Ultra-large-span full-composite hatch cover plate and preparation method thereof

Abstract

The invention relates to the technical field of ship composite material structures and forming, and provides a super-large-span full-composite material hatch cover plate and a preparation method thereof. The hatch cover plate comprises a lower panel, a middle layer, an upper panel and an external connecting structure; the lower panel is attached to the upper panel through the middle layer to form a hatch cover plate body, the two ends of the hatch cover plate body are connected with an external connecting structure respectively, the hatch cover plate body is rapidly and conveniently connected with the external structure through the method that the main beam and the lattice structure are combined, and the force transmission supporting effect is achieved. The preparation method of the hatch cover plate comprises the following steps: step 1, forming the lower panel; 2, preparing an intermediate layer; step 3, paving an upper panel; fourthly, the main beam is connected with an external structure; pouring according to a vacuum integral forming process to obtain the required hatch cover plate; by means of the method, the span not smaller than 5 meters can be achieved, deformation is smaller than 2 mm under the self-weight working condition, and the hatch cover plate has the advantages of being light, high in strength, high in rigidity, designable in lattice structure, low in manufacturing cost, high in forming rate, low in process risk and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of ship composite material structures and forming technologies, and more particularly, to an extra-large span all-composite hatch cover and a preparation method thereof. Background Art

[0002] Currently, in the design of ship devices, composite materials are highly favored due to their excellent high specific stiffness, specific strength, etc. For underwater ships, their hatch covers need to meet various working conditions such as opening and closing, hoisting, etc. underwater or on the water surface. In the past, most hatch covers were made of metal structures, which were relatively heavy and required more connecting arms, hydraulic devices and other connecting structures in the middle to ensure that the structural strength meets the usage requirements of each working condition. On the one hand, the structural connection is relatively complex and the cost is high; on the other hand, it results in a relatively heavy overall structure and occupies a large amount of weight margin of underwater ships. Nowadays, the ship field is developing towards lightweight and diversified directions. The extra-large span all-composite hatch cover can, on the one hand, reduce the weight of the hatch cover and lower the center of gravity of the ship; on the other hand, the extra-large span reduces internal mechanical connections, saves space, and the internal sandwich functional core material can also perform various functional designs while providing buoyancy.

[0003] In order to better save ship energy consumption, reduce the connecting arms or hydraulic devices connecting the midship and the hatch cover, reduce the overall weight, save equipment space and many other problems, it is particularly important to carry out the research on the manufacture of extra-large span size composite hatch covers. The lattice-reinforced sandwich composite material integrates the respective advantages of traditional foam sandwich composite materials and composite material lattices, not only retaining the advantages of traditional foam sandwich composite materials such as lower density, higher strength, higher modulus, etc., but also giving full play to the excellent mechanical properties of the composite material lattice, that is: on the premise of a slightly increased overall density, the mechanical properties such as lightweight, high strength, high stiffness, flat compression, side compression, bending, shear, impact resistance, etc. of the lattice-reinforced foam sandwich composite material are significantly improved. Therefore, introducing the lattice-reinforced sandwich composite material into the extra-large span composite hatch cover and applying the effective connection and smooth transition between the lattice-reinforced foam sandwich composite material and the structure of the extra-large span all-composite hatch cover is an effective way to solve the above problems.

[0004] In recent years, there have been many research achievements in the design and manufacture of hatch covers. The invention patent "Method for integrally forming a composite material hatch door and a composite material hatch door" (Application No.: CN20211193040.9) proposes a method for integrally forming a composite material hatch door. The invention patent "Optimized design method for a self-locking composite material pre-deformed hatch door structure of an aircraft" (Application No.: CN201610464009.7) proposes a manufacturing process for preventing deformation in advance of a composite hatch door of an aircraft through self-locking. The invention patent "Manufacturing method for a composite material integrated shelter hatch door" (Application No.: CN202311534535.2) proposes a manufacturing method for a composite material integrated pouring and forming shelter hatch door. The invention patent "Composite material hatch door for an underwater protective cover, underwater protective cover and preparation method thereof" (Application No.: CN202310767455.5) provides a preparation method for a composite material hatch door of an underwater protective cover. The invention patent "Machine forming method for a composite material lattice sandwich structure hatch door" (Application No.: CN202311726754.0) proposes a composite material lattice sandwich structure hatch door and its forming method. The above cases mainly involve forming and manufacturing methods such as integrally formed composite material hatch doors, pre-deformation of self-locking composite material hatch doors of aircraft, composite material shelter hatch doors, composite material hatch doors for underwater protective covers, and composite material lattice sandwich structures. None of them involve the structure of a super-large-span all-composite material hatch cover plate and its preparation method. Even in the patent CN115257123A, a lightweight and high-strength composite plate and its preparation method are disclosed, which are applied to the forming technology field of composite plates. The structure of the composite plate has three layers: upper, middle, and lower. The upper and lower layers are the upper skin and the lower skin respectively, and the middle layer is a honeycomb-like structure, which is composed of multiple small pieces connected together; the shape of the small pieces is not limited, and each small piece has a foam core material in the middle and is wrapped with a layer of carbon yarn or fiber cloth. The foam core material and the carbon yarn or fiber cloth are tightly bonded by hot pressing. Through the setting of the plate and its preparation method, it is easy to prepare large-sized special-shaped products. The products are lightweight and high-strength, and the manufacturing cycle is shortened. However, due to its relatively complex preparation method, it is easy to cause the problem of high cost. Moreover, the core material prepared by heating and foaming molding is likely to result in low uniformity and tightness among the molecules inside the plate, thereby affecting the quality of the plate. In addition, the setting of this kind of plate structure cannot achieve the application of super-large span.

[0005] As one of the new types of ship composite hatch covers, when designing a super-large-span hatch cover, on the one hand, its weight and mechanical properties need to be fully considered; on the other hand, the connecting arms or hydraulic devices for connecting the ship's midship and the hatch cover also need to be considered. At present, there is no report on the structure and preparation method of super-large-span all-composite hatch covers in the publicly available domestic and foreign literature and patents. Therefore, it is of great significance to study how to prepare super-large-span hatch covers while improving the mechanical properties of the hatch covers, reducing the connecting arms or hydraulic devices for connecting the midship and the hatch cover, reducing the overall weight, saving equipment space, and thus saving the ship's energy consumption. Summary of the Invention

[0006] In view of this, the present invention relates to a super-large-span all-composite hatch cover structure and its preparation method, mainly solving the problem that there is currently no design and preparation method for super-large-span all-composite cover structures. The structure design method of the present invention can achieve a span of not less than 5 meters, with a deformation of less than 2 mm under its own weight condition, and has the characteristics of light weight, high strength, and high stiffness. At the same time, it can effectively reduce the connecting arms or hydraulic devices for connecting the ship's midship and the hatch cover, reduce the overall weight, effectively save space, and reduce costs. This preparation method can solve the overall stability and quality consistency of the sandwich preform during the forming process of the lattice-reinforced sandwich composite material, and has the characteristics of low manufacturing cost, high forming efficiency, low process risk, and stable quality.

