Reinforcing sheet and reinforcing floor

Abstract

The invention relates to the technical field of reinforcing structures, in particular to a reinforcing sheet and a reinforcing floor, the reinforcing sheet comprises a continuous fiber reinforcing layer and a porous fabric layer, the continuous fiber reinforcing layer comprises matrix resin and continuous fibers impregnated in the matrix resin, and the porous fabric layer is arranged between the continuous fiber reinforcing layer and the porous fabric layer. The porous fabric layer comprises an embedded part embedded in the continuous fiber reinforced layer and an exposed part exposed out of the surface of the continuous fiber reinforced layer, and the air permeability P of the porous fabric layer and the parameter X of the continuous fiber reinforced layer meet certain limiting conditions. The reinforcing sheet disclosed by the invention not only has an excellent mechanical strength reinforcing effect, but also can effectively improve the interface bonding force between the reinforcing sheet and a traditional material substrate and between the reinforcing sheet and a plastic substrate; according to the reinforced floor, the adhesive layer or the substrate resin permeates into the pores of the exposed part of the porous fabric, so that the reinforcing sheet and the substrate are combined into a whole, and the reinforced floor has excellent mechanical properties.

Description

Technical Field

[0001] This invention relates to the technical field of reinforcement structures, and more specifically, to a reinforcement sheet and a reinforcement floor. Background Technology

[0002] Natural materials such as wood and bamboo have advantages such as being renewable, environmentally friendly, having natural textures, and being comfortable to the touch, and are therefore widely used in the manufacture of structural substrates for flooring, furniture, and other products. However, these materials also have significant drawbacks: on the one hand, their mechanical properties are poor, with low bending strength and insufficient rigidity, making them prone to deformation or breakage during use; on the other hand, they have poor environmental tolerance, easily absorbing moisture and swelling, corroding, or becoming moldy, which seriously affects their service life.

[0003] To improve these shortcomings, traditional methods usually start from two aspects: in terms of mechanical reinforcement, the thickness of the substrate is often increased or reinforcing components such as metal and plastic are embedded. However, due to the weak interfacial bonding force, the strengthening effect is limited and it is difficult to significantly improve the overall performance. In terms of environmental resistance, a skin layer is often laid on the surface of the substrate to isolate external influences.

[0004] Continuous fiber reinforced thermoplastic composites (CFRPs) possess advantages such as high strength, low density, impact resistance, aging resistance, and the ability to be remolded, making them widely used in new energy vehicles, logistics transportation, photovoltaics, and other fields. As reinforcing layers, CFRPs are laid on the surface of various materials, including traditional natural wood panels and composite panels, not only improving the mechanical strength of the substrate but also serving as a skin layer to enhance environmental resistance. However, due to the poor compatibility between the matrix resin used in CFRPs and the base resins used in traditional natural wood panels and composite panels, simply placing them on the surface or inside the panel results in weak interfacial bonding, easily leading to delamination. This not only fails to provide effective reinforcement but may also impair overall performance. Summary of the Invention

[0005] The purpose of this invention is to overcome the problem of incompatibility between reinforcing sheets and traditional substrates in the prior art, and to provide a reinforcing sheet that is compatible with the substrate and has excellent reinforcing effect; it also provides a reinforcing floor with good mechanical properties and waterproof performance.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A reinforcing sheet is provided, comprising a continuous fiber reinforcement layer and a porous fabric layer. The continuous fiber reinforcement layer comprises a matrix resin and continuous fibers impregnated in the matrix resin. The porous fabric layer comprises an embedded portion embedded in the continuous fiber reinforcement layer and an exposed portion exposed on the surface of the continuous fiber reinforcement layer. The air permeability P of the porous fabric layer and the parameter X of the continuous fiber reinforcement layer satisfy the following condition: P-1070X ranges from (0, 600), where X = R × W / H × 100%, where R is the density of the continuous fiber reinforcement layer in kg / m²; W is the fiber content in the continuous fiber reinforcement layer in %; and H is the thickness of the continuous fiber reinforcement layer in mm.

[0007] In this invention, P-1070X can be any value of 40, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, or 595, or a range of values ​​formed by any two of the above values.

[0008] The reinforcing sheet of the present invention has a continuous fiber reinforcement layer with high strength, low density, excellent impact resistance and aging resistance, providing a mechanical strength basis for the reinforcing sheet; the porous fabric layer is partially embedded in the continuous fiber reinforcement layer and partially exposed on the surface of the continuous fiber reinforcement layer. The porous fabric exposed on the surface of the continuous fiber reinforcement layer is glued to the substrate, so that the reinforcing sheet and the substrate can be integrated. The porous fabric helps to achieve structural reinforcement of the interface and is not limited by whether the matrix resin has adhesive properties.

[0009] The density R of the continuous fiber reinforced layer was tested in accordance with GB / T 9914.3-2013 "Test Methods for Reinforced Products - Part 3: Determination of Mass per Unit Area"; the fiber content W in the continuous fiber reinforced layer was tested in accordance with ASTM D3171-22 "Standard Test Methods: Fiber Content in Composite Materials".

[0010] The reinforcing sheet of the present invention not only has excellent mechanical strength reinforcement, but also effectively improves the interfacial bonding force between the reinforcing sheet and traditional material substrates and plastic substrates, thereby broadening the application range of the reinforcing sheet.

[0011] Preferably, the air permeability P of the porous fabric layer is in the range of 1000 mL / min to 2000 mL / min, specifically any value of 1000 mL / min, 1200 L / min, 1400 L / min, 1600 L / min, 1800 L / min, or 2000 L / min, or a range formed by any two of the above values; the basis weight G of the porous fabric layer is in the range of 40 g / m² to 90 g / m², specifically any value of 40 g / m², 50 g / m², 60 g / m², 70 g / m², 80 g / m², or 90 g / m², or a range formed by any two of the above values; the melting point of the porous fabric layer is 30°C to 80°C higher than the melting point of the matrix resin, specifically any value of 30°C, 40°C, 50°C, 60°C, 70°C, or 80°C, or a range formed by any two of the above values.

[0012] In this invention, the high air permeability and low basis weight settings are to ensure that the matrix resin fully impregnates the pores of the porous fabric layer. When the air permeability of the porous fabric layer is 1000 mL / min-2000 mL / min, the matrix resin can fully impregnate the porous fabric without penetrating it, and the porous fabric provides sufficient bonding targets. When the basis weight G of the porous fabric layer is in the range of 40 g / m²-90 g / m², the matrix resin can fully impregnate the porous fabric without penetrating it, and the porous fabric provides sufficient bonding targets. Setting the melting point of the porous fabric layer is to prevent it from melting during heating and losing its function of embedding into the reinforcing interface. When hot pressing the continuous fiber reinforcement layer and the porous fabric layer, the heating temperature is generally 20℃-80℃ higher than the melting point of the matrix resin and 20℃-50℃ lower than the melting point of the porous fabric layer, so that the matrix resin can fully melt and flow into the pores of the porous fabric, thereby allowing the porous fabric layer to partially embed into the continuous fiber reinforcement layer.

[0013] The air permeability P of the porous fabric layer was tested according to GB / T5453-2025 "Textiles - Determination of Air Permeability of Fabrics"; the basis weight G of the porous fabric layer was tested according to GB / T 24218.1-2023 "Textiles - Test Methods for Nonwoven Fabrics - Part 1: Determination of Mass per Unit Area"; and the melting point of the porous fabric layer was tested according to GB / T 19466.3-2004 "Plastics - Differential Scanning Calorimetry (DSC) - Part 3: Determination of Melting and Crystallization Temperature and Enthalpy".

[0014] Preferably, the thickness ratio of the embedded portion to the exposed portion is 1:1 to 1:3, and the thickness of the continuous fiber reinforcement layer is 0.2 mm to 2.0 mm.

[0015] In this invention, when the thickness ratio of the embedded portion to the exposed portion is between 1:1 and 1:3, the matrix resin is fully impregnated within the porous fabric layer, and the matrix resin does not permeate through the porous fabric, thereby effectively ensuring the bonding strength between the porous fabric layer and the matrix resin, while providing sufficient bonding targets. The reinforcing sheet can be directly laid on the surface of the board whose performance needs to be improved. In this case, a thinner continuous fiber reinforcement layer is selected, and the thickness of the continuous fiber reinforcement layer has almost negligible impact on the overall thickness of the board. When the reinforcing sheet is used to replace a layer structure of a certain layer of the board, a thicker continuous fiber reinforcement layer can be selected as needed.

[0016] Preferably, the melt index of the matrix resin is 30g / 10min to 60g / 10min, and the fiber content in the continuous fiber reinforcement layer is 40% to 80%.

[0017] In this invention, when the melt index of the matrix resin is 30 g / 10 min to 60 g / 10 min, the matrix resin can fully impregnate the porous fabric layer without permeating it, thereby effectively ensuring the interfacial reinforcement effect of the reinforcing sheet. When the fiber content in the continuous fiber reinforcement layer is 40% to 80%, the matrix resin can fully impregnate the pores of the continuous fibers and effectively ensure the mechanical reinforcement effect of the reinforcing sheet.

[0018] The melt index of the matrix resin of the present invention was tested in accordance with GB / T 3682.1-2018 "Determination of melt mass flow rate (MFR) and melt volumetric flow rate (MVR) of thermoplastic plastics - Part 1: Standard method", with test conditions of 190°C and 2.16 kg.

[0019] Preferably, the continuous fiber reinforcement layer comprises at least two unidirectional tape layers, and the at least two unidirectional tape layers are symmetrically laid up. When the number of unidirectional tape layers is even, the multiple unidirectional tape layers adopt a symmetrical layup pattern such as 0 / 90 / 90 / 0 / ; when the number of unidirectional tape layers is odd, the multiple unidirectional tape layers adopt a symmetrical layup pattern of 0 / 90 / 0.

[0020] Preferably, the continuous fiber is one of glass fiber, carbon fiber, basalt fiber, and aramid fiber, and the matrix resin is one of polyethylene, polypropylene, acrylonitrile-butadiene-styrene copolymer, polyamide, and polyethylene terephthalate. The matrix resin in the continuous fiber reinforcement layer of this invention is not required to have adhesive properties, and the selection of the specific materials mentioned above is not intended to limit the scope of protection of this invention.

[0021] Preferably, the porous fabric layer can be one of PET spunlace nonwoven fabric, PET thermally rolled nonwoven fabric, or PP thermally rolled nonwoven fabric, or other nonwoven fabrics with polar groups.

[0022] Preferably, the thickness of the continuous fiber reinforcing sheet is 0.3 mm to 3 mm. When the continuous fiber reinforcing sheet of the present invention is used to reinforce a substrate, because the thickness of the reinforcing sheet is relatively thin, it has almost no impact on the overall thickness of the substrate.

[0023] Preferably, the porous fabric layer is a single layer, and the porous fabric layer is laid on one side surface of the continuous fiber reinforcement layer. This type of reinforcing sheet is used as the surface layer of a substrate, with the porous fabric layer located between the continuous fiber reinforcement layer and the substrate. It can effectively improve the mechanical strength of the substrate without increasing the thickness and weight of the substrate. In applications where the substrate surface is black, the use of the reinforcing sheet can also eliminate the step of spraying black paint on the product surface.

[0024] Preferably, the porous fabric layer consists of two layers, with each layer laid on opposite sides of the continuous fiber reinforcement layer. This type of reinforcing sheet is embedded within the substrate, effectively improving its mechanical strength with minimal increase in thickness and weight. Furthermore, the number of reinforcing sheet layers can be adjusted according to the product's mechanical performance requirements.

[0025] The present invention also provides a reinforced floor, including a substrate and a reinforcing sheet as described above, wherein the reinforcing sheet is laminated with the substrate.

[0026] The reinforcing floor of the present invention uses a reinforcing sheet as a reinforcing layer of a substrate, and the reinforcing sheet and the substrate are integrated into one piece, thereby giving the reinforcing floor excellent mechanical properties.

[0027] Preferably, an adhesive layer is provided between the reinforcing sheet and the substrate, and the reinforcing sheet is laid on one side surface or two opposite side surfaces of the substrate through the adhesive layer. The adhesive layer is selected to be compatible with the substrate; the porous fabric layer is partially embedded inside the reinforcing sheet, and the adhesive layer penetrates into the pores of the exposed part of the porous fabric. In this case, the reinforcing sheet is used as the surface layer of the substrate, which can effectively improve the mechanical strength of the substrate and hardly increase the thickness and weight of the substrate; in application scenarios where the substrate surface is black, the use of the reinforcing sheet can also eliminate the step of spraying black paint on the product surface.

[0028] Preferably, the reinforcing sheet is embedded inside the substrate. In this case, the reinforcing sheet is embedded inside the substrate during injection molding / compression molding / co-extrusion and other molding processes. Although the substrate resin and the matrix resin are incompatible, the substrate resin has fluidity during processing and can penetrate into the porous fabric. After molding, the resin is locked inside the porous fabric, thereby integrating the reinforcing sheet with the substrate, giving the product excellent impact resistance and drop resistance. The embedded design also allows manufacturers to set the number of reinforcing sheet layers according to the product's mechanical performance requirements.

[0029] Compared with the prior art, the beneficial effects of the present invention are: The reinforcing sheet of the present invention not only has excellent mechanical strength reinforcement, but also effectively improves the interfacial bonding force between the reinforcing sheet and traditional material substrates and plastic substrates, and is suitable for reinforcement between incompatible matrix materials, thereby broadening the application range of the reinforcing sheet. The reinforcing floor of the present invention has a porous fabric layer embedded in the interior of the reinforcing sheet, and an adhesive layer or substrate resin infiltrates into the pores of the exposed portion of the porous fabric, thereby integrating the reinforcing sheet and the substrate into one unit, thus giving the reinforcing floor excellent mechanical properties. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of a reinforcing sheet; Figure 2 This is a schematic diagram of another type of reinforcing sheet; Figure 3 This is a structural schematic diagram of a reinforced floor. Figure 4 This is a structural diagram of another type of reinforced flooring; In the attached diagram: 100, reinforcing sheet; 110, continuous fiber reinforcement layer; 120, porous fabric layer; 200, substrate; 300, adhesive layer. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0032] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0033] The porous fabric layer, continuous fiber reinforcement layer, and reinforcing sheet selected in each embodiment and comparative example of the present invention are described as follows: The parameters, manufacturers, and parameters of the selected continuous fiber reinforcement layer 110 of the porous fabric layer 120 in Examples 1-6 and Comparative Examples 1-2 are shown in the table below.

[0034]

[0035] In Examples 1-8 and Comparative Examples 1-2, the continuous fiber reinforcement layer 110 used a matrix resin of polypropylene, manufactured by Sinopec Beihai Refining & Chemical Co., Ltd., with the grade PPH. MN60, melt flow index 60 g / 10 min, continuous fiber is glass fiber, grade EDR17 2400 362A(U), manufactured by Jushi Group. In Example 9, the continuous fiber reinforcement layer 110 uses polypropylene as the matrix resin, manufactured by China Petroleum Lanzhou Petrochemical Co., Ltd., with the grade PP H9018 and a melt flow index of 54 g / 10 min.

[0036] The preparation method of the continuous fiber reinforcement layer 110 includes the following steps: fiber unwinding; fiber spreading and dispersing: the continuous fiber yarn passes through a spreading roller and is spread into a fiber bundle by heating at a temperature of 180~210℃; melt impregnation: the resin fully impregnates the continuous fiber yarn through a melt impregnation mold, and the mold temperature is controlled at 250~300℃; cooling and setting: after the fiber yarn is impregnated with resin, it is cooled and set into a unidirectional belt by a setting roller, and the cooling temperature is 50~90℃; traction and winding: the continuous unidirectional belt is wound and packaged, with a winding speed of 9~18m / min and a winding tension of 40%~70%.

[0037] The preparation method of the reinforcing sheet 100 includes the following steps: hot pressing: the continuous fiber reinforcing layer 110 and the porous fabric layer 120 are heated by a composite press at 190~200℃ in zone 1, 190~220℃ in zone 2, and 200~225℃ in zone 3; wherein, the continuous fiber reinforcing layer 110 contains 4 layers of unidirectional tape, and the layup of the 4 layers of unidirectional tape is 0 / 90 / 90 / 0; cooling and shaping: the reinforcing sheet is cooled and shaped in the cooling section of the composite press at a cooling temperature of 8~30℃; winding / slicing: the reinforcing sheet is then cut into the required length by a cutting machine.

