Porous core material, composite material, and method for forming porous core material

Abstract

The application discloses a kind of porous core material, composite material and the forming method of porous core material, porous core material includes porous core plate, first film and second film, porous core plate has first board face and second board face, first board face and second board face both have the aperture connected in the internal space of porous core plate;First film covers first board face and is connected with porous core plate, second film covers second board face and is connected with porous core plate, to seal the aperture on first board face and second board face using first film and second film.The porous core material of the embodiment of the application is used in high-pressure resin transfer molding process to form composite material product, its first film and second film can form closed layer, and then block resin from seeping into the interior of porous core material from the root, so as to prevent the problem of composite material product overweight, realize the lightweight of composite material product, improve product performance.

Description

Technical Field

[0001] This invention relates to the field of resin transfer technology, specifically to a porous core material, a composite material, and a method for molding the porous core material. Background Technology

[0002] High-pressure resin transfer molding (HP-RTM) is a molding process that uses high pressure to inject resin into a mold, allowing it to bond with reinforcing materials within the mold to form composite materials. It features high resin wetting efficiency, short molding cycle, high dimensional accuracy, and stable mechanical properties, making it widely used in high-end equipment manufacturing fields such as automotive, aerospace, and rail transportation. Foamed core materials, due to their lightweight, high specific strength, good cushioning and thermal insulation properties, and significant weight reduction effect, are often used as sandwich structures in composite materials to achieve lightweighting.

[0003] Because the foamed core material has a large number of pores, during the resin injection process, the resin will continuously penetrate into the interior of the foamed core material under pressure, causing the actual weight of the composite product to exceed the standard, making it difficult to achieve the lightweighting of the composite product and affecting the product performance. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the technical problems in the related art.

[0005] Therefore, embodiments of the present invention propose a porous core material, a composite material, and a molding method for the porous core material. When the porous core material of the present invention is used in a high-pressure resin transfer molding process to form a composite material product, its first film and second film can form a sealing layer, thereby blocking the resