Manufacturing method of bulletproof integrated composite material cabin plate of cabin body structure

Abstract

The invention discloses a manufacturing method of a bulletproof integrated composite material cabin plate of a cabin structure. The composite material cabin plate comprises an inner surface layer, a foam layer, a transition layer, a bulletproof layer and an outer surface layer which are sequentially arranged and bonded through resin curing. The preparation method comprises the following steps: sequentially stacking the outer surface layers according to a sequence, sealing the outer surface layers, vacuumizing the outer surface layers, pouring resin for the first time, and heating the outer surface layers until the resin is gel-shaped; the bulletproof layer, the transition layer, the foam layer and the inner surface layer are sequentially stacked, the bulletproof integrated composite material cabin plate is formed by curing and bonding through an integrated pouring process, bulletproof structure units and cabin body structure units are combined into a whole, and the bulletproof structure units and the cabin body structure units are combined into a whole to form the bulletproof integrated composite material cabin plate. The mutual positive effect and contribution of the structure units and the bulletproof units are fully utilized, the application number of the unit layers is reduced, the overall structure thickness and self weight are reduced, and meanwhile the purposes of the bulletproof function of the boat and structural weight and cost reduction are achieved.

Description

Technical Field

[0001] The invention relates to a method for manufacturing a bulletproof integrated composite cabin plate for a cabin structure, and belongs to the technical field of composite cabin plate preparation. Background Art

[0002] Composite foam sandwich structures are increasingly being used in industries such as shipbuilding, rail transit, and aerospace due to their light weight and high strength. The inner and outer composite panels of existing composite foam sandwich structures of ships and boats are mostly symmetrical structures, designed as balanced and symmetrical laminates to avoid warping deformation after curing caused by tension-shear and tension-bending coupling. In actual bulletproof applications of ships and boats, a 14.5-16.3mm thick high-molecular polyethylene UD hot-pressed bulletproof plate is usually installed on the outer side of the inner surface of the cabin, and installed on the inner wall of the cabin by using a metal bracket. This type of external bulletproof plate only plays a bulletproof role and has no mechanical effect on the structural performance of the boat. The installation of the external plate not only increases the additional material cost and installation cost, but also increases the weight of the cabin and reduces the flexibility of the boat. At the same time, the internal external plate also reduces the effective use space in the cabin. Summary of the invention

[0003] The purpose of the present invention is to provide a method for manufacturing a bulletproof integrated composite cabin panel of a cabin structure, which can reduce the dead weight of the overall structure, optimize the mechanical properties and ballistic performance of the bulletproof panel under complex environmental forces, and significantly reduce the delamination effect between composite layers.

[0004] To solve the above technical problems, the purpose of the present invention is achieved as follows: The present invention relates to a method for manufacturing a bulletproof integrated composite cabin panel of a cabin structure, wherein the composite cabin panel comprises an inner surface layer, a foam layer, a transition layer, a bulletproof layer and an outer surface layer which are sequentially arranged and bonded by resin curing; The inner layer and the outer layer both include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, aromatic-carbon hybrid cloth or carbon-glass hybrid fiber cloth; The foam layer is a porous foam material; The bulletproof layer is an ultra-high molecular weight polyethylene bulletproof plate; The production method comprises the following steps: First, stack the outer layers in order, seal them, evacuate them, and pour resin for the first time, and heat them until the resin becomes a gel; then open it and stack the bulletproof layer, transition layer, foam layer and inner layer in order on one side of the outer layer, seal them, evacuate them, pour resin for the second time, and heat to cure.

[0005] On the basis of the above scheme and as a preferred scheme of the above scheme: the foam layer is a PVC foam material.

[0006] On the basis of the above scheme and as a preferred scheme of the above scheme: the ultra-high molecular weight polyethylene bulletproof plate is formed by heating and compression molding multiple layers of ultra-high molecular weight polyethylene unidirectional fabrics stacked in a cycle at 0° and 90° on a molding machine; The ultra-high molecular weight polyethylene unidirectional fabric comprises ultra-high molecular weight polyethylene filaments arranged in parallel on a PE film.

[0007] On the basis of the above scheme and as a preferred scheme of the above scheme: the number of layers of the ultra-high molecular weight polyethylene unidirectional cloth is 80-110 layers.

