Preparation method and application of carbon fiber composite building component

Abstract

The invention discloses a preparation method of a carbon fiber composite building component. The preparation method comprises the following steps: 1) dividing cured and molded high-density PU foam into polygonal foam blocks based on an overall building shape in a factory; (2) grooves are milled in all corners of each polygonal foam block; (3) the pre-embedded plate of the connecting piece is placed in the groove of the polygonal foam block; 4) performing carbon fiber coating on the foam block on which the connecting piece is placed for many times; and (5) molding and curing the preformed part obtained in the step (4) by adopting a wet molding technology. Compared with other structural materials such as steel structures or concrete, the carbon fiber composite building component prepared through the method is quite light and thin. The structure forming of various curved surface buildings can be met, the functions of prefabricating and assembling non-standard products and quickly assembling roofs can be achieved according to parameter design, and most special-shaped hyperbolic shapes are achieved. In a series of simulation tests and tests, building construction requirements are met through structural stress calculation.

Description

Technical Field

[0001] The present invention relates to the technical field of building structural members. Background Art

[0002] In the construction industry, many projects demand free-flowing, flexible curves while also requiring lightweight, minimalist structures. Traditional roofing systems often rely on molds for specific shapes, but this styling necessitates molds with only one-to-many or one-to-one capabilities, resulting in high costs and material waste. Another approach utilizes metal components as structural support for the roof, with insulation, waterproofing, and finishes applied on top. However, the external insulation layer, including support nodes and other structures, often requires a greater thickness, which also imposes limitations on design.

[0003] In recent decades, the molding and manufacturing technology of resin-based composites has developed into an independent, cutting-edge modern engineering discipline. With the accumulation of experience, resin-based composites have gradually expanded beyond aerospace into other industries. Currently, the main markets for composite materials include: aerospace, such as aircraft cabins, fuel silos, and rocket fairings; transportation and marine applications, such as small boat cabins, masts, decks, automobile hulls, tails, battery compartments, and high-speed rail fronts; wind turbine blades; and sports and civilian applications, such as drones, bicycles, fishing rods, and decorative components. Carbon fiber resin composites, when used in main structures in the building industry, such as roofs, can meet the requirements for lightweight, compact, and thin structures.

[0004] However, in the construction industry, the application of carbon fiber materials in primary structural components is mainly aimed at reinforcing concrete and steel components, such as wet-bonding reinforcement of beam bottoms, wet-bonding reinforcement of slab bottoms, and winding reinforcement of structural columns. Currently, there is no evidence that carbon fiber products are used as primary structural components. At the same time, traditional carbon fiber composite component connection methods, such as mechanical connection with external metal heads or stacking and gluing, are not suitable for construction scenarios. Summary of the Invention

[0005] The purpose of the present invention is to address the problems existing in the above-mentioned prior art and provide a method for preparing carbon fiber composite building components, which can be prefabricated in batches in a factory and spliced ​​on site to meet various personalized roof shapes and have a light structure.

[0006] The concept of this patent is: in order to cope with the characteristics of irregular curved surfaces and lightness of architectural shapes, the architectural shape can be decomposed into different component units through rational plate division. For example, the roof system can be divided into basic units spliced ​​by carbon fiber composite panel units, and then the ratio and thickness are adjusted according to the structural calculation requirements to achieve the shape requirements of different spans. After that, it is prefabricated in the manufacturer and transported to the site for splicing after confirmation.

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

[0008] A method for preparing a carbon fiber composite building component, comprising:

[0009] 1) The high-density PU foam after curing and molding is divided into polygonal foam blocks based on the overall building shape in the factory;

[0010] 2) Mill a groove at each corner of each polygonal foam block;

[0011] 3) Place the embedded plate of the connector into the groove of the polygonal foam block;

[0012] 4) The foam block with the connectors is coated with carbon fiber multiple times;

[0013] 5) Using wet molding technology to mold and solidify the preform obtained in step 4).

[0014] The polygonal foam blocks all have the same configuration, preferably hexagonal hyperbolic foam blocks, and the side length and thickness can be calculated and adjusted according to the stress requirements of the entire building body; the thickness is preferably less than 1 / 10 of the overall span of the carbon fiber composite building component.

[0015] Furthermore, the depth of the groove milled in step 2) is the same as the thickness of the embedded plate of the connector, preferably a fan-shaped groove; further, a limiting pit is continued to be milled at the side wall of the groove, and the outer edge of the embedded plate of the connector is set in the limiting pit.

[0016] The connecting piece described in step 3) includes an embedded plate and two folded edges at an angle, the height of the two folded edges is lower than the top surface of the PU foam block, and the two folded edges are provided with oblong holes. The connection between the two folded edges can be further connected by welding. When the foam block is hexagonal, the angle between the two folded edges of the connecting piece is 120°. The connecting piece is preferably a one-piece bent sheet metal part, and the two folded edges are bent at 90°. Furthermore, the connecting piece also includes bolts, which penetrate the oblong holes during construction to connect and fix adjacent carbon fiber composite building components.

[0017] Furthermore, in step 4), the 3K (0-90) carbon fiber woven cloth and the 12K (0-90) carbon fiber woven cloth are wrapped in sequence for multiple times, and are fixed at the edges using spray glue.

[0018] Furthermore, the wet forming technology described in step 5) refers to: placing the preform obtained in step 4) on a diversion mold, setting vacuum films that exceed the edge size on the upper and lower sides, sealing the edges with double-sided tape on all sides, setting drainage tubes at each corner inside to allow the resin to be evenly introduced and discharged, installing a diversion pump to check the sealing, and applying a pressure of 0.08-0.09 MPa for diversion; then observing and judging the resin infiltration state, and closing the diversion valve after completion; finally, letting it stand for more than 24 hours, and demolding after curing is completed.

[0019] Beneficial effects of the present invention:

[0020] The carbon fiber composite building components produced by the method of this invention are significantly lighter and thinner than other structural materials, such as steel or concrete. They can not only meet the structural requirements of various curved buildings, but also enable the prefabrication and assembly of non-standard products based on parameter design, allowing for rapid roof assembly and the realization of most unusual hyperbolic shapes.

[0021] The carbon fiber composite building components produced by the method of the present invention can adapt to splicing at multiple angles at each unit node and can be fine-tuned and calibrated during installation. In a series of simulation experiments and tests, they passed structural force calculations and met construction requirements.

[0022] The specific embodiments of the present invention are described below with reference to the accompanying drawings: BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the structure of a hexagonal carbon fiber composite building component obtained by the method of an embodiment of the present invention.

[0024] Figure 2 for Figure 1 Schematic diagram of the structure of the carbon fiber composite building component when the connecting parts are not installed in the grooves of the PU foam block.

[0025] Figure 3 A partial cross-sectional view of the preform obtained in step 4) of the method for preparing a carbon fiber composite building component provided in an embodiment of the present invention.

[0026] Figure 4 for Figure 1 Schematic diagram of the longitudinal section of the middle part.

[0027] Figure 5 for Figure 1 Schematic diagram of the connected part after splicing.

[0028] Figure 6 for Figure 1 Partial schematic diagram after splicing and forming.

[0029] Figure 7 To adopt Figure 1 Schematic diagram of the spliced ​​shell roof.

[0030] Description of reference numerals:

[0031] 1PU foam base, 101 groove, 102 limit pit

[0032] 2 Connectors, 201 embedded base plate, 202 folded edge, oblong hole 202a, 203 bolts

[0033] 3 carbon fiber covering DETAILED DESCRIPTION

[0034] The specific embodiments described herein are only used to explain the technical solutions of this patent, and are not intended to limit the disclosed technical solutions. It should also be noted that, for ease of description, the accompanying drawings only show parts related to the disclosed technical solutions, rather than all structures.

[0035] Before discussing the exemplary embodiments in more detail, it should be mentioned that the structures of the device components and / or modules themselves mentioned in the embodiments, if not described in detail, can be understood by those skilled in the art based on existing public technologies or commercially available products.

[0036] Attach Figure 7 Taking the shell roof as an example, it can be divided into hexagonal blocks. This embodiment uses this hexagonal building component as an example to provide a method for preparing a carbon fiber composite building component as a main structure, and the steps are as follows:

[0037] 1. 80 density PU (polyurethane) foam is fully matured and molded in the factory.

[0038] 2. The foam block formed in step 1) is processed into a hyperbolic foam block with a side length of 600 mm and a thickness of 30 mm by CNC or other milling production lines.

[0039] 3.Reference Figure 2 A fan-shaped groove 101 with a radius of 85 mm and a depth of 20 mm is milled at each corner of each hexagonal foam block 1, and the arc is milled at an obtuse angle of 141°; on this basis, a 3 mm limit pit 102 is milled downward at the top of the fan.

[0040] 4. Prepare connector 2: Use a whole piece of metal plate in the factory. The whole metal connector is made of Q235 3mm steel plate and laser cut. Figure 2 The connector 2 includes an embedded plate 201 and two folded edges 202 at an angle. The height of the two folded edges needs to be lower than the top surface of the PU foam block, and the two folded edges are provided with oblong holes 202a. The embedded part is processed into a fan shape with a radius of 63.1mm and a central angle of 120°. The two folded edges are formed by bending the pre-cut folded edges 90° through a sheet metal bending process, and the two vertical plates are connected by fill welding. The two folded edges are 19mm high, 87mm long, and 3mm thick, and the angle with the bevel of the embedded plate is about 51°. The processed metal connector 2 is placed on the groove 101 of the processed foam block 1, and the outer edge of the embedded plate 101 is placed in the limit pit 102.

[0041] 5. Repeatedly wrap the foam block with the connectors with carbon fiber: Figure 3After installing the connectors, place the foam block on the platform for carbon fiber coating. Wrap it with 6 layers of 3K (0-90) carbon fiber woven cloth and 7 layers of 12K (0-90) carbon fiber woven cloth in sequence. Finally, use all-purpose spray glue to initially fix it at the edge. Figure 3 and Figure 4 .

[0042] 6. Using wet molding technology to mold and cure the carbon fiber-wrapped preform: This embodiment uses the RTM process. The preform obtained in step 5 is placed on a diversion mold. Vacuum membranes are set at the top and bottom, extending approximately 200 mm beyond the edge. Double-sided tape is used to seal the edges. Drainage tubes are set at each corner to uniformly guide and discharge the resin. A diversion pump is installed to check the sealing. A pressure of 0.08-0.09 MPa is applied for diversion. The resin infiltration state is then observed and determined. After completion, the diversion valve is closed. Finally, the preform is left to stand for more than 24 hours. After curing, the carbon fiber composite building component is demolded to obtain the result.

[0043] Before on-site construction, the prepared carbon fiber composite building components need to undergo a loading test to check whether the mechanical properties of the finished products meet the design requirements. After confirmation, they are transported to the construction site for splicing.

[0044] refer to Figure 5 and Figure 6 During construction, each carbon fiber composite building component is connected and fixed by cylindrical head bolts penetrating the oblong holes on the adjacent connecting parts. The type of bolt 203 matches the oblong hole on the folding edge 202. When both adopt industry standard sizes, commercially available parts can be used. After the connection is fixed, the gap is filled with resin structural glue. Each carbon fiber composite building component is set in the exact position by positioning methods such as laying out lines and marking points. After all the splicing is completed, Figure 7 As shown in the shell roof, a glass panel can also be installed on the top of the roof for lighting.

[0045] The above is an illustration of the preferred implementation of the present invention, but the invention is not limited to the embodiments. Those skilled in the art can make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A method for preparing a carbon fiber composite building component, comprising: 1) Dividing the matured high-density PU foam into polygonal foam blocks based on the overall architectural shape; 2) Mill a groove at each corner of each polygonal foam block; 3) Place the embedded plate of the connector into the groove of the polygonal foam block; 4) The foam block with the connectors is coated with carbon fiber multiple times; 5) The preform obtained in step 4) is molded and cured by wet molding.

2. The method for preparing a carbon fiber composite building component according to claim 1, wherein: The polygonal foam block is a hexagonal foam block.

3. The method for preparing a carbon fiber composite building component according to claim 1, wherein: The thickness of the polygonal foam block is less than 1 / 10 of the overall span of the carbon fiber composite building component.

4. The method for preparing a carbon fiber composite building component according to claim 1, wherein: Step 2) The depth of the milled groove is the same as the thickness of the embedded plate of the connector.

5. The method for preparing a carbon fiber composite building component according to claim 1, wherein: Step 2) Mill a limiting pit on the side wall of the groove.

6. The method for preparing a carbon fiber composite building component according to claim 1, wherein: The connecting piece comprises an embedded plate and two folded edges at an angle. The height of the two folded edges is lower than the top surface of the PU foam block, and oblong holes are provided on the two folded edges.

7. The method for preparing a carbon fiber composite building component according to claim 6, wherein: The connecting piece is an integrated bent sheet metal piece, with two folded edges bent at 90°.

8. The method for preparing a carbon fiber composite building component according to claim 1, wherein: Step 4) Wrap the 3K (0-90) carbon fiber woven cloth and the 12K (0-90) carbon fiber woven cloth multiple times in sequence and fix them with spray glue at the edges.

9. The method for preparing a carbon fiber composite building component according to claim 1, wherein: The wet forming process described in step 5) is as follows: placing the preform obtained in step 4) on a diversion mold, setting vacuum films that exceed the edge size on the upper and lower sides, sealing the edges with double-sided tape on all sides, setting drainage tubes at each corner inside to allow the resin to be evenly introduced and discharged, installing a diversion pump to check the sealing, and applying a pressure of 0.08-0.09 MPa for diversion; then observing and judging the resin infiltration state, closing the diversion valve after completion; finally, letting it stand for more than 24 hours, and demolding after curing is completed.

10. A carbon fiber composite building component, characterized in that: The carbon fiber composite building component is obtained by the preparation method of any one of claims 1 to 9.

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