of a portion of the continuous fibers are not impregnated with thermoplastic resin for shaping, thereby forming a prepreg tape for making the honeycomb core 110, so that the end of the first continuous fiber 113 of the honeycomb core 110 can extend out of the end face of the thermoplastic tube 111, and it is also convenient to adjust the length of the first continuous fiber 113 extending out of the end face of the thermoplastic tube 111.

[0063] Optionally, a portion of the continuous glass fiber (i.e., the second continuous fiber) is fully impregnated with thermoplastic resin and then shaped to form a prepreg tape for making the outer skin 120, thereby improving the strength of the plastic outer skin.

[0064] Optionally, the prepreg tape is bent, and two prepreg tapes are spliced ​​together and extruded to form a honeycomb tube. The manufacturing method is simple, the manufacturing cost is low, and the honeycomb tube formed by extrusion has high structural strength.

[0065] Optionally, the two prepreg tapes are extruded and compressed using a trapezoidal temperature curve formed by three temperature segments: the preheating stage, the constant temperature stage, and the cooling stage. This allows the two prepreg tapes to be heated step by step, enabling them to be thermally fused together and further extruded and compressed.

[0066] Optionally, a heat insulation section is provided between the constant temperature section and the heating section, and a heat insulation section is provided between the constant temperature section and the cooling section, so as to prevent temperature leakage between the heating section and the cooling section.

[0067] Specifically, refer to Figure 3 A preferred embodiment of the manufacturing method of the honeycomb composite panel 100 includes: S1, the production process of the honeycomb core 110; S2, the production process of the outer skin 120; S3, the composite process of the honeycomb core 110 and the outer skin 120.

[0068] The manufacturing process of cellular core 110 includes:

[0069] S101, Unwinding: The first continuous fiber 113 is unwound under uniform tension by the unwinding mechanism and the tension control system.

[0070] S102, Yarn spreading: The first continuous fiber 113 is spread by a tension adjusting roller and a yarn spreading roller. The yarn spreading roller contains a heating component to preheat the first continuous fiber 113.

[0071] S103, Impregnation: The first continuous fiber 113 with uniform tension is spread to a certain width by the spreading roller and then fed into the impregnation die head; the impregnation die head is a thermoplastic resin melt channel, and the thermoplastic resin is extruded into the melt channel through the screw extruder. The temperature in the melt channel can be adjusted, and the channel is equipped with several forced coating blades; the coating blades repeatedly coat the surface of the first continuous fiber 113 with thermoplastic resin melt. After repeated coating, the surface of the first continuous fiber 113 is uniformly wetted by thermoplastic resin.

[0072] S104. Shaping: The first continuous fiber 113 and thermoplastic resin are co-extruded through an impregnation die and cold-pressed by a cold-pressing roller group to form a continuous fiber thermoplastic resin prepreg sheet (i.e., prepreg tape).

[0073] S105, the roll, the two layers of prepreg tape output in parallel are bent into a semi-circular arc shape by multiple guide devices in the initial planar shape (the angle of the arc is slightly greater than 180°, it can be 181° to 190°), the two layers of prepreg tape are arranged opposite each other and enter the honeycomb tube forming mold together.

[0074] S106, Diameter Reduction: The interior of the honeycomb tube forming mold is a ring-shaped through-hole cavity. The cavity is divided into three sections—front, middle, and rear—along the conveying direction of the prepreg tape. The front section is a heat-controlled hot-melt forming section (i.e., the preheating section), through which the prepreg tape is formed circumferentially. The middle section is a heat-controlled constant-temperature section with insulation sections at both ends, allowing the temperature inside the cavity to be set in a trapezoidal shape, thus separating the temperatures of the preheating section and the cooling section to prevent cross-temperature. The circumferentially formed prepreg tape is extruded in the constant-temperature section to ensure the density of the honeycomb tube wall 112. Two layers of prepreg tape are spliced ​​together in the honeycomb tube forming mold to form a tube (in the preheating section, the edges of the spliced ​​prepreg tape overlap). In the constant-temperature section, the inner diameter of the cavity gradually decreases, i.e., the honeycomb tube is heated and extruded to reduce its diameter. The honeycomb tube that has been extruded and reduced in diameter passes through the cooling section, allowing the honeycomb tube to cool and solidify, thereby stabilizing the size of the honeycomb tube.

[0075] S107, Filling glue: The rear section of the honeycomb tube forming mold is connected to the honeycomb core 110 surface coating system (i.e., homogeneous molten resin is directly extruded into the rear section of the honeycomb tube forming mold through an extruder), thereby filling the defects in the tube wall 112 of the honeycomb tube. The cooled honeycomb core 110 tube can quickly pass through the coating system.

[0076] S108. Applying adhesive: At the outlet of the honeycomb tube forming mold, adhesive resin strip 114 (i.e., a dissimilar resin with a heat melt temperature lower than that of the honeycomb tube resin) is extruded radially along the outer wall of the honeycomb tube.

[0077] S109. Cutting: The honeycomb tube coated with bonding resin is cut to a fixed length after water cooling and air cooling (drying).

[0078] S110, Stacking: Stacking honeycomb tubes radially.

[0079] S111, Pressing: The stacked honeycomb tubes are placed in an oven for hot-melt bonding. The oven temperature can be adjusted according to process requirements, and pressure is applied to the stacked honeycomb tubes along the radial direction of the honeycomb tubes to achieve hot-melt bonding. The hot-melt bonded honeycomb tubes are removed from the oven while maintaining pressure, and the cooled honeycomb tubes are depressurized to obtain the bonded honeycomb core 110.

[0080] S112. Cutting: Cut the honeycomb core 110 radially along the honeycomb tube according to process requirements.

[0081] The manufacturing process of the outer skin 120 includes:

[0082] S201. Unwinding: The second continuous fiber is unwound under uniform tension by the tension control system through the unwinding mechanism.

[0083] S202, Yarn spreading: The second continuous fiber is spread by a tension adjusting roller and a yarn spreading roller. The yarn spreading roller contains a heating component to preheat the second continuous fiber.

[0084] S203. Impregnation: The second continuous fiber with uniform tension is spread to a certain width by the spreading roller and then fed into the impregnation die head. The impregnation die head is a thermoplastic resin melt channel. The thermoplastic resin is extruded into the melt channel through a screw extruder. The temperature in the melt channel can be adjusted. The channel is equipped with several forced coating blades. The coating blades repeatedly coat the surface of the second continuous fiber with thermoplastic resin melt. After repeated coating, the surface of the second continuous fiber is uniformly wetted by thermoplastic resin.

[0085] S204, shaping, the second continuous fiber and thermoplastic resin are co-extruded through an impregnation die, and then cold-pressed by a cold press roller group to form a continuous fiber thermoplastic resin prepreg sheet (i.e., prepreg tape).

[0086] S205. Cutting: Cut the prepreg tape to the required length according to the process requirements.

[0087] S206, Composite, the prepreg tape is laid in multiple layers at a specific angle (i.e. the second continuous fiber in the prepreg tape is set at a certain angle, the angle is between 0° and 90°) and hot-pressed to form the outer skin 120.

[0088] The composite process of the honeycomb core 110 and the outer skin 120 includes:

[0089] S301, Laying out: Laying out the prefabricated outer skin 120 and honeycomb core 110.

[0090] S302, Composite, the outer skin 120 and the honeycomb core 110 of the layup are passed through a hot composite machine, and the outer skin 120 on both sides of the hot composite machine is tightly attached to the honeycomb core 110. After being heated in the heating zone of the hot composite machine, they are conveyed by the hot composite machine belt to the cooling zone of the hot composite machine for cooling. Pressure is applied in the cooling zone to improve the thermal bonding strength of the honeycomb composite panel 100.

[0091] The cooled and shaped honeycomb composite panel 100 is conveyed out of the hot laminating machine by the belt conveyor and then trimmed by the slitting saw configured with the hot laminating machine to produce the finished honeycomb composite panel 100.