[0007] To achieve the above object, the technical solution of the present invention is realized as follows:

[0008] The present invention relates to a super-large-span all-composite hatch cover and its preparation method. The super-large-span all-composite hatch cover has a span of ≥5 m for the hatch cover, and the deformation amount under the self-weight condition of the hatch cover is <2 mm. The hatch cover includes a lower panel, an intermediate layer, an upper panel, and an external connection structure; the lower panel is attached to the upper panel through the intermediate layer to form the main body of the hatch cover, and both ends of the main body of the hatch cover are respectively connected to the external connection structure; the intermediate layer includes a fiber component, a lattice, and a core material component; the bottom of the lattice is attached to the top of the lower panel through the fiber component, and the outer side walls of the upper ends of the lattice are respectively attached to the bottom of the upper panel and the outer side walls of the core material component through the fiber component, and both ends of the core material component are respectively attached to the lower panel and the upper panel.

[0009] Further, the fiber component is a dry fiber cloth or a prepreg fiber fabric; the materials of the upper panel and the lower panel are any one or more of glass fiber, carbon fiber, carbon / glass hybrid fiber, quartz fiber, Kevler fiber, ultra-high molecular weight polyethylene fiber, and PBO fiber fabric.

[0010] Further, the fiber assembly includes a first fiber assembly and a second fiber assembly; the bottom sides of the first fiber assembly and the core material assembly are both arranged on the top of the lower panel, the top side of the first fiber assembly is connected to the lattice; the bottom of the second fiber assembly is conformally arranged at the upper end of the lattice; the top sides of the second fiber assembly are respectively attached to the bottom of the upper panel and the outer side wall of the core material assembly.

[0011] Further, the lattice includes a lattice core material and a main beam core material; the lattice core material and the main beam core material are arranged alternately; the bottom and top of the lattice core material and the main beam core material are respectively attached to the first fiber assembly and the second fiber assembly, and the outer side walls of the lattice core material and the main beam core material are attached to the outer side wall of the core material assembly through the second fiber assembly.

[0012] Further, there are 2N + 1 lattice core materials and M main beam core materials, where N and M are both positive integers, and N ≥ 1, M ≥ 1.

[0013] Further, the lattice further includes precast blocks, and both ends of the main beam core material are respectively connected to the external connection structure through the precast blocks.

[0014] Further, the materials of the lattice core material and the main beam core material are any one or more of PVC, PET, and buoyancy materials.

[0015] Further, the material of the core material assembly is a foaming material or a buoyancy material.

[0016] A preparation method for an extra-large span all-composite cabin cover plate, which is applied to prepare the above-mentioned extra-large span all-composite cabin cover plate, and the method includes the following steps:

[0017] Step 1. Lower panel forming: According to the specifications and dimensions of the required lower panel, select the type, number of layers, and laying method of the reinforcing fiber fabric for preparing the lower panel, and prepare the formed lower panel by means of spray adhesive setting.

[0018] Step 2. Preparation of the intermediate layer: Determine the setting method and position of the fiber assembly, the lattice, and the core material assembly. After assembling the fiber assembly, the lattice, and the core material assembly, obtain the intermediate layer.

[0019] Step 3. Laying of the upper panel: Lay at least one layer of the required fiber fabric for the upper panel on the top of the lattice filled with the core material assembly to obtain the upper panel.

[0020] Step 4. Integral forming: Process according to the VARI forming process to obtain the integrally formed cabin cover plate.

[0021] Further, Step 2 includes:

[0022] Step S21: According to the configuration of the lattice and the setting of the main beam structure, process the shapes and dimensions of the fiber assembly, the lattice core material, and the main beam core material respectively.

[0023] Step S22: Lay the fiber one component in the processing fiber component on the mold according to the configuration of the lattice, and bond the lattice core material and the main beam core material with adhesive applied to the bottom on the fiber one component;

[0024] Step S23: Laying of the fiber two component: Select the laying layer number of the fiber two component according to the setting of the lattice, and alternately lay the fiber two component in the up and down directions at the upper end of the lattice to form a composite material lattice;

[0025] Step S24: Processing of the core component: Process the shape and size of the core component according to the configuration setting requirements of the lattice;

[0026] Step S25: Filling of the core component: Spray an appropriate amount of spray adhesive on the top side of the prepared composite material lattice, and place the processed core component as a whole steadily on the upper side of the laid fiber two component, thereby forming a composite material lattice structure filled with the core material.

[0027] Compared with the prior art, the super-large-span all-composite cabin cover and its preparation method of the present invention have the following beneficial effects:

[0028] Through the setting of the cabin cover and its preparation method, it mainly includes two key processes: the structure setting of the super-large-span cabin cover and the forming of the lattice-reinforced sandwich composite material. It can simplify the overall structure of the cabin cover, realize the preparation of the super-large-span cabin cover, optimize the preparation method of the cabin cover, reduce the preparation cost of the cabin cover, improve the tightness and uniformity of the internal molecules of the prepared cabin cover, ensure the quality of the cabin cover, reduce the internal mechanical connection of the cabin cover, save the space inside the middle of the ship cabin cover, reduce the weight of the cabin cover, realize the lightweight and diversified setting of the cabin cover; and further realize the saving of energy consumption during the operation of the ship. In addition, it can also achieve a span of not less than 5 meters and a deformation of less than 2 mm under the self-weight condition, making the cabin cover have the characteristics of super-large span, light weight, high strength, high stiffness, lattice structure designable, low manufacturing cost, high forming efficiency, and low process risk, etc., and is easy to realize production and popularization and application. The super-large-span all-composite cabin cover structure and its preparation method can be widely applied to fields such as ships, aerospace, etc., and can be quickly and conveniently connected to the external structure through the method of combining the main beam and the lattice structure, and has a broad application prospect. Description of the Drawings

[0029] The attached drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0030] Figure 1 It is a schematic diagram of the forming structure of the lower panel;

[0031] Figure 2a Schematic diagram of the cross-sectional shape of the structure core material

[0032] Figure 2b Schematic diagram of the cross-sectional shape of the main beam core material

[0033] Figure 2c Schematic diagram of the cross-sectional shape of the lattice filling core material assembly

[0034] Figure 3 Schematic diagram of the lattice integral structure assembly

[0035] Figure 4a Schematic diagrams of the radial, chordal and cross-laying methods in the lattice laying

[0036] Figure 4b Schematic diagram of the circumferential laying method in the lattice laying

[0037] Figure 5 Schematic diagram of the overall structure of the lattice reinforced sandwich composite preform

[0038] Figure 6a Schematic diagram of the self-weight deformation simulation under the self-weight condition of the hatch cover

[0039] Figure 6b Schematic diagrams of the ultimate tensile and ultimate compressive simulations under the self-weight condition of the hatch cover

[0040] Figure 6c Schematic diagram of the self-weight plus deformation simulation under the condition of adding load to the hatch cover

[0041] Figure 6d Schematic diagrams of the ultimate tensile and ultimate compressive simulations under the condition of adding load to the hatch cover

[0042] Explanation of reference numerals: 1, lower panel; 2, intermediate layer; 20, fiber assembly; 201, fiber one assembly; 202, fiber two assembly; 202a, fiber one piece; 202b, fiber two pieces; 202c, fiber three pieces; 202d, fiber four pieces; 202e, fiber five pieces; 202f, fiber six pieces; 202g, fiber seven pieces; 21, lattice; 211, structure core material; 212, main beam core material; 2121, precast block; 22, core material assembly; 3, upper panel; 4, mold; 5, external connection structure Detailed implementation manners

[0043] The following will describe the inventive concepts of the present disclosure using the terms that those skilled in the art would typically use to convey the substance of their work to other skilled persons in the art. However, these inventive concepts may be embodied in many different forms and should not be considered limited to the embodiments described herein

[0044] It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other.

[0045] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0046] The present invention will be described in detail below with reference to the drawings and in combination with embodiments.

[0047] In order to solve the problems existing in the prior art that the method for preparing plates is relatively complex and the cost is relatively high, and the core material prepared by heating and foaming molding is likely to cause relatively low uniformity and compactness among molecules in the plate, thereby affecting the quality of the plate; this embodiment proposes an ultra-large-span all-composite cabin cover plate and its preparation method. The span of the ultra-large-span all-composite cabin cover plate is ≥5 m, and the deformation amount under the self-weight condition of the cabin cover plate is <2 mm. The cabin cover plate includes a lower panel 1, an intermediate layer 2, an upper panel 3, and an external connection structure 5. The lower panel 1 is attached to the upper panel 3 through the intermediate layer 2 to form the main body of the cabin cover plate, and both ends of the main body of the cabin cover plate are respectively connected to the external connection structure 5. The intermediate layer 2 includes a fiber assembly 20, a lattice 21, and a core material assembly 22. The bottom of the lattice 21 is attached to the top of the lower panel 1 through the fiber assembly 20, and the outer side walls of the upper ends of the lattice 21 are respectively attached to the bottom of the upper panel 3 and the outer side walls of the core material assembly 22 through the fiber assembly 20. Both ends of the core material assembly 22 are respectively attached to the lower panel 1 and the upper panel 3. Among them, the fiber assembly 20 is a dry fiber cloth or a prepreg fiber fabric. In this embodiment, the outer side wall refers to the side wall composed of the front, rear, left, and right four side faces of the component. The materials of the upper panel 3 and the lower panel 1 are any one or more of glass fiber, carbon fiber, carbon / glass hybrid fiber, quartz fiber, Kevler fiber, ultra-high molecular weight polyethylene fiber, and PBO fiber fabric. The areal density of both the upper panel 3 and the lower panel 1 is ≥100 g / m 2 ; the thickness, ply lay-up method, and type of fiber fabric used for the upper panel 3 and the lower panel 1 can be the same or different.

[0048] Through the setting of the cabin cover plate, the overall structure of the cabin cover plate can be simplified, the preparation of the ultra-large-span cabin cover plate can be realized, the preparation method of the cabin cover plate can be optimized, the preparation cost of the cabin cover plate can be reduced, the compactness and uniformity among molecules inside the prepared cabin cover plate can be improved, the quality of the cabin cover plate can be guaranteed, and the weight of the cabin cover plate can be reduced; thereby achieving energy consumption savings during the operation of the ship.

[0049] The fiber assembly 20 includes a fiber assembly 201 and a fiber assembly 202. The bottom sides of the fiber assembly 201 and the core material assembly 22 are both arranged on the top of the lower panel 1, and the top side of the fiber assembly 201 is connected to the bottom of the lattice 21. The fiber assembly 201 is strip-shaped, and the width of the fiber assembly 201 is consistent with the bottom width of the lattice 21. At least 2N fiber assemblies 201 are arranged, and N is a positive integer. The specific number of strips is set as required. The N fiber assemblies 201 are arranged parallel to each other. The N fiber assemblies 201 and the other N fiber assemblies 201 are arranged vertically on the top of the lower panel 1. The bottom of the fiber assembly 202 is arranged at the upper end of the lattice 21 in a conformal manner. Specifically, the bottom side of the fiber assembly 202 is respectively fitted with the top, left end, right end, front end, and rear end of the lattice 21. The top side of the fiber assembly 202 is respectively fitted with the bottom of the upper panel 3 and the outer side wall of the core material assembly 22. The two ends of the fiber component 1 201 abut against the two ends of the fiber component 202 to form a fiber full wrapping of the lattice 21, so as to enhance the structural strength of the hatch cover.

[0050] The fiber fabric used in the fiber component 201 is any one or more of glass fiber, carbon fiber, carbon / glass hybrid fiber, quartz fiber, Kevler fiber, ultra-high molecular weight polyethylene fiber, and PBO fiber. The surface density of the fiber component 201 is ≥100g / m 2 The second fiber component 202 is a dry fiber cloth or prepreg for the composite lattice 21. The fiber fabric type of the second fiber component 202 can be the same as or different from the fiber fabric type of the upper panel 3 or the lower panel 1.

[0051] By setting the fiber component 1 201 and the fiber component 202, which are respectively set on both sides of the lattice 21, on the one hand, the relative stability between the lattice 21 and the lower panel 1 can be improved to avoid the problem of position misalignment when filling the core material component 22 into the grid in the lattice 21. On the other hand, the filling density between the filled core material component 22 and the lattice 21 can be improved. By setting the fiber component 202, the friction between the core material component 22 and the lattice 21 can be improved, and the tightness of the fit between the core material component 22 and the lattice 21 can be achieved, thereby improving the strength and rigidity between the components in the hatch cover.

[0052] The second fiber assembly 202 includes long fiber sheets and short fiber sheets. The long fiber sheets and short fiber sheets are alternately laid on the upper end of the lattice 21 to enhance the strength and rigidity of the lattice 21.

