Fiber-reinforced resin-based composite board, composite board component and preparation method

Abstract

The invention discloses a fiber-reinforced resin-based composite board, a composite board component and a preparation method.The fiber-reinforced resin-based composite board comprises a first preformed body and a second preformed body, and the first preformed body and the second preformed body are matched to form a hollow structure with a cavity; the first preformed body and the second preformed body are formed by laying fiber prepregs layer by layer in different directions, so that fibers in the first preformed body and the second preformed body are distributed in different directions. According to the fiber-reinforced resin-based composite board prepared by adopting a two-step method, the porosity in the composite board can be greatly reduced, the fibers are in a straightened arrangement state, and the bearing performance or mechanical performance of the fiber-reinforced resin-based composite board is superior to that of a laminated board, a plate rib structure composite board and a pultrusion hollow structure composite board under the same thickness. The problem that in the prior art, bearing capacity, light weight and sound insulation performance of a plate, especially a vehicle body plate are difficult to consider at the same time is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of composite materials, and in particular to a fiber-reinforced composite material, and in particular to a fiber-reinforced resin-based composite plate, a composite plate component and a preparation method thereof. Background Art

[0002] Fiber reinforced polymer (or fiber reinforced plastic, referred to as FRP) is a composite material formed by winding, molding or pultrusion of reinforcing fiber materials, such as glass fiber, carbon fiber, aramid fiber, etc., with matrix materials. According to the different reinforcing materials, common fiber reinforced composite materials are divided into glass fiber reinforced composite materials (GFRP), carbon fiber reinforced composite materials (CFRP) and aramid fiber reinforced composite materials (AFRP). Fiber reinforced composite materials have the characteristics of high specific strength, large specific modulus, strong designability, good corrosion resistance and durability, and are increasingly widely used in the fields of construction, transportation, etc.

[0003] As an important part of rail vehicles, train bodies must meet multiple design requirements such as lightweight, functional, and high performance. The application of fiber-reinforced resin-based composite materials is an inevitable trend to meet the advanced performance and usage requirements of future rail vehicles. There are several types of body structures in the existing technology: The first type is a laminated plate structure or a plate-reinforced structure composite plate (laminated plate). Although its load-bearing capacity can be met by designing the plate thickness or reinforcing ribs, its sound insulation performance must be improved by using additional composite sound insulation cotton or porous foam and other sound insulation materials, which does not meet the sound insulation requirements of the train.

[0004] The second type is a sandwich structure composite material panel which is composed of a surface layer and a core layer (sandwich panel). Although it has certain load-bearing and sound insulation properties, its surface layer and core layer are bonded together with adhesives. During long-term load-bearing, the surface layer and the core layer are prone to debonding and loss of load-bearing capacity.

[0005] The third type is the pultruded hollow structure composite material plate (pultruded hollow plate), which can only form a hollow structure with equal cross-section during preparation. Its fibers are mainly arranged in the pultrusion direction (longitudinal). Except for the strong bearing capacity in the longitudinal direction, the bearing capacity in other directions (such as the transverse direction) is relatively poor. The reinforcing ribs in the hollow structure formed are bridges (sound bridges) for sound wave transmission, and its sound insulation performance is difficult to meet the sound insulation requirements of the train body. Summary of the invention

[0006] In response to the above technical problems and needs, the present invention provides a fiber-reinforced resin-based composite plate, a composite plate component and a preparation method, which solves the above problems and brings other technical effects by adopting the following technical features.

[0007] On the one hand, the present invention provides a fiber-reinforced resin-based composite panel, comprising a first preform and a second preform, wherein the first preform and the second preform cooperate to form a hollow structure having a cavity, and the first preform and the second preform are formed by fiber prepregs laid layer by layer in different directions, so that the fibers in the first preform and the second preform are distributed along different directions.

[0008] According to the above technical features, the first preform and the second preform provided by the present invention cooperate to form a hollow structure with a cavity, which can further reduce the weight of the board due to the internal hollowness while isolating the sound. Since the first preform and the second preform are formed by laying fiber prepregs in layers in different directions, the fibers in the first preform and the second preform are distributed in different directions, so that they can play a reinforcing role in all directions of the composite board. Compared with the composite board with fibers arranged in a single direction, the present invention can meet the higher requirements of the vehicle body for strength and bearing capacity.

