A manufacturing method of a bulletproof integrated composite cabin panel for a cabin structure

Abstract

The present invention discloses a manufacturing method of a bulletproof integrated composite material cabin panel for a cabin structure. The composite material cabin panel comprises an inner layer, a foam layer, a transition layer, a bulletproof layer, and an outer layer which are sequentially arranged and bonded by resin curing. The manufacturing method includes the following steps: First, stack the outer layer in sequence, seal it, evacuate the air, and perform the first resin infusion, and heat it until the resin becomes gel-like; then open and stack the bulletproof layer, the transition layer, the foam layer, and the inner layer in sequence. The manufacturing method of a bulletproof integrated composite material cabin panel for a cabin structure involved in the present invention is cured and bonded by an integrated infusion process, combining the bulletproof structural unit and the cabin structural unit into one, making full use of the positive effects and contributions of the structural unit and the bulletproof unit to each other, reducing the application quantity of each unit layer, thereby reducing the overall structural thickness and self-weight, and simultaneously achieving the goals of the bulletproof function of the boat and the reduction of the structure weight and cost.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a bulletproof integrated composite material cabin panel for a cabin structure, belonging to the technical field of composite material cabin panel preparation. Background Art

[0002] Due to the characteristics of light weight and high strength of the composite material foam sandwich structure, it is increasingly applied in industries such as ships, rail transit, aerospace, etc. Most of the inner and outer composite material panels of the existing composite material foam sandwich structure of boats and ships are symmetric structures, designed as balanced and symmetric laminated plates to avoid warping deformation caused by tension-shear and tension-bending coupling after curing. In the actual bulletproof application of boats and ships at present, usually a high molecular weight polyethylene UD hot-pressed bulletproof plate with a thickness of 14.5 - 16.3 mm is installed on the outer side of the inner surface of the cabin, and it is installed on the inner wall of the cabin by using metal brackets. This way of installing an 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 self-weight of the cabin, reduces the flexibility of the boat, and at the same time, the method of installing the internal and external plates also reduces the effective usable space inside the cabin. Summary of the Invention

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

[0004] To solve the above technical problems, the purpose of the present invention is achieved as follows:

[0005] A method for manufacturing a bulletproof integrated composite material cabin panel for a cabin structure according to the present invention, the composite material cabin panel includes an inner layer, a foam layer, a transition layer, a bulletproof layer and an outer layer which are arranged in sequence and bonded by resin curing;

[0006] Both the inner layer and the outer layer include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, aramid-carbon hybrid cloth or carbon-glass hybrid fiber cloth;

[0007] The foam layer is a porous foaming material;

[0008] The bulletproof layer is a ultra-high molecular weight polyethylene bulletproof plate;

[0009] The manufacturing method includes the following steps:

[0010] First, stack the outer layer in sequence, seal it, evacuate it to vacuum, and perform the first resin perfusion, then heat it until the resin becomes gel-like; then open it and stack the bulletproof layer, transition layer, foam layer, and inner layer on one side of the outer layer in sequence, then seal it, evacuate it to vacuum, and perform the second resin perfusion, and heat it for curing.

[0011] Based on the above solution and as a preferred solution of the above solution: The foam layer is made of PVC foaming material.

[0012] Based on the above solution and as a preferred solution of the above solution: The ultra-high molecular weight polyethylene bulletproof plate is formed by heating and molding multiple layers of ultra-high molecular weight polyethylene unidirectional cloth stacked in a 0° and 90° cycle on a molding press.

[0013] The ultra-high molecular weight polyethylene unidirectional cloth includes ultra-high molecular weight polyethylene filaments arranged in parallel on a PE film.

[0014] Based on the above solution and as a preferred solution of the above solution: The number of layers of the ultra-high molecular weight polyethylene unidirectional cloth is 80 - 110 layers.

[0015] Based on the above solution and as a preferred solution of the above solution: The transition layer is made of aramid fiber cloth, and the number of layers is 2; the areal density of the aramid fiber cloth is 100 - 300 grams per square meter.

[0016] Based on the above solution and as a preferred solution of the above solution: The thickness of the foam layer is 30mm.

[0017] The beneficial effects of the present invention are: The manufacturing method of a bulletproof integrated composite material cabin plate for a cabin structure involved in the present invention is cured and bonded by an integrated perfusion process, combining the bulletproof structure unit and the cabin structure unit into one, making full use of the positive effects and contributions of the structure unit and the bulletproof unit to each other, reducing the application quantity of each unit layer, thereby reducing the overall structure thickness and self-weight, and at the same time achieving the goals of the bulletproof function of the boat and the reduction of the structure weight and cost. Description of the Drawings

[0018] Figure 1 It is a schematic structural diagram of the composite material cabin plate involved in the present invention. Detailed Embodiments

[0019] The present invention will be further described below with reference to the drawings and specific embodiments.

[0020] A manufacturing method of a bulletproof integrated composite material cabin plate for a cabin structure involved in the present invention, wherein the composite material cabin plate includes an inner layer 1, a foam layer 2, a transition layer 3, a bulletproof layer 4, and an outer layer 5 that are arranged in sequence and cured and bonded by resin.

[0021] The inner layer 1 and the outer layer 5 each include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, carbon-aramid hybrid cloth, or carbon-glass hybrid fiber cloth; the foam layer 2 is a porous foaming material; the bulletproof layer 4 is an ultra-high molecular weight polyethylene bulletproof plate.

[0022] In the present invention, the manufacturing method of the bulletproof integrated composite material cabin panel for the cabin structure selects the vacuum assisted resin infusion molding technology (VARI). One side of the equipment used in VARI adopts a flexible vacuum bag structure, and the other side is a mold. The flexible vacuum bag structure can be conveniently opened, and the composite material cabin panel can be conveniently prepared by the method of temperature-controlled fractional infusion.