[0053] The lattice 21 includes a lattice core material 211 and a main beam core material 212. The lattice core material 211 and the main beam core material 212 are arranged alternately. The bottom and top of the lattice core material 211 and the main beam core material 212 are respectively attached to the first fiber assembly 201 and the second fiber assembly 202, and the outer side walls of the lattice core material 211 and the main beam core material 212 are attached to the outer side wall of the core material assembly 22 through the second fiber assembly 202. Among them, there are 2N + 1 lattice core materials 211 and M main beam core materials 212, where N and M are both positive integers, and N≥1, M≥1. The 2N + 1 lattice core materials 211 are perpendicular or parallel to each other. The lattice core materials 211 are arranged on the top of the lower panel 1 in the front-rear direction or the left-right direction through the first fiber assembly 201. The M main beam core materials 212 are arranged in the left-right direction and are respectively connected to the lattice core materials 211 and the first fiber assembly 201. Specifically, the 2N + 1 lattice core materials 211 and the M main beam core materials 212 are arranged alternately to form grids of different sizes distributed in a matrix. The materials of the lattice core material 211 and the main beam core material 212 are any one or more lightweight materials among PVC, PET, and buoyancy materials. The characteristics of this lightweight material are relatively high compression hardness and low density. From the perspective of composite material structure design, the cross-sections of the lattice core material 211, the main beam core material 212, and the core material assembly 22 are all n-sided polygons, where n is a positive integer and n≥3. Preferably, the cross-sections of the lattice core material 211, the main beam core material 212, and the core material assembly 22 can adopt any one or more simple geometric shapes such as rectangles, trapezoids, and triangles.

[0054] In this embodiment, the lattice 21 is composed of 2N + 1 lattice core materials 211 and 1 main beam core material 212. Among them, the lattice core material 211 is arranged with a trapezoidal cross-section structure, the main beam core material 212 is arranged with a hexagonal cross-section structure, and the core material assembly 22 is arranged with a trapezoidal cross-section structure. The machining tolerances of the lattice core material 211 and the main beam core material 212 are respectively ±2mm. The shapes and sizes of the 2N + 1 lattice core materials 211 are the same. In addition, the length value ranges of the lattice core material 211 and the main beam core material 212 are both 1500mm - 6000mm. The length value range of the core material assembly 22 is 500 - 1000mm. A cross-shaped intersection or a T-shaped intersection area is formed at the intersection of the lattice core material 211 and the main beam core material 212. The long fiber sheets and the short fiber sheets in the second fiber assembly 202 are arranged on the arms of the cross-shaped intersection or the T-shaped intersection area in an alternating laying manner. It is used to improve the tightness of the connection between the lattice core material 211 and the main beam core material 212.

[0055] Through the distributed arrangement of the structure core material 211 and the main beam core material 212, the rapid installation of the lattice 21 can be realized, and the manufacturing cost of the lattice 21 can also be reduced. By cooperating with the fiber assembly 20, the structural stability of the lattice 21 can be greatly improved. In addition, through the staggered arrangement of the structure core material 211 and the main beam core material 212, the realization of a cabin cover plate with a span of 5 meters can be achieved. Combining with the laying structure of the fiber one assembly 201 and the fiber two assembly 202, the deformation of the main beam core material 212 under its own weight condition can be less than 2 mm, improving the safety and reliability of the overall structure of the cabin cover plate. In addition, through the method of combining the main beam core material 212 and the lattice 21 structure, it can be quickly and conveniently connected to the external connection structure 5, and can also play a role in force transmission and support.

[0056] The lattice 21 further includes a precast block 2121. The two ends of the main beam core material 212 are respectively connected to the external connection structure 5 through the precast block 2121. The lattice 21 further includes a bolt. One end of the bolt is arranged on the precast block 2121, and the other end of the bolt is connected to the external connection structure 5.

[0057] Through the arrangement of the precast block 2121, the fixation between the main beam core material 212 and the external connection structure 5 can be facilitated, and the pre-burial setting of the bolt can also be facilitated, reducing the difficulty of the manufacturing process of the cabin cover plate, improving the manufacturing efficiency of the cabin cover plate, and realizing the preparation of a full-composite cabin cover plate with an ultra-large span.

[0058] The core material assembly 22 is arranged in the lattice inside the lattice 21. Preferably, the material of the core material assembly 22 is a foaming material or a buoyancy material. The foaming material includes any one or more of polyvinyl chloride (PVC), glass microspheres, polymethacrylimide (PMI), polyethylene terephthalate (PET), and polyurethane (PU). When the core material assembly 22 is a foaming material, the density of the core material assembly 22 ≤ 300 kg / m 3 ± 20 kg / m 3 . When the core material assembly 22 is a buoyancy material, the density value range of the core material assembly 22 is 380 kg / m 3 ± 20 kg / m 3 -500 kg / m 3 ± 20 kg / m 3 . When the length of the core material assembly 22 is too long, it can be processed by splicing. The geometric shape of the cross-section of the core material assembly 22 is set as required.

[0059] By providing the core component 22 made of foaming material or buoyancy material, the usage amount of high-cost fibers can be reduced, the processing rate of the core component 22 can be increased, and the noise reduction and vibration damping functions of the hatch cover plate can be enhanced. It can also prevent the fiber layer from buckling and maintain the stability of the structural shape. Moreover, it can absorb energy through plastic deformation and disperse impact stress.

[0060] A method for preparing an extra-large-span all-composite hatch cover plate, which is applied to prepare the above-mentioned extra-large-span all-composite hatch cover plate. The method includes the following steps:

[0061] Step 1: Molding the lower panel 1: According to the specifications and dimensions of the required lower panel 1, select the type, number of layers, and laying method of the reinforcing fiber fabric for preparing the lower panel 1, and prepare the molded lower panel 1 through the method of spray gluing and shaping.

[0062] Step 2: Preparation of the intermediate layer 2: Determine the setting method and position of the fiber component 20, the lattice 21, and the core component 22. After assembling the fiber component 20, the lattice 21, and the core component 22, obtain the intermediate layer 2;

[0063] Step 3: Laying the upper panel 3: Lay at least one layer of the required fiber fabric of the upper panel 3 on the top of the lattice 21 filled with the core component 22 to obtain the upper panel 3;

[0064] Step 4: Integral molding: After connecting the main beam core 212 with the external connection structure 5; perform vacuum integral molding process perfusion according to the VARI molding process, and obtain the required hatch cover plate of integral molding. Among them, the VARI molding process is the vacuum-assisted resin infusion integral molding process.