[0009] In some embodiments of the present invention, a sound insulation reinforcement layer is provided at the connection between the first preform and the second preform.

[0010] According to the above technical features, the sound insulation reinforcement layer provided by the present invention can enhance the sound insulation on the one hand, and on the other hand, it is conducive to strengthening the fastening of the connection. Preferably, the sound insulation reinforcement layer is made of polyurethane elastomer, polyborosiloxane elastomer, and interpenetrating network polymer.

[0011] In some embodiments of the present invention, the first preform includes a first panel and a first branch body integrally formed on one side of the first panel and protruding outward, the second preform includes a second panel and a second branch body integrally formed on one side of the second panel and protruding outward, and the first panel, the first branch body, the second panel and the second branch body are enclosed to form a cavity.

[0012] According to the above technical features, the first panel and the second panel provided by the present invention are used as the use surface. The first branch body and the second branch body protrude from the surface of one side of the first panel and the second panel respectively, and can play the role of reinforcing ribs to improve the strength of the entire composite panel on the first aspect, and can serve as a connecting structure of the first preform and the second preform on the second aspect, and can play a connecting role on the third aspect. A hollow structure with a cavity is formed inside the composite panel through the first panel, the first branch body, the second panel and the second branch body, so as to further improve the degree of lightweight, and have better sound insulation performance while reducing the overall vehicle weight.

[0013] In some embodiments of the present invention, a sound insulation reinforcement layer is provided at the joint between the first branch body and the second branch body.

[0014] In some embodiments of the present invention, the end of the first branch body and the end of the second branch body are connected by a mortise and tenon structure.

[0015] According to the above technical features, the first branch body and the second branch body provided by the present invention are connected by a mortise and tenon structure, the structure is simple and easy to install, and the connection stability is good.

[0016] In some other examples of the present invention, the end of the first branch body and the end of the second branch body can also be connected by mechanical fasteners such as bolts and screws, as well as buckles, snap rings, etc. Under the guidance of the present invention, those skilled in the art can easily think of connection methods that can achieve the same function and can replace the mortise and tenon connection. These connection methods should all be regarded as equivalent replacement methods of the present utility model and are within the protection scope of the present invention.

[0017] In some embodiments of the present invention, the first branch body and the second branch body extend in a straight line, a curve, or a folded line on the first panel and the second panel respectively, and the extension directions of the first branch body and the second branch body are consistent.

[0018] According to the above technical features, the extension forms of the first branch body and the second branch body provided by the present invention can be selected based on actual conditions such as the required plate size, plate load bearing conditions, plate application scenarios, time, cost and other factors, such as straight line extension, curved line extension, broken line extension or other forms.

[0019] On the other hand, a composite plate component provided by the present invention includes a plurality of fiber-reinforced resin-based composite plates, and two adjacent fiber-reinforced resin-based composite plates are laid in different directions.

[0020] In another aspect, the present invention provides a method for preparing a fiber-reinforced resin-based composite plate, comprising: S1, laying the fiber prepreg layer by layer in different directions in the mold and preliminarily shaping it to obtain a first preform and a second preform; S2. Connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then hot pressing to obtain a fiber-reinforced resin-based composite plate.

[0021] The preparation method of the fiber-reinforced resin-based composite board provided by the present invention is to lay fiber prepregs layer by layer in different directions in a mold and form them into a first preform and a second preform according to a pre-designed composite board shape (including an internal shape structure), and then pass pressurized gas into the cavity to apply isotropic pressure to the inner wall of the cavity, so that the fibers distributed in different directions of each layer are arranged in order under the action of pressure, and the fibers originally bent in the resin are straightened due to the action of pressure. Under the influence of these two aspects, the strength of the composite board is greatly improved. This strength improvement is not limited to the direction of the fiber itself. Due to the omnidirectional distribution of each layer of fibers and the difference in the laying direction of each layer of fiber prepreg, the composite board as a whole has fibers distributed in all directions, so that the strength in all directions or positions can be further improved, avoiding the situation that the existing composite board has strong strength only in one direction (fiber distribution direction) and low strength in other positions. In addition, since the present invention changes the structure of the composite board from a laminate, sandwich panel, pultruded hollow panel, etc. as an integral structure into two separate structures with a cavity by pre-preparing the first preform and the second preform, a "broken bridge" structure similar to doors and windows is formed, so that the energy propagation of sound is greatly reduced due to the truncation of the medium during the propagation process, thereby achieving the effect of sound insulation. It should be noted that the "isotropic pressure" referred to in the present invention means that the pressure in all directions is the same.

[0022] In some embodiments of the present invention, the above-mentioned hot pressing forming includes: (1) Melting stage: heating the first preform and the second preform at 20-300° C. for 0.5-1 h; (2) Impregnation stage: after the resins in the first preform and the second preform are melted, pressurized gas is introduced into the cavity to increase the pressure to 1-5 atm and maintained at 100-400°C for 0.5-1h; (3) Curing stage: Continue to increase the pressure to 5-20atm at 100-400℃, maintain for 0.5-1h, and then cool and solidify.

[0023] According to the above technical features, the preparation method provided by the present invention is carried out in stages during the hot pressing molding process. In the melting stage, the resin in the first preform and the second preform is melted and has a certain fluidity by heating, and this stage prepares for the subsequent impregnation stage. After the resin has a certain fluidity, pressurized gas is introduced to increase the pressure in the cavity so that the resin can fully infiltrate and fill the gaps between the fibers under the action of pressure. During the impregnation stage, due to the dual effects of temperature and pressure, the resin undergoes a chemical reaction to form macromolecular chains and a three-dimensional network structure, which helps to improve the strength of the composite board after curing. In the curing stage, as the pressure continues to increase, the fibers are in a straightened state under the action of tension, and the gas between the fibers is removed to form a dense structure, further improving the strength of the composite board.

[0024] In some embodiments of the present invention, the number of stacked layers of the fiber prepreg is 5 to 50. Those skilled in the art can reasonably select the number of stacked layers according to actual application scenarios.

[0025] In some embodiments of the present invention, the reinforcing fiber of the fiber prepreg is one or more combinations of carbon fiber, aramid fiber, glass fiber, polypropylene fiber and polyethylene fiber; the resin of the fiber prepreg is epoxy resin, polyurethane or polyimide.

[0026] Technical effects of the present invention: The fiber-reinforced resin-based composite board of the present invention forms a hollow composite board with a cavity through the first preform and the second preform, and further realizes lightweight under the premise of ensuring bearing capacity. At the same time, since the first preform and the second preform are independent and discontinuous, the sound wave will be lost due to the truncation of the propagation medium (broken bridge structure) during the transmission process, thereby achieving the effect of sound insulation. And by arranging a sound insulation reinforcement layer at the connection between the first preform and the second preform, the propagation of sound can be further blocked, and the sound insulation performance can be improved. The present invention adopts prepreg plying to prepare the first preform and the second preform to achieve load-bearing in three-dimensional directions, avoiding the shortcomings of single fiber orientation and easy delamination of the sandwich structure under stress in the pultrusion molding process. Therefore, the sound insulation performance of the fiber-reinforced resin-based composite board of the present invention is better than that of the laminated board and the plate-rib structure composite board, and the bearing performance or mechanical performance is better than that of the sandwich board, which solves the problem that the bearing capacity, lightweight and sound insulation performance of the board, especially the body board, are difficult to be taken into account at the same time in the prior art. It has broad application prospects in the field of high-end equipment manufacturing and can create huge economic value.