[0023] The main raw materials, articles, and mechanical equipment used in the vacuum assisted molding process of fiberglass boats are as follows:

[0024] 1) Main raw materials: vinyl resin or epoxy resin, curing agent, accelerator, glass fiber cloth, carbon-aramid hybrid cloth, carbon fiber cloth, PVC foaming core material, etc. The carbon-aramid hybrid cloth used is a fabric woven from carbon fiber raw filaments and aramid fiber raw filaments in a plain or twill weave.

[0025] 2) Main auxiliary materials and mechanical equipment: release cloth, vacuum bag, conduit, vacuum pump, resin storage device, etc.

[0026] The specific design principles during laminating are as follows:

[0027] ① Laminating orientation principle: The included angle between adjacent laminates in the four laminating directions of 0°, 90°, and ±45° should be as small as possible less than 60° to reduce the influence of interlayer stress and microcracks caused by curing.

[0028] ② Balanced and symmetric laying principle: Design it into a balanced and symmetric laminate form to avoid warping deformation after curing caused by tension-shear and tension-bending coupling.

[0029] ③ Laminating orientation selection according to load principle: The fiber direction of the laminate should be consistent with the tensile and compressive directions of the internal forces of the structure to make the best use of the high performance in the 0° direction of the fiber.

[0030] ④ Laying sequence principle: The ±45° laminates should be laid away from the middle fiber layer of the laminate to avoid concentrating the laminates with the same laying angle. If it has to be used, generally no more than 4 layers to reduce the cracking and edge delamination of the oriented layer, 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, 0° or 90° layers should be used to separate between the +45° and -45° layers as much as possible, and +45° or -45° layers should be used to separate between the 0° and 90° layers, and avoid the 90° layers being laid in groups to reduce the interlayer stress.

[0031] 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 shear loads; the outermost layer should be a continuous and complete layer, which can improve the compression and impact resistance of the laminate.

[0032] Vacuum-assisted resin infusion molding technology removes the gas in the fiber reinforcement under vacuum conditions. Through the flow and penetration of the resin, the fibers and their fabrics are impregnated, and curing is carried out at room temperature to form a process method with a certain resin / fiber ratio. Under the vacuum negative pressure, the resin slowly flows. At the same time, using the resin distribution system, the resin completely penetrates the fiberglass layer and the sandwich structure, realizing one-time penetration molding of the sandwich structure, avoiding the relatively weak secondary bonding in the hand lay-up process, and also eliminating the complex work brought about by secondary bonding.

[0033] The manufacturing method described in the present invention uses vacuum-assisted resin infusion molding technology, which specifically includes the following steps:

[0034] First, stack the outer layer 5 in sequence, seal it, evacuate it, and perform the first resin infusion, and heat it until the resin becomes gel-like; then open and stack the bulletproof layer 4, transition layer 3, foam layer 2, and inner layer 1 on one side of the outer layer 5 in sequence, and then seal it, evacuate it, and perform the second resin infusion, and heat and cure it.

[0035] Example 1

[0036] For the manufacturing method of a bulletproof integrated composite cabin panel for a cabin structure involved in this example, the materials used are shown in the following table.

[0037]

[0038] Lay the corresponding number of layers of the outer layer 5, ultra-high molecular weight polyethylene bulletproof plate 4, transition layer 3, foam layer 2, and inner layer 1 on the manufactured mold. The specific laying sequence is shown in the following table:

[0039]

[0040] After arranging the sealing system, after checking and confirming, perform the vacuum evacuation operation, calculate the resin dosage, quantitatively dispense it into the system, and the resin is slowly injected into the system along with the vacuum, and the resin content should be ≤ 35% mass fraction, and 30% is selected in this example.

[0041] 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.

[0042] Embodiment 2

[0043] 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.

[0044]

[0045] 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:

[0046]

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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".

[0051] 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.

[0052] 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.

[0053]

[0054] 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.

[0055] 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 manufacturing method of a bulletproof integrated composite cabin panel for a cabin structure, characterized in that, The composite material cabin panel includes 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. Both the inner layer (1) and the outer layer (5) include one or more of carbon fiber cloth, glass fiber cloth, aramid fiber cloth, PBO fiber cloth, aramid-carbon hybrid cloth, or carbon-glass hybrid fiber cloth. The foam layer (2) is a porous foaming material. The bulletproof layer (4) is an ultra-high molecular weight polyethylene bulletproof plate. The manufacturing method includes the following steps: First, stack the outer layer (5) in sequence, seal it, evacuate it, and perform the first resin infusion, and heat it until the resin becomes gel-like. Then open it and stack the bulletproof layer (4), the transition layer (3), the foam layer (2), and the inner layer (1) in sequence on one side of the outer layer (5), and then seal it, evacuate it, and perform the second resin infusion, and heat it for curing. One side of the equipment used adopts a flexible vacuum bag structure, and the other side is a mold. The transition layer (3) is aramid fiber cloth. The dosage of the resin is 30-35% mass fraction.

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

3. The manufacturing method of a bulletproof integrated composite cabin panel for the cabin structure according to claim 1, characterized in that, The ultra-high molecular weight polyethylene bulletproof plate is formed by heating and molding multiple layers of ultra-high molecular weight polyethylene unidirectional cloth stacked in a 0°, 90° cycle on a molding press. The ultra-high molecular weight polyethylene unidirectional cloth includes ultra-high molecular weight polyethylene filaments arranged parallel to the PE film.

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

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

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

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