[0008] On the basis of the above scheme and as a preferred scheme of the above scheme: the transition layer is aramid fiber cloth, and the number of layers is 2; the surface density of the aramid fiber cloth is 100-300 grams per square meter.

[0009] On the basis of the above scheme and as a preferred scheme of the above scheme: the thickness of the foam layer is 30 mm.

[0010] The beneficial effects of the present invention are as follows: the method for manufacturing a bulletproof integrated composite cabin panel of a cabin structure involved in the present invention is formed by curing and bonding through an integrated infusion process, the bulletproof structural unit and the cabin structural unit are combined into one, the positive effects and contributions of the structural unit and the bulletproof unit are fully utilized, the number of respective unit layers used is reduced, thereby reducing the overall structural thickness and deadweight, while achieving the goal of reducing the bulletproof function of the boat and the weight and cost of the structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a schematic structural diagram of the composite material cabin panel involved in the present invention. DETAILED DESCRIPTION

[0012] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0013] The present invention relates to a method for manufacturing a bulletproof integrated composite cabin panel of a cabin structure, wherein the composite cabin panel comprises an inner layer 1, a foam layer 2, a transition layer 3, a bulletproof layer 4 and an outer layer 5 which are arranged in sequence and bonded by resin curing.

[0014] The inner layer 1 and the outer layer 5 both include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, aromatic-carbon hybrid cloth or carbon-glass hybrid fiber cloth; the foam layer 2 is a porous foam material; and the bulletproof layer 4 is an ultra-high molecular weight polyethylene bulletproof plate.

[0015] In the present invention, the method for manufacturing the integrated bulletproof composite cabin panel of the cabin structure adopts the vacuum assisted resin infusion molding technology (VARI). The equipment used by VARI adopts a flexible vacuum bag structure on one side and a mold on the other side. The flexible vacuum bag structure can be easily opened, and the composite cabin panel can be easily prepared by temperature-controlled multi-step infusion.

[0016] The main raw materials, items and machinery used in the vacuum-assisted forming process of FRP boats are as follows: 1) Main raw materials: vinyl resin or epoxy resin, curing agent, accelerator, glass fiber cloth, aromatic carbon hybrid cloth, carbon fiber cloth, PVC foam core material, etc. The aromatic carbon hybrid cloth used is a fabric woven from carbon fiber precursor and aramid fiber precursor by plain or twill weave.

[0017] 2) Main auxiliary materials and mechanical equipment: release cloth, vacuum bag, guide tube, vacuum pump, resin storage device, etc.

[0018] The specific design principles for laying layers are: ① Laying orientation principle: The angle between adjacent laminations in the four laying directions of 0°, 90° and ±45° should be as small as possible less than 60° to reduce the influence of interlaminar stress and micro cracks caused by solidification.

[0019] ② Principle of balanced and symmetrical laying: Design the laminate in a balanced and symmetrical form to avoid warping deformation after curing caused by tension-shear and tension-bending coupling.

[0020] ③ The orientation of the plies should be selected according to the load-bearing principle: the fiber direction of the plies should be consistent with the tension and compression direction of the internal force of the structure to maximize the high performance of the fiber in the 0° direction.

[0021] ④ Principle of laying sequence: ±45° plies should be laid away from the middle fiber layer of the laminate, and avoid placing plies with the same ply angle together. If it is necessary to use it, generally no more than 4 layers are used to reduce the cracking and edge delamination of the oriented layer, so as to improve the buckling stiffness of the laminate and make the bending stiffness coefficient as small as possible. If the laminate contains ±45°, 0° and 90° layers, try to separate the +45° and -45° layers with 0° or 90° layers, and separate the 0° and 90° layers with +45° or -45° layers, and avoid grouping the 90° layers in order to reduce interlaminar stress.

[0022] ⑤ Principles for laying the surface and intermediate fiber layers: The surface of the workpiece should be laid at 45° to withstand the pressure caused by the shear load; the outermost layer should be a continuous and complete layer, which can improve the compression and impact resistance of the laminate.