[0027] The fiber-reinforced resin-based composite panels of the present invention can be used alone or in combination, and can be combined into composite panel components by stacking and laying. Since each layer of the composite panels is laid in an anisotropic manner, on the one hand, the reinforcing fibers in each layer of the composite panels can be distributed in all directions, which improves the strength of the composite panels in all directions, avoiding the problem that the fiber-reinforced composite panels in the prior art only have excellent strength properties in a certain direction. On the other hand, the first branch and the second branch that act as reinforcing ribs in each layer of the composite panels are also distributed in all directions, which further improves the strength of the composite panels in all directions. Therefore, while meeting the requirements of lightweight and good sound insulation, the strength grade of the composite panel components can be further improved as a whole, thereby improving the comprehensive performance of the product.

[0028] The preparation method of the fiber-reinforced resin-based composite board of the present invention adopts a two-step method, and the process is very simple. The first preform and the second preform are integrally formed according to a pre-designed mold, and then the first preform and the second preform are cured and formed by hot pressing. The prepared first preform and the second preform are simply assembled to obtain a hollow composite board with a cavity, which can simultaneously meet the requirements of strength, lightness and sound insulation performance. The preparation method of the present invention can greatly reduce the void ratio in the composite board, and the fibers are in a straight arrangement state. At the same thickness, its bearing performance or mechanical properties are better than those of laminated boards, plate-rib structure composite boards and pultruded hollow structure composite boards. The preparation method provided by the present invention is simple and easy to implement, and the prepared fiber-reinforced resin-based composite board has excellent performance and high production efficiency, and can quickly realize industrial production. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solution of the present invention, 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 of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0030] Figure 1 is a schematic cross-sectional view of the structure of a fiber-reinforced resin-based composite plate according to an embodiment of the present invention; Figure 2 is a schematic cross-sectional view of the structure of a first preform and a second preform according to an embodiment of the present invention; Figure 3 is a schematic structural diagram of a first preform according to an embodiment of the present invention; Figure 4 is a schematic structural diagram of a second preform according to an embodiment of the present invention; Figure 5 It is a schematic diagram of the structure of a fiber reinforced resin-based composite plate according to an embodiment of the present invention.

[0031] Figure 6 (a) is an X-ray scan of the comparison sample; Figure 6 (b) is an X-ray scan photograph of Example 11; Figure 6 (c) is an X-ray scan photograph of Example 12; Figure 6 (d) is an X-ray scan photograph of Example 13; Figure 7 This is a diagram of the straightened state of the fibers in the comparison sample; Figure 8 This is a diagram of the straightened state of the fiber in Example 11.

[0032] It should be noted that the above-mentioned drawings only capture the parts that can reflect the characteristics of the present invention, and the upper, lower, left (front), and right (rear) parts can extend or repeat the structures shown in the drawings, such as the repetition of the structures of the first branch and the second branch body, and the extension of the first panel and the second panel to the surrounding areas.

[0033] In the figure: 1: fiber reinforced resin-based composite board, 10: first preform, 20: second preform, 30: cavity, 40: sound insulation reinforcement layer, 101: first panel, 102: first branch, 103: protrusion, 201: second panel, 202: second branch, 203: groove. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solution and advantages of the technical solution of the present invention clearer, the technical solution of the embodiment of the present invention will be clearly and completely described below in conjunction with the drawings of the specific embodiments of the present invention. The same figure marks in the drawings represent the same parts. It should be noted that the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the described embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] Unless otherwise defined, the technical or scientific terms used herein shall have the common meanings understood by persons of ordinary skill in the field to which the present invention belongs. The words "first", "second" and similar words used in the patent application specification and claims of the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, words such as "one" or "an" do not necessarily indicate quantity restrictions. Words such as "include" or "comprise" mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Words such as "connect" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship also changes accordingly.

[0036] The fiber-reinforced resin-based composite plate of the present invention is suitable for devices or equipment that require strength, lightness, and sound insulation. These devices or equipment include various transportation vehicles, such as vehicles, aircraft, ships, etc., and are particularly suitable for train bodies, and have significant improvements in reducing the weight of the body and improving the sound insulation performance.

[0037] The first preform and the second preform of the present invention refer to components pre-formed by a mold. Since the present invention is a fiber-reinforced resin-based composite board, the first preform and the second preform are pre-processed using fiber-reinforced resin-based composite materials. Those skilled in the art can replace materials under the guidance of the present invention, but all should be within the scope of protection of the present invention.