[0065] Through the setting of the above method, the problem that there is currently no structural design and preparation method for extra-large-span all-composite cover plates can be solved. A hatch cover plate with a span of not less than 5 meters can be realized, and the deformation of the hatch cover plate under its own weight condition can be less than 2 mm. The method mainly includes two key processes: the structural setting of the extra-large-span hatch cover plate and the molding of the lattice-reinforced sandwich composite material. It can also make the hatch cover plate have the characteristics of extra-large span, light weight, high strength, high stiffness, flexible setting of the lattice 21 structure, low manufacturing cost, high molding efficiency, low process risk, and stable quality. It can effectively reduce the connecting arms or hydraulic devices connecting the ship's midship and the hatch cover plate, reduce the overall weight, effectively save space, and thus reduce costs; it can also solve the problems of the overall stability and quality consistency of the sandwich preform during the molding process of the lattice 21-reinforced sandwich composite material. It is easy to realize production and popularization and application. The structure of the extra-large-span all-composite hatch cover plate and its preparation method can be widely applied in the fields of ships, aerospace, etc., and can be quickly and conveniently connected with external structures through the method of combining the main beam and the lattice 21 structure, and has broad application prospects.

[0066] Step 1 includes:

[0067] Step S11: Molding the lower panel 1: According to the target thickness of the required lower panel 1 and the type of selected reinforcing fiber fabric, determine the preparation specifications and dimensions of the lower panel 1; and select the type, number of layers, and laying method of the reinforcing fiber fabric required for preparing the lower panel 1.

[0068] Step S12: After drying and pre-treating the selected reinforcing fiber fabric, lay it according to the requirements of fiber placement.

[0069] Step S13: During laying, place the whole roll of fiber on the cloth rack for laying, and by means of spray gluing and shaping, evenly spray the spray glue on the fiber fabrics of different layers, and cut the fiber fabric to the required size.

[0070] Step S14: After injecting glue into the cut fiber fabric, cure and mold it to prepare the formed lower panel 1.

[0071] Among them, in step S12, the requirements for fiber placement are that the cloth layers are flat without obvious wrinkles or bubbles. The size of the fiber fabric > the planar area of the target size required for the lower panel 1, and the planar area is the area in the length and width directions of the lower panel 1, which is used to facilitate improving the laying efficiency of fiber fabrics of different layers. After complete laying, cut it to obtain the lower panel 1 of the required target size, which is not only beneficial for preparing the lower panel 1 by subsequent glue injection and curing, but also beneficial for realizing the rapid preparation of the lower panel 1.

[0072] Through the settings of each step in Step 1, the efficiency and quality of the molding of the lower panel 1 can be improved. By pre-drying the fiber fabric in step S12, it can prevent the influence on its mechanical properties during the later fusion and curing with the resin. In step S13, due to the large laying area, when spray gluing and shaping, it is necessary to ensure the uniformity of spraying. In addition, placing the whole roll of fiber on the cloth rack for laying is beneficial for avoiding fiber twisting, thereby improving the quality of the lower panel 1. It can also prevent the phenomenon that affects the layout position of the lattice 21 when establishing a vacuum during subsequent molding perfusion.

[0073] Through the preparation settings of the lower panel 1 in Step 1, it can play a role in improving the strength, rigidity, and impact resistance of the cabin cover plate. It can also enhance the ability of the cabin cover plate to resist external impacts and local damages, improve the bending and torsional stiffness of the overall structure of the cabin cover plate, and inhibit low-frequency vibrations.

[0074] Step 2 includes:

[0075] Step S21: Through the previous structural settings of the required cabin cover plate, process the shapes and sizes of the fiber components 20, the lattice core 211, and the main beam core 212 according to the configuration of the lattice 21 and the settings of the main beam structure.

[0076] Step S22: Lay the fiber component 201 in the processing fiber component 20 on the mold 4 according to the configuration of the lattice 21, and bond the lattice core material 211 and the main beam core material 212 with adhesive applied to the bottom on the fiber component 201;

[0077] Step S23: Laying of the fiber component 202: According to the laying layers of the fiber component 202 set in the lattice 21, lay the fiber component 202 alternately in the up and down directions at the upper end of the lattice 21 to form a composite material lattice 21.

[0078] Step S24: Processing of the core component 22: Process the shape and size of the core component 22 according to the configuration requirements of the lattice 21, especially the size of the grids within the lattice 21;

[0079] Step S25: Filling of the core component 22: Sprinkle an appropriate amount of spray adhesive on the top side of the prepared composite material lattice 21, and gently and steadily place the processed core component 22 as a whole into the grids inside the lattice 21 on the upper side of the lower panel 1, so as to fill the processed core component 22 into the prefabricated composite material lattice 21, thereby forming a composite material lattice 21 structure filled with a core material. Among them, place the composite material lattice 21 structure filled with a core material as a whole gently and steadily on the laid fiber cloth, that is, the fiber component 201. After the laying is completed, fill the gaps with fiber filaments to ensure that there are no gaps between the filled lattice 21 and the core component 22, so as to more precisely control the perfusion quality.

[0080] By cooperating with the setting of the super-large-span cabin cover structure, this key process of forming the lattice 21 reinforced sandwich composite material in Step 2 can, on the one hand, improve the stability and reliability of the overall structure of the cabin cover. On the other hand, through the setting of the lattice 21 reinforced sandwich composite material forming, it can ensure the intermolecular compactness of the cabin cover, and can also avoid the problem of excessive rigidity easily caused by materials with a single fiber fabric composition. Through the setting of the foam core component 22, it can absorb energy through plastic deformation, disperse impact stress, and also because the core component 22 has the characteristics of low density and light weight, therefore, the setting of the lattice 21 reinforced sandwich composite material forming is beneficial to reducing the cost of the cabin cover, reducing the weight of the cabin cover, and enhancing the anti-impact ability and energy absorption ability of the cabin cover. In addition, the cooperation of the core component 22 and the lattice 21 component is also beneficial to reducing high-frequency vibration and noise and suppressing low-frequency vibration.

[0081] Among them, in step S22, the bottom of the lattice core material 211 and the main beam core material 212 is coated with adhesive in whole or in part. This is used to prevent the assembly position of the lattice core material 211 and the main beam core material 212 from changing with respect to each component, enabling the lattice core material 211 and the main beam core material 212 to be stably bonded to the mold 4. Preferably, in step S22, adjacent different lattice core materials 211 are arranged in parallel. The main beam core material 212 includes precast blocks 2121, which are arranged at both ends of the main beam core material 212. The main beam core material 212 is connected to the external connection structure 5 on the mold 4 by bolts. Among them, the composite precast block 2121 structure is a protruding part of the main beam core material 212. In step S23, at the cross position of the connection points between the lattice core material 211 and the main beam core material 212 within the lattice 21, a conforming winding layup from the upper side to the lower side and an alternating layup from the lower side to the upper side are carried out, which serves to strengthen the lattice 21.

[0082] Through the action of the bolts, the connection tightness between the precast block 2121 and the external connection structure 5 can be improved, thereby realizing the stability of the connection between the main beam core material 212 and the mold 4. It can also obtain a structural layout with mechanical characteristics such as high strength and high stiffness through the main beam force transmission structure.

[0083] Step S23 includes:

[0084] Step S231: According to the shape of the intersection of the lattice core material 211 and the main beam core material 212 within the lattice 21, cut the fiber two-component 202 with the required size to obtain a long fiber sheet and a short fiber sheet;

[0085] Step S232: First, lay the long fiber sheet along the chord direction of the intersection of the lattice core material 211 and the main beam core material 212, and lay the short fiber sheet along the radial direction of the intersection of the lattice core material 211 and the main beam core material 212; among them, according to whether the intersection of the lattice core material 211 and the main beam core material 212 is cross-shaped or T-shaped, two or one short fiber sheet is set.

[0086] Step S233: Then adjust the laying direction, lay the long fiber sheet along the radial direction of the intersection of the lattice core material 211 and the main beam core material 212, and lay the short fiber sheet along the chord direction of the intersection of the lattice core material 211 and the main beam core material 212; according to whether the intersection of the lattice core material 211 and the main beam core material 212 is cross-shaped or T-shaped, two or one short fiber sheet is still set.

[0087] Step S234: Determine whether the long fiber sheet has been laid. If yes, execute step S24; if not, return to step S232. Among them, the radial direction is the left-right direction as shown in the figure, and the chord direction is the front-back direction as shown in the figure.

[0088] By selectively laying the fiber two-component 202 according to the shape of the intersection of the structure core material 211 and the main beam core material 212, the structural stability of the lattice 21 can be effectively improved, and the strength and stiffness of the intersection of the structure core material 211 and the main beam core material 212 in the lattice 21 can also be enhanced. It is possible to reduce the internal mechanical connections of the hatch cover plate, save the space on the inner side of the middle part of the ship's hatch cover plate, and thus prepare for the lightweight and diversification of the hatch cover plate.

[0089] Step four includes: integral molding: after connecting the main beam core material 212 with the external connection structure 5; performing vacuum integral molding process perfusion according to the VARI molding process, arranging the release cloth and the flow guiding net in sequence, setting the glue injection pipeline, the glue outlet and the glue injection port, and after evacuating with the vacuum bag film, the glue injection is completed, cured and demolded to obtain the integrally molded hatch cover plate.

[0090] Among them, in step four, the curing temperature is normal temperature and the curing time is 48h.

[0091] Through the coordinated setting of step four and steps one, two, and three, on the one hand, by the method of combining the hatch cover plate with a span of not less than 5 meters, the main beam core material 212 with a self-weight deformation of 2 mm and the lattice 21 sandwich composite material proposed in this application, the effective and stable transfer of the external structure and the self-weight load can be achieved, providing a reliable solution for the structural strength and weight problems of the super-large-span composite material hatch cover plate. On the other hand, through the research and development of the super-large-span hatch cover plate structure, the connecting arms or hydraulic devices connecting the ship's midship and the hatch cover plate can be effectively reduced, the overall weight can be reduced, the space can be effectively saved, and the cost can be reduced. In addition, it can also solve problems such as the overall stability and quality consistency of the sandwich preform during the forming process of the lattice 21 reinforced sandwich composite material, and has the characteristics of low manufacturing cost, high forming efficiency, low process risk, and stable quality, laying the conditions for mass production and application.

[0092] Example 1:

[0093] When a single main beam core material 212 is set in the lattice 21, it is a lattice 21 reinforced sandwich composite material with an isosceles trapezoid cross-section as the minimum repeating unit of the lattice 21. Among them, the dimensions of the isosceles trapezoid are 41.3 mm for the upper base, 60 mm for the lower base, and 53 mm for the height. The dimensions of the main beam core material 212 are 90 mm for the upper base, 164 mm for the lower base, and 134 mm for the height. The length of the upper panel 3 is 5750 mm, and the length of the lower panel 1 is 5900 mm. The widths and thicknesses of the upper panel 3 and the lower panel 1 are the same, which are 1500 mm and 3.5 mm respectively; the length and thickness of the lattice 21 are 5750 mm and 5 mm respectively; the cross-section of the strip core component 22 is an isosceles trapezoid, the number is 32, the length is 5750 mm, and the cross-section dimensions are 120 mm for the upper base, 60 mm for the lower base, and 53 mm for the height. The high-strength connection structure parts at both ends of the main beam core material 212 are made of titanium alloy TC4, and the connecting bolts are TC4 8.8 grade internal hexagonal cylinders and nuts and gaskets, and 2 bolts are distributed on both sides for connection; the upper panel 3 and the lower panel 1 select a biaxial high-strength carbon fiber cloth with a surface density of 420 g / m 2 The number of layers of the biaxial high-strength carbon fiber cloth is 8 layers; the lattice 21 also selects a biaxial high-strength carbon fiber cloth with a surface density of 420 g / m 2 The number of layers of the biaxial high-strength carbon fiber cloth is 11 layers.

[0094] A preparation method of an ultra-large-span all-composite cabin cover plate in the first embodiment specifically includes the following steps:

[0095] Step 1, forming the lower panel 1: According to the target thickness of the lower panel 1 and the type of the first fiber component 201 in the selected reinforcing fiber fabric, that is, the fiber component 20, determine any one or more material information such as the number of layers of the fiber fabric to be laid and the laying method. When laying the fiber, it is required that the cloth layer is flat without obvious wrinkles or bubbles. Spray glue can be used for shaping, and the uniformity of spraying should be ensured when spraying the spray glue. Due to the large laying area, during the laying process, the whole roll of fiber is directly placed on the cloth rack for laying to avoid fiber twisting. The size of the fiber fabric is larger than the designed ultra-large-span plane (length * width) size by 10 mm - 80 mm respectively, and then the fiber fabric is cut and then injected with glue to complete the curing and forming. The material is selected as a biaxial high-strength carbon fiber cloth with a surface density. Through the injection and curing and forming of the first fiber component 201, it can prevent the layout position of the lattice 21 on the lower panel 1 from being affected during the subsequent vacuum infusion one-piece forming process, and then is conducive to improving the accuracy of the positions of each component of the cabin cover plate before and after the vacuum infusion forming, and is conducive to improving the infusion efficiency and quality.

[0096] Step 2: Processing of the structure core material 211, the main beam core material 212, and the corresponding fiber one-component 201 on the bottom surface of the core material. Through the previous structural settings, according to the configuration of the lattice 21 and the main beam core material 212, process the core material fiber fabric or prepreg, that is, the shape and size of the fiber one-component 201, the structure core material 211, and the main beam core material 212. The material of the fiber one-component 201 is selected as biaxial high-strength carbon fiber cloth, and the areal density of the prepreg is 400 Kg / m 3 Buoyancy material.