[0092] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for descriptive purposes only and is not intended to limit the scope of this application. Terms such as “setup” appearing herein can refer to either a component being directly attached to another component or a component being attached to another component via an intermediary. A feature described in one embodiment herein may be applied, alone or in combination with other features, to another embodiment, unless that feature is not applicable in that other embodiment or is otherwise stated.

[0093] This application has been described through the above embodiments; however, it should be understood that the above embodiments are for illustrative purposes only and are not intended to limit this application to the described embodiments. Those skilled in the art will understand that many more variations and modifications can be made based on the teachings of this application, and all such variations and modifications fall within the scope of protection claimed in this application.

Claims

1. A honeycomb composite panel, characterized in that, The honeycomb composite panel includes: Outer skin; and The honeycomb core includes: A thermoplastic tube, the thermoplastic tube being heat-fused to the outer skin; and A first continuous fiber, at least partially distributed within the wall of the thermoplastic tube, extends axially from the end face of the thermoplastic tube and into the outer skin, wherein the outer skin is thermally bonded to the first continuous fiber. Wherein, the first continuous fiber extends at least partially in a direction parallel to the surface of the outer skin; Furthermore, the outer skin has a recessed portion on its surface near the honeycomb core, and at least a portion of the recessed portion is provided corresponding to the axis of the honeycomb core.

2. The honeycomb composite panel according to claim 1, characterized in that, Along the radial direction of the thermoplastic tube, the first continuous fiber extends to the outer side of the tube wall.

3. The honeycomb composite panel according to claim 1, characterized in that, Along the radial direction of the thermoplastic tube, the first continuous fiber extends to the inner side of the tube wall.

4. The honeycomb composite panel according to claim 1, characterized in that, The outer side of the thermoplastic tube wall is provided with an adhesive strip, which allows the outer sides of the thermoplastic tube walls to be heat-fused together.

5. The honeycomb composite panel according to claim 1, characterized in that, The outer skin comprises multiple layers of prepreg tape, each layer of which contains a second continuous fiber, and the second continuous fibers of the multiple layers of prepreg tape are arranged at an angle to each other.

6. The honeycomb composite panel according to claim 5, characterized in that, The first continuous fiber and the second continuous fiber are the same or different fibers.

7. The honeycomb composite panel according to any one of claims 1 to 6, characterized in that, The honeycomb composite panel includes two outer skin layers, and the honeycomb core is disposed between the two outer skin layers.

8. A method for manufacturing a honeycomb composite panel, the method being used to manufacture a honeycomb composite panel according to any one of claims 1 to 7, characterized in that, The manufacturing method includes: Continuous fibers are impregnated with thermoplastic resin and shaped to form a prepreg tape, wherein a portion of the end portions of the continuous fibers are not impregnated with thermoplastic resin and shaped, thereby forming a prepreg tape for forming the honeycomb core, such that the end of the first continuous fiber of the honeycomb core can extend out of the end face of the thermoplastic tube. The prepreg tape is bent and spliced ​​to form a honeycomb tube, which is then coated with glue and stacked, and finally hot-melt bonded to form a honeycomb core. The multi-layered prepreg tape is hot-pressed together with the continuous fibers arranged at an angle to form an outer skin. The honeycomb core and the outer skin are thermally melted together to form the honeycomb composite panel.

9. The method for manufacturing a honeycomb composite panel according to claim 8, characterized in that, A portion of the continuous fibers are fully impregnated with a thermoplastic resin and then shaped to form the prepreg tape used to make the outer skin.

10. The method for manufacturing a honeycomb composite panel according to claim 8, characterized in that, The prepreg tape is bent, and two prepreg tapes are spliced ​​together and extruded to compress the diameter, thereby forming the honeycomb tube.

11. The method for manufacturing a honeycomb composite panel according to claim 10, characterized in that, The two prepreg tapes are extruded and compressed using a trapezoidal temperature curve formed by three temperature sections: the preheating section, the isothermal section, and the cooling section.

12. The method for manufacturing a honeycomb composite panel according to claim 11, characterized in that, A heat insulation section is provided between the constant temperature section and the heating section, and / or A heat insulation section is provided between the constant temperature section and the cooling section.

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