[0038] The fibers referred to in the present invention include but are not limited to carbon fibers, glass fibers, aramid fibers and ultra-high molecular weight polyethylene fibers.

[0039] The sound insulation reinforcement layer of the present invention, which can also be called a sound insulation layer, a sound absorbing layer or a sound absorbing layer, is a layer structure that can reduce sound propagation or block sound. The materials used to prepare the sound insulation reinforcement layer of the present invention include but are not limited to polyurethane elastomers, polyborosiloxane elastomers, and interpenetrating network polymers.

[0040] The first panel and the second panel of the present invention refer to the panels on both sides of the larger size of the composite board, rather than the edge side of the smaller size, and are also the exposed use panels and load-bearing panels of the composite board when in use.

[0041] The first branch body and the second branch body of the present invention are protrusion structures integrally formed with the first panel and the second panel respectively, which can be strip-shaped protrusions, plate-shaped protrusions, or block-shaped protrusions, and their cross-sections can be square, triangular, trapezoidal, etc. The specific shapes of the first branch body and the second branch body can be deformed and adjusted accordingly according to the shape of the cavity. The first branch body and the second branch body are used to connect the first preform and the second preform, and also have the function of supporting and improving the strength of the composite board.

[0042] See also Figure 1 The fiber-reinforced resin-based composite panel 1 of the present invention includes a first preform 10 and a second preform 20. The first preform 10 and the second preform 20 cooperate to form a hollow structure having a cavity 30. A sound insulation reinforcement layer 40 is provided at the connection between the first preform 10 and the second preform 20. The first preform 10 includes a first panel 101 and a first branch 102 integrally formed on one side of the first panel 101 and protruding outward. The second preform 20 includes a second panel 201 and a second branch 202 integrally formed on one side of the second panel 201 and protruding outward. A sound insulation reinforcement layer 40 is provided at the matching connection between the first branch 102 and the second branch 202. The end of the first branch 102 and the end of the second branch 202 are connected by a mortise and tenon structure.

[0043] exist Figure 2 In the embodiment shown, a protrusion 103 is provided at the end of the first branch 102, and a groove 203 is provided at the end of the second branch 202 to match the protrusion 103, so as to achieve a mortise and tenon connection. Obviously, in an embodiment not shown in the figure, the protrusion 103 can also be provided at the end of the second branch 202, and the groove 203 can also be provided at the end of the first branch 102.

[0044] See also Figure 3 and Figure 4 , the first branch body 102 and the second branch body 202 extend in a straight line on the first panel 101 and the second panel 201 respectively. In an embodiment of the present invention not shown, the first branch body 102 and the second branch body 202 can also extend in a curve. In an embodiment of the present invention not shown, the first branch body 102 and the second branch body 202 can also extend in a broken line. Regardless of the linear extension, the extension direction of the first branch body 102 and the second branch body 202 remains consistent, which facilitates the coordinated installation of the two. The first branch body 102 and the second branch body 202 can be continuous or discontinuous in their extension direction.

[0045] A plurality of first branches 102 are arranged at intervals on one side of the first panel 101, and a plurality of second branches 202 are arranged at intervals on one side of the second panel 201. Two adjacent first branches 102 and two adjacent second branches 202 cooperate to form a cavity 30. A plurality of first branches 102 and a plurality of second branches 202 are arranged at intervals to form a plurality of cavities 30. Figure 1 In the illustrated embodiment, the number of the first branch bodies 102 and the second branch bodies 202 is 3, which are in an E-shape, the number of the cavities 30 is 2, and the cross-section of the cavity 30 is square. As the required size of the fiber-reinforced resin-based composite panel 1 increases, the number of the first branch bodies 102 and the second branch bodies 202 increases accordingly to 4, 5, 6, or even more, and those skilled in the art can make adaptive adjustments according to the specific application of the fiber-reinforced resin-based composite panel 1. Similarly, in other embodiments of the present invention, the cross-section of the cavity 30 can also be rectangular, circular, triangular, or trapezoidal, and as the shape of the cavity 30 changes, the first branch body 102 and the second branch body 202 also change in structure accordingly. Figure 5 As shown, the cross section of the cavity 30 is a trapezoid, and correspondingly, the cross sections of the first branch body 102 and the second branch body 202 are also trapezoid.

[0046] To adapt to different use conditions, the fiber reinforced resin-based composite panel 1 of the present invention can be a flat panel or a curved panel. The "curved surface" referred to in the present invention should be understood as a circular arc surface, a wavy surface, a free-form surface, and the like.

[0047] The fiber-reinforced resin-based composite board 1 of the present invention is prepared by laying fiber prepregs layer by layer and then forming by hot pressing. When laying, each layer of fiber prepregs is laid in a different direction, so that the fibers of each layer of the fiber-reinforced resin-based composite board 1 diverge in a cross-shaped pattern as a whole and extend in all directions, thereby improving the strength of the composite board in all directions, overcoming the problem in the prior art that the composite board has low strength in the non-extended direction of the fibers due to the fibers extending in only one direction.

[0048] The composite plate component of the present invention comprises a plurality of fiber-reinforced resin-based composite plates 1, and two adjacent fiber-reinforced resin-based composite plates 1 are laid in different directions. The present invention further distributes the fibers in all directions by stacking a plurality of fiber-reinforced resin-based composite plates 1 and laying them in different directions, thereby improving the strength of the composite plate component.

[0049] The preparation method of the fiber-reinforced resin-based composite plate of the present invention is described below with reference to examples.

[0050] Example 1 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and epoxy resin. The first preform and the second preform to be formed are laid in a pre-designed mold according to the designed laying direction and number of layers. Figure 1 The first preform 10 and the second preform 20 of the embodiment shown are in an E-shape, the cavity 30 is in a square shape, and the mold is designed according to the E-shape structure and the cavity is square. In this embodiment, the number of stacked layers of fiber prepreg is 5. After stacking, the prepreg cloth is cut to the corresponding size.

[0051] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 100 °C for 1 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 1 atm and maintained at 200°C for 0.5 h; (3) Curing stage: Continue to increase the pressure to 5 atm at 200 °C, maintain for 1 h, and then cool and solidify.

[0052] Example 2 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and polyurethane. The first preform and the second preform to be formed are laid in a pre-designed mold according to the designed laying direction and number of layers. Figure 5 The first preform 10 and the second preform 20 of the embodiment shown are in an E-shape, the cavity 30 is in a trapezoidal shape, and the mold is designed according to the E-shape structure and the cavity is in a trapezoidal shape. In this embodiment, the number of stacked layers of fiber prepreg is 10.

[0053] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 20°C for 1 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 2 atm and maintained at 100°C for 1 hour; (3) Curing stage: Continue to increase the pressure to 10 atm at 100°C, maintain for 0.5 h, and then cool and solidify.

[0054] Example 3 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and polyimide. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25.

[0055] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 50°C for 45 minutes; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 1 atm and maintained at 150°C for 0.5 h; (3) Curing stage: Continue to increase the pressure to 5 atm at 150 °C, maintain for 1 h, and then cool and solidify.

[0056] Example 4 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of aramid fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 50.

[0057] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 150°C for 0.5h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 2 atm and maintained at 300 °C for 1 h; (3) Curing stage: Continue to increase the pressure to 10 atm at 300 °C, maintain for 0.5 h, and then cool and solidify.

[0058] Example 5 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of glass fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25.

[0059] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 200 °C for 0.5 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 5 atm and maintained at 400°C for 0.5 h; (3) Curing stage: Continue to increase the pressure to 10 atm at 400 °C, maintain for 45 min, and then cool and solidify.

[0060] Example 6 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of polypropylene fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25.

[0061] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 80°C for 45 min; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 1 atm and maintained at 160°C for 1 hour; (3) Curing stage: Continue to increase the pressure to 15 atm at 160°C, maintain for 0.5 h, and then cool and solidify.

[0062] Example 7 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of polyethylene fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25.

[0063] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 100°C for 0.5h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 5 atm and maintained at 200°C for 45 min; (3) Curing stage: Continue to increase the pressure to 20 atm at 200°C, maintain for 0.5 h, and then cool and solidify.

[0064] Example 8 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber, glass fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25.

[0065] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 300 °C for 0.5 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 2 atm and maintained at 400°C for 0.5 h; (3) Curing stage: Continue to increase the pressure to 10 atm at 400 °C, maintain for 45 min, and then cool and solidify.

[0066] Example 9 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of aramid fiber, polypropylene fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25 layers.

[0067] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 100°C for 0.5h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 3 atm and maintained at 150°C for 45 min; (3) Curing stage: Continue to increase the pressure to 15 atm at 150 °C, maintain for 45 min, and then cool and solidify.

[0068] Example 10 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of aramid fiber, polypropylene fiber, polyethylene fiber and epoxy resin. In this embodiment, the fiber prepreg is preliminarily shaped to obtain the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 25 layers.

[0069] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 60°C for 0.5h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 5 atm and maintained at 120°C for 0.5 h; (3) Curing stage: Continue to increase the pressure to 20 atm at 120°C, maintain for 0.5 h, and then cool and solidify.

[0070] Embodiment 11 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 10.

[0071] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 50 °C for 1 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 1 atm and maintained at 50°C for 1 hour; (3) Curing stage: Continue to increase the pressure to 5 atm at 50°C, maintain for 0.5 h, and then cool and solidify.

[0072] Example 12 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 10.

[0073] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 50 °C for 1 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 1 atm and maintained at 120°C for 1 hour; (3) Curing stage: Continue to increase the pressure to 5 atm at 120°C, maintain for 0.5 h, and then cool and solidify.

[0074] Example 13 The method for preparing the fiber-reinforced resin-based composite plate according to the embodiment of the present invention comprises: S1. Lay the fiber prepreg layer by layer in different directions in the mold and preliminarily shape it to obtain a first preform and a second preform. The fiber prepreg of this embodiment is made of carbon fiber and epoxy resin. This embodiment preliminarily shapes the fiber prepreg and obtains the first prepreg and the second prepreg with reference to the mold of Example 1, except that the number of stacked layers of the fiber prepreg in this embodiment is 10.

[0075] S2, connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then performing hot pressing to obtain a fiber-reinforced resin-based composite plate. The hot pressing includes: (1) Melting stage: heating the first preform and the second preform at 50 °C for 1 h; (2) Impregnation stage: After the resin in the first preform and the second preform is melted, pressurized gas is introduced into the cavity to increase the pressure to 5 atm and maintained at 120°C for 1 hour; (3) Curing stage: Continue to increase the pressure to 15 atm at 120°C, maintain for 0.5 h, and then cool and solidify.

[0076] The above embodiments were subjected to X-ray scanning and compared with the existing carbon fiber epoxy resin based composite board comparison sample. In view of the length of the text, the experimental results of some preferred embodiments 11-13 of the present invention are compared with the comparison sample for explanation.

[0077] Figure 6 (a)-(d) are X-ray scans of the comparative sample, Example 11, Example 12, and Example 13, respectively. Figure 6(a) It can be seen that the control sample has significantly more pores than the embodiment of the present invention. The porosity of the control sample is measured to be over 10%, while the porosity of the embodiment of the present invention can be controlled below 1%. Since the porosity is greatly reduced, the bending strength and interlaminar shear strength of the fiber-reinforced resin-based composite plate of the embodiment of the present invention are greatly improved: the bending strength of the control sample is 820MPa, and the bending strength of the fiber-reinforced resin-based composite plate of the embodiment of the present invention can reach 1230MPa, an increase of 50%; the interlaminar shear strength of the control sample is 30MPa, and the interlaminar shear strength of the fiber-reinforced resin-based composite plate of the embodiment of the present invention can reach 39MPa, an increase of 30%. From Figure 6 (b) Figure 6 (c) and Figure 6 (d) It can be seen that with the increase of temperature and pressure, the pores in the composite plate gradually decrease, especially the increase of pressure, which has a significant improvement on the reduction of porosity, such as Figure 6 (c) and Figure 6 (d).