[0097] Fixing, bonding, and assembling of the fiber one-component 201, the structure core material 211, and the main beam core material 212: Lay the dry fiber cloth or prepreg fiber fabric, that is, the fiber one-component 201, on the mold 4 according to the configuration of the lattice 21. Apply adhesive to all or part of the bottom of the structure core material 211 and the main beam core material 212 in sequence, and bond them to the fiber one-component 201 to prevent position changes and make them stably bonded to the mold 4. Adjacent different structure core materials 211 are distributed in parallel, and the radial and chordal directions of the structure core material 211 and the main beam core material 212 are perpendicular to each other; the protruding part of the main beam core material 212 is a composite material fiber fabric prefabricated block 2121 with dimensions of 120*100*40 (length * width * thickness / mm). Connect the two ends of the titanium alloy external connection structure 5 to the prefabricated block 2121 through high-strength bolts for embedded connection. It should be noted here that this embodiment is only for a single main beam core material 212. Subsequently, double main beam core materials 212 or more than two main beam core materials 212 can be set according to needs, and it is necessary to re-set according to the working conditions, weight, and equipment space requirements.

[0098] Laying of the composite material lattice 21 with dry fiber cloth or prepreg, that is, the fiber two-component 202. First, as shown in Figures 4a - 4b, the fiber two-component 202 includes fiber piece 202a, fiber piece 202b, fiber piece 202c, fiber piece 202d, fiber piece 202e, fiber piece 202f, and fiber piece 202g. The fiber piece 202a, fiber piece 202b, fiber piece 202c, fiber piece 202d, fiber piece 202e, fiber piece 202f, and fiber piece 202g are respectively arranged around the upper end of the lattice 21. Among them, the cutting size of the fiber piece 202a: 100*1500 / mm, 3 layers. The cutting size of the fiber piece 202b: 100*5800 / mm, 3 layers.

[0099] During laying, first, the fiber piece 202a and the fiber piece 202b are laid layer by layer, intersecting with each other and being disconnected from each other. After laying, cut according to the configuration structure; secondly, for the respective cutting sizes of the fiber piece 202c: 100*1400 / mm, 3 layers. The cutting size of the fiber piece 202b: 300*5900, 3 layers. The cutting size of the fiber piece 202d: 100*1700 / mm, 3 layers.

[0100] The three - layer fiber 202c, the seven - layer fiber 202g, and the four - layer fiber 202d are also laid layer by layer, intersecting and disconnecting from each other. The operation requirements ensure that each layer of dry fiber cloth or prepreg, that is, the fiber two - component 202, is closely attached to and tightly pressed against the structure core material 211 and the main beam core material 212.

[0101] Next, the six - layer fibers 202f of different layers are respectively laid around the structure core material 211 and the main beam core material 212. The respective cutting sizes of the six - layer fibers 202f are 80 * 2200 / mm, with 3 layers. It is required to lay layer by layer, intersecting and disconnecting from each other for wrapping. At the cross - shaped and T - shaped intersections of the lattice 21, the five - layer fiber 202e is used to wrap from the upper side to the lower side. Five layers of the five - layer fiber 202e are selected, and the fiber cloth size of the five - layer fiber 202e is 200 * 200 / mm. When the five - layer fiber 202e is wrapped, it needs to be tightly pressed. According to the setting requirements, the number of layers to be laid for the lattice 21 is 11 layers. Subsequently, the number of automatic forming mold frames and the component laying are calculated according to the above - mentioned laying sequence to obtain the total number of laid layers. Here, it is finally stated that after the above laying is completed, finally, at the cross - shaped and T - shaped intersections of the lattice 21, the seven - layer fiber 202g is used to wrap from the lower side to the upper side. The number of laying layers of the seven - layer fiber 202g is 5 layers, and the fiber cloth size of the seven - layer fiber 202g is 200 * 200 / mm. When the seven - layer fiber 202g is laid, it needs to be tightly pressed. Finally, ensure that the overall thickness of the lattice 21 remains consistent at 5 mm, which is 11 layers. The material of the fiber two - component 202 is a biaxial high - strength carbon fiber cloth with a surface density.

[0102] Processing of the core material component 22. According to the configuration of the lattice 21, the shape and size of the core material component 22 are processed. The material of the core material component 22 is a buoyancy material with a density of 400 Kg / m 3 On the core material component 22, through - holes with a diameter of φ3 mm are drilled for the buoyancy material at intervals of 30 mm * 30 mm (length * width) to prevent the phenomenon of being blocked by glue injection, which may cause poor perfusion effects in some parts and affect the performance.

[0103] Filling of the core material component 22. Spray an appropriate amount of spray glue on the surface of the prepared composite material lattice 21 at a speed of 30 cm / s, and fill the processed core material component 22 into the previously prepared composite material lattice 21. Thus, a composite material lattice 21 structure with a filled core material is formed. Then, place it as a whole and steadily on the laid fiber cloth. After the laying is completed, fiber filaments can be added to the positions with gaps to ensure complete filling without gaps and more precisely control the perfusion quality.

[0104] Step three: Laying of the upper panel 3. Lay the upper panel 3 on the composite material lattice 21 with a filled core material. The laying requirements are the same as those for the lower panel 1.

[0105] Step 4: Use the conventional vacuum infusion molding process of composite materials to integrally encapsulate and mold the formed body. Since the span is relatively large, a relay injection design with a diversion pipeline is adopted. A glue injection pipe is set in the middle, and air extraction pipes are set on both sides (the distance between the air extraction pipes and the edge of the preform is 60±5 mm). Two integrated air extraction and injection pipelines are evenly distributed on the preform. One glue injection port is set at an interval of 1.5 m. When laying the pipelines, it is required that the glue injection pipe is suspended about 30 mm directly above the glue injection hole; the vacuum pipe should be as parallel as possible to the edge of the upper panel 3, and the release cloth wrapped around the vacuum pipe should overlap with the edge of the shell plate. Each pipeline is evenly provided with 4 glue injection ports. Except at the first glue injection pipe, the diversion nets at the other three sides are disconnected by 30 mm at the edge of the board.

[0106] Through the above embodiments, by using the preparation method of the present application, the required cabin cover plate can be quickly prepared. The quality and impact resistance of the prepared cabin cover plate are relatively high, and the cost of the prepared cabin cover plate is lower and the mechanical properties are more stable.

[0107] For the cabin cover plate prepared by using the preparation method of the present application, through finite element analysis and simulation, relevant data under the self-weight condition and the added load condition of the cabin cover plate are obtained respectively (as Figures 6a-6d shown).

[0108] Among them, the deformation amount under the self-weight condition of the cabin cover plate is between 0.35 mm and 0.36 mm, the ultimate tensile strength under self-weight is 9 Mpa, and the ultimate compressive strength is 6.77 Mpa. It is not difficult to see that: under the state of no load, the self-weight condition of the cabin cover plate is less than 2 mm.