[0023] Vacuum assisted molding technology is a process method that removes gas from fiber reinforcement under vacuum state, impregnates fibers and fabrics through the flow and penetration of resin, and solidifies at room temperature to form a certain resin / fiber ratio. The resin flows slowly under vacuum negative pressure, and the resin distribution system is used to completely saturate the glass fiber layer and sandwich structure, achieving one-time penetration molding of the sandwich structure, avoiding the relatively weak secondary bonding in the hand lay-up process, and also eliminating the complicated work caused by secondary bonding.

[0024] The manufacturing method of the present invention adopts vacuum assisted resin infusion molding technology, which specifically includes the following steps: First, the outer layers 5 are stacked in sequence, sealed, vacuumed, and poured with resin for the first time, and heated until the resin is in a gel state; then the bulletproof layer 4, the transition layer 3, the foam layer 2 and the inner layer 1 are opened and stacked on one side of the outer layer 5 in sequence, and then sealed, vacuumed, and poured with resin for the second time, and heated to cure.

[0025] Embodiment 1 The present embodiment involves a method for manufacturing a bulletproof integrated composite cabin panel for a cabin structure, and the materials used are shown in the table below.

[0026]

[0027] On the prepared mold, lay the corresponding number of outer layers 5, ultra-high molecular weight polyethylene bulletproof plate 4, transition layer 3, foam layer 2 and inner layer 1. The specific laying order is shown in the table below:

[0028] After the sealing system is arranged, the vacuum operation is carried out after inspection, and the amount of resin is calculated and quantitatively added to the system. The resin is slowly injected into the system along with the vacuum, and the resin content should be ≤35% by mass, which is selected as 30% in this embodiment.

[0029] The present invention adopts the method of pouring resin in batches, specifically, glass fiber cloth, aromatic carbon mixed cloth, and glass fiber cloth are laid in order and in the set number of layers. It is sealed and vacuumized. After the vacuum degree reaches the set requirement, the resin supply valve is opened, and the resin flows under the vacuum negative pressure to complete the first pouring of resin. After the first pouring is completed, the resin is heated to reach a gel state. The vacuum bag is opened, and the ultra-high molecular weight polyethylene bulletproof plate 4, the transition layer 3, the foam layer 2 and the inner surface layer 1 are laid in order, and the seal is again performed, and the resin is poured for the second time, and the temperature is controlled to be raised until the resin is cured. The resin used is a medium-wet resin. After the curing is completed, the formed product needs to be tested for a Barcol hardness of ≥50HD, and after the corners are processed, the glass fiber composite structure / bulletproof plate is made.

[0030] Embodiment 2 The present embodiment involves a method for manufacturing a bulletproof integrated composite cabin panel for a cabin structure, and the materials used are shown in the table below.

[0031]

[0032] On the prepared mold, lay the corresponding number of outer layers 5, ultra-high molecular weight polyethylene bulletproof plate 4, transition layer 3, foam layer 2 and inner layer 1. The specific laying order is shown in the table below:

[0033] After the sealing system is arranged, the vacuum operation is carried out after inspection, and the amount of resin is calculated and quantitatively added to the system. The resin is slowly injected into the system along with the vacuum, and the resin content should be ≤35% by mass, which is selected as 35% in this embodiment.

[0034] The present invention adopts the method of resin infusion in batches, specifically, carbon fiber cloth, aromatic carbon mixed cloth, and carbon fiber cloth are laid in order and in the set number of layers. It is sealed and vacuumized. After the vacuum degree reaches the set requirement, the resin supply valve is opened, and the resin flows under the vacuum negative pressure to complete the first resin infusion. After the first infusion is completed, the resin is heated to a gel state. The vacuum bag is opened, and the ultra-high molecular weight polyethylene bulletproof plate 4, the transition layer 3, the foam layer 2, and the inner surface layer 1 are laid in order, and the seal is again performed, and the resin is infused for the second time, and the temperature is controlled to be raised until the resin is cured. The resin used is a medium-wet resin. After the curing is completed, the formed product needs to be tested for a Barcol hardness of ≥50HD, and after the corners are processed, the glass fiber composite structure / bulletproof plate is made.