[0078] Figure 7 and Figure 8 The following are the straightening state diagrams of the fibers in the comparative sample and Example 11. It can be clearly seen that the comparative sample ( Figure 7 ) The fibers in the embodiment of the present invention are in a bent state and have many breaks, while the fibers in the embodiment of the present invention are straight and orderly arranged. Compared with the control sample, the tensile and bending moduli of embodiment 11 are greatly improved: the tensile and bending moduli of the control sample are 85.6 GPa and 87.2 GPa respectively, while the tensile and bending moduli of the fiber-reinforced resin-based composite plate of the embodiment of the present invention reach 91.2 GPa and 94.4 GPa respectively, which are increased by 6.5% and 8.4% respectively.

[0079] In addition, through the comparison of the sound insulation effect detection test, it was found that the weighted sound insulation value of the fiber reinforced resin-based composite panel of the embodiment of the present invention is 30dB. After further adding the sound insulation reinforcement layer, the weighted sound insulation value can reach 36dB, which is 20% higher than the control sample.

[0080] The above description is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several modifications and improvements without departing from the creative concept of the present invention, which all belong to the protection scope of the present invention.

Claims

1. A fiber-reinforced resin-based composite panel, characterized in that: The invention comprises a first preform and a second preform, wherein the first preform and the second preform cooperate to form a hollow structure having a cavity, and the first preform and the second preform are formed by fiber prepregs laid layer by layer in different directions, so that the fibers in the first preform and the second preform are distributed in different directions.

2. The fiber-reinforced resin-based composite panel according to claim 1, characterized in that: A sound insulation reinforcement layer is provided at the connection between the first preform and the second preform.

3. The fiber-reinforced resin-based composite panel according to claim 1, characterized in that: The first preform includes a first panel and a first branch body integrally formed on one side of the first panel and protruding outward, the second preform includes a second panel and a second branch body integrally formed on one side of the second panel and protruding outward, and the first panel, the first branch body, the second panel and the second branch body enclose the cavity.

4. The fiber-reinforced resin-based composite panel according to claim 3, characterized in that: The end of the first branch body and the end of the second branch body are connected by a mortise and tenon structure.

5. The fiber-reinforced resin-based composite panel according to claim 3, characterized in that: The first branch body and the second branch body extend in a straight line, a curve, or a folded line on the first panel and the second panel, respectively, and the extending directions of the first branch body and the second branch body are consistent.

6. A composite plate component, characterized in that: It comprises a plurality of fiber reinforced resin-based composite panels according to any one of claims 1 to 5, wherein two adjacent fiber reinforced resin-based composite panels are laid in different directions.

7. A method for preparing a fiber-reinforced resin-based composite board, characterized in that: include: S1, laying the fiber prepreg layer by layer in different directions in the mold and preliminarily shaping it to obtain a first preform and a second preform; S2. Connecting the cavities of the first preform and the second preform to a high-pressure gas source to apply isotropic pressure to the cavities, and then hot pressing to obtain a fiber-reinforced resin-based composite plate.

8. The method for preparing a fiber-reinforced resin-based composite panel according to claim 7, characterized in that: The hot pressing forming comprises: (1) Melting stage: heating the first preform and the second preform at 20-300° C. for 0.5-1 h; (2) Impregnation stage: after the resins in the first preform and the second preform are melted, pressurized gas is introduced into the cavity to increase the pressure to 1-5 atm and maintained at 100-400°C for 0.5-1h; (3) Curing stage: Continue to increase the pressure to 5-20atm at 100-400℃, maintain for 0.5-1h, and then cool and solidify.

9. The method for preparing a fiber-reinforced resin-based composite panel according to claim 7 or 8, characterized in that: The fiber prepreg has 5 to 50 layers of plies.

10. The method for preparing a fiber-reinforced resin-based composite panel according to claim 7 or 8, characterized in that: The reinforcing fibers of the fiber prepreg are one or more combinations of carbon fibers, aramid fibers, glass fibers, polypropylene fibers and polyethylene fibers; and the resin of the fiber prepreg is epoxy resin, polyurethane or polyimide.

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