[0038] The reinforced flooring in Application Examples 1-6, Comparative Example 1, and Comparative Example 2 was obtained by molding the reinforcing sheet 100 and the substrate in Application Examples 1-6, Comparative Example 1, and Comparative Example 2, respectively. The preparation method steps were: reinforcing sheet laying - substrate coating - pre-pressing - hot pressing and curing - cooling and demolding - cutting; the substrate was a 15mm bamboo plywood.

[0039] In the embodiments and comparative examples of the present invention, the longitudinal direction of the reinforced flooring is along the direction of the outermost continuous fiber, and the transverse direction is perpendicular to the longitudinal direction. The longitudinal bending strength, longitudinal elastic modulus, and longitudinal shear force are all tested in accordance with the test methods in GB / T 17657-2022 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels".

[0040] The P-1070X values ​​and performance test data of the reinforced floors applied in Examples 1-6, Comparative Examples 1 and 2 are shown in the table below:

[0041] As shown in the test data above, when the P-1070X reinforcement sheet in the range of (0, 600) is used for floor reinforcement, the reinforced floor can achieve excellent shear performance.

[0042] In the specific implementation of the above embodiments, the technical features can be combined in any non-contradictory way. For the sake of brevity, not all possible combinations of the above technical features are described. However, as long as the combination of these technical features is not contradictory, it should be considered to be within the scope of this specification.

[0043] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A reinforcing sheet (100), characterized in that, The material includes a continuous fiber reinforcement layer (110) and a porous fabric layer (120). The continuous fiber reinforcement layer (110) includes a matrix resin and continuous fibers impregnated in the matrix resin. The porous fabric layer (120) includes an embedded portion embedded in the continuous fiber reinforcement layer (110) and an exposed portion exposed on the surface of the continuous fiber reinforcement layer (110). The air permeability P of the porous fabric layer (120) and the parameter X of the continuous fiber reinforcement layer (110) satisfy the following conditions: P-1070X ranges from (0, 600), where X=R×W / H×100%, where R is the density of the continuous fiber reinforcement layer in kg / m², W is the fiber content in the continuous fiber reinforcement layer in % and H is the thickness of the continuous fiber reinforcement layer in mm.

2. The reinforcing sheet (100) according to claim 1, characterized in that, The air permeability P of the porous fabric layer (120) ranges from 1000 mL / min to 2000 mL / min, the basis weight G of the porous fabric layer (120) ranges from 40 g / m² to 90 g / m², and the melting point of the porous fabric layer (120) is 30°C to 80°C higher than the melting point of the matrix resin.

3. The reinforcing sheet (100) according to claim 1, characterized in that, The thickness ratio of the embedded portion to the exposed portion is 1:1 to 1:3, the thickness of the continuous fiber reinforcement layer (110) is 0.2 mm to 2.0 mm, and the thickness of the reinforcing sheet (100) is 0.3 mm to 3 mm.

4. The reinforcing sheet (100) according to claim 1, characterized in that, The melt index of the matrix resin is 30 g / 10 min to 60 g / 10 min, and the fiber content in the continuous fiber reinforcement layer is 40% to 80%.

5. The reinforcing sheet (100) according to claim 1, characterized in that, The continuous fiber reinforcement layer (110) includes at least two unidirectional tapes, and the at least two unidirectional tapes are symmetrically laid up.

6. The reinforcing sheet (100) according to any one of claims 1 to 5, characterized in that, The porous fabric layer (120) is a single layer, and the porous fabric layer (120) is laid on one side surface of the continuous fiber reinforcement layer (110).

7. The reinforcing sheet (100) according to any one of claims 1 to 5, characterized in that, The porous fabric layer (120) consists of two layers, and the two porous fabric layers (120) are respectively laid on the two opposite sides of the continuous fiber reinforcement layer (110).

8. A type of reinforcing flooring, characterized in that, It includes a substrate (200) and a reinforcing sheet (100) as described in any one of claims 1 to 7, wherein the reinforcing sheet (100) is disposed in a layer with the substrate (200).

9. The reinforcing floor according to claim 8, characterized in that, An adhesive layer (300) is provided between the reinforcing sheet (100) and the substrate (200), and the reinforcing sheet (100) is laid on one side surface or two opposite side surfaces of the substrate (200) through the adhesive layer (300).

10. The reinforced flooring according to claim 8, characterized in that, The reinforcing sheet (100) is embedded inside the substrate (200).

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