[0035] The ultra-high molecular weight polyethylene bulletproof plate used in Example 1 and Example 2 is made of ultra-high molecular weight polyethylene fiber (UHMWPE) 0° non-weft cloth, which is cut into the required size as required, and the stacked composite non-weft cloth layers are stacked at 0° and 90° and placed in the hot plate of the hot press vulcanizer to obtain the required plate product. The number of layers of non-weft cloth is 80-110 layers. In this embodiment, 100 layers are selected, and the stacking order is one layer of 0° and one layer of 90°. The surface density of 0° unidirectional non-weft cloth is 57.5-60g / ㎡, and each non-weft cloth contains only one layer of high-density polyethylene (HDPE) film, so that the fiber is constrained by the film, not easy to debond, and the integrity of the fiber 0° / 90° direction structure is maintained.

[0036] The bulletproof plate is pressed by stacking multiple layers of 0° non-wefted cloth composite structure. The debonding between the interfaces of the multi-level gradient layers can improve the energy absorption of the projectile and improve the protective performance. The bulletproof plate is not penetrated at high temperature of 70℃ and low temperature of -40℃. It has high protective performance and small dent depth. The fire resistance performance also meets the requirements of GJB 6109-2007 "General Specifications for Military Shelters".

[0037] We purchased 14.5mm ultra-high molecular weight polyethylene bulletproof plates according to the standard design of 7.62*51mm NATO bullet resistance, and conducted three-shot target shooting test, with the bullet speed of 847±9.1m / s. The bulletproof plates of the same batch passed the target shooting test.

[0038] The live-fire target shooting test was conducted on the cabin structure bulletproof integrated composite cabin panels prepared in Example 1 and Example 2. Test requirements: Under normal temperature and humidity conditions, the shooting distance is 25m, and no penetration is achieved after effective shooting with a 7.62*51mm NATOM80 bullet; target shooting conditions: gun: 7.62*51mm ballistic gun; bullet: 7.62*51mm ordinary bullet (lead core); shooting distance: 25m; bullet speed: 847±9.1m / s. Target shooting results: Both structural bulletproof panels were not penetrated after three shots.

[0039]

[0040] Referring to STANAG 4569 Level I, under normal temperature and humidity conditions, at a shooting distance of 25m, each sample was effectively hit by three 7.62×51 mm NATO M80 bullets, but none of them penetrated.

[0041] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure, characterized in that: The composite material cabin panel comprises an inner surface layer (1), a foam layer (2), a transition layer (3), a bulletproof layer (4) and an outer surface layer (5) which are arranged in sequence and bonded by resin curing; The inner layer (1) and the outer layer (5) both include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, aromatic-carbon hybrid cloth or carbon-glass hybrid fiber cloth; The foam layer (2) is a porous foam material; The bulletproof layer (4) is an ultra-high molecular weight polyethylene bulletproof plate; The production method comprises the following steps: First, the outer layers (5) are stacked in sequence, sealed, vacuumed, and injected with resin for the first time, and heated until the resin is in a gel state; then, the bulletproof layer (4), the transition layer (3), the foam layer (2), and the inner layer (1) are stacked in sequence on one side of the outer layer (5), and then sealed, vacuumed, and injected with resin for the second time, and heated to cure.

2. The method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure according to claim 1, characterized in that: The foam layer (2) is a PVC foam material.

3. The method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure according to claim 1, characterized in that: The ultra-high molecular weight polyethylene bulletproof plate is formed by heating and compression molding multiple layers of ultra-high molecular weight polyethylene unidirectional fabrics stacked in a cycle at 0° and 90° on a molding machine; The ultra-high molecular weight polyethylene unidirectional fabric comprises ultra-high molecular weight polyethylene filaments arranged in parallel on a PE film.

4. The method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure according to claim 3, characterized in that: The number of layers of the ultra-high molecular weight polyethylene unidirectional fabric is 80-110.

5. The method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure according to claim 1, characterized in that: The transition layer (3) is aramid fiber cloth, and the number of layers is 2; the surface density of the aramid fiber cloth is 100-300 grams per square meter.

6. The method for manufacturing a bulletproof integrated composite material cabin panel of a cabin structure according to claim 1, characterized in that: The thickness of the foam layer (2) is 30 mm.

Images