[0109] Under the added load condition, the sum of the self-weight and deformation of the cabin cover plate is between 2.5 mm and 2.6 mm, the ultimate tensile strength under the design load is 66 Mpa, and the ultimate compressive strength is 48 Mpa.

[0110] Through the finite element analysis of the cabin cover plate prepared by using the preparation method of the present application under the above two different conditions and comparing with the mechanical properties of the selected materials, it is not difficult to see that: through the combination of the main beam core material 212 and the lattice 21 of the present application, combined with different laying methods of the fiber assembly 20, and the cooperation of the vacuum integrated infusion molding process, the self-structural strength and stiffness of the cabin cover plate can be greatly improved. And through the analysis under the condition of added load, it can be further seen that the cabin cover plate prepared by the present application can be used for the preparation of all-composite cabin cover plates with an ultra-large span of not less than 5 meters. And as Figures 6c-6d shown, it can also be seen that the maximum deformation of the prepared cabin cover plate is at its middle position, and the overall deformation distribution is as follows: the deformation amount from the center to both ends of the cabin cover plate decreases in a stepped trend. Therefore, it is not difficult to see that the present application is suitable for the preparation of ultra-large span cabin cover plates. And the cabin cover plate has the characteristics of high strength and high rigidity.

[0111] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An ultra-large-span all-composite cabin cover plate, characterized in that, The span of the hatch cover plate ≥ 5m, and the deformation amount under the self-weight condition of the hatch cover plate < 2mm. The hatch cover plate includes a lower panel (1), an intermediate layer (2), an upper panel (3), and an external connection structure (5); the lower panel (1) is attached to the upper panel (3) through the intermediate layer (2) to form the main body of the hatch cover plate, and both ends of the main body of the hatch cover plate are connected to the external connection structure (5); the intermediate layer (2) includes a fiber assembly (20), a lattice (21), and a core material assembly (22); the bottom of the lattice (21) is attached to the top of the lower panel (1) through the fiber assembly (20), and the outer side walls of the upper ends of the lattice (21) are respectively attached to the bottom of the upper panel (3) and the outer side walls of the core material assembly (22) through the fiber assembly (20), and both ends of the core material assembly (22) are respectively attached to the lower panel (1) and the upper panel (3).

2. The super-large-span all-composite cabin cover plate according to claim 1, wherein The fiber assembly (20) is a dry fiber cloth or a prepreg fiber fabric; the materials of the upper panel (3) and the lower panel (1) are any one or more fiber fabrics of glass fiber, carbon fiber, carbon / glass hybrid fiber, quartz fiber, Kevler fiber, ultra-high molecular weight polyethylene fiber, PBO fiber, etc.

3. The super-large-span all-composite cabin cover plate according to claim 1, characterized in that, The fiber assembly (20) includes a fiber one assembly (201) and a fiber two assembly (202); the bottom sides of the fiber one assembly (201) and the core material assembly (22) are both arranged on the top of the lower panel (1), and the top side of the fiber one assembly (201) is connected to the lattice (21); the bottom of the fiber two assembly (202) is conformally arranged on the upper end of the lattice (21); the top sides of the fiber two assembly (202) are respectively attached to the bottom of the upper panel (3) and the outer side walls of the core material assembly (22).

4. The super-large-span all-composite cabin cover plate according to claim 3, characterized in that, The lattice (21) includes a structure core material (211) and a main beam core material (212); the structure core material (211) and the main beam core material (212) are arranged in an alternating manner; the bottoms and tops of the structure core material (211) and the main beam core material (212) are respectively attached to the fiber one assembly (201) and the fiber two assembly (202), and the outer side walls of the structure core material (211) and the main beam core material (212) are attached to the outer side walls of the core material assembly (22) through the fiber two assembly (202).

5. The super-large-span all-composite cabin cover plate according to claim 4, wherein, There are 2N + 1 structure core materials (211) and M main beam core materials (212), where N and M are both positive integers, and N ≥ 1, M ≥ 1.

6. The super-large-span all-composite cabin cover plate according to claim 4, characterized in that, The lattice (21) further includes a precast block (2121), and both ends of the main beam core material (212) are respectively connected to the external connection structure (5) through the precast block (2121).

7. The super-large-span all-composite cabin cover plate according to claim 4, wherein The materials of the structure core material (211) and the main beam core material (212) are any one or more of PVC, PET, and buoyancy materials.

8. The super-large-span all-composite cabin cover plate according to claim 1, wherein The material of the core material assembly (22) is a foamed material or a buoyancy material.

9. A preparation method for a super-large-span fully composite cabin cover plate, characterized in that, The method is applied to prepare a super-large-span all-composite hatch cover plate described in any one of claims 1-8, and the method includes the following steps: Step 1. Forming the lower panel (1): According to the required specifications and dimensions of the lower panel (1), select the type, number of layers, and laying method of the reinforcing fiber fabric for preparing the lower panel (1), and prepare the formed lower panel (1) by means of spray gluing and shaping. Step 2. Preparation of the intermediate layer (2): Determine the setting method and position of the fiber assembly (20), lattice (21), and core material assembly (22). After assembling the fiber assembly (20), lattice (21), and core material assembly (22), obtain the intermediate layer (2). Step 3. Laying of the upper panel (3): Lay at least one layer of the required fiber fabric of the upper panel (3) on the top of the lattice (21) filled with the core material assembly (22) to obtain the upper panel (3). Step 4. Integral forming: Process according to the VARI forming process to obtain the integrally formed cabin cover plate.

10. The preparation method of an ultra-large-span all-composite cabin cover plate according to claim 9, characterized in that, The said Step 2 includes: Step S21: According to the configuration of the lattice (21) and the setting of the main beam structure, process the shapes and dimensions of the fiber assembly (20), lattice core (211), and main beam core (212) respectively. Step S22: Lay the fiber one assembly (201) in the fiber assembly (20) on the mold (4) according to the configuration of the lattice (21), and bond the lattice core (211) and main beam core (212) with adhesive applied to the bottom on the fiber one assembly (201). Step S23: Laying of the fiber two assembly (202): According to the setting of the lattice (21), select the number of laying layers of the fiber two assembly (202), and alternately lay the fiber two assembly (202) in the vertical direction at the upper end of the lattice (21) to form a composite material lattice (21). Step S24: Processing of the core material assembly (22): Process the shape and dimensions of the core material assembly (22) according to the configuration setting requirements of the lattice (21). Step S25: Filling of the core material assembly (22): Sprinkle an appropriate amount of spray glue on the top side of the prepared composite material lattice (21), and gently place the processed core material assembly (22) as a whole on the upper side of the laid fiber two assembly (202), thereby forming a composite material lattice (21) structure filled with the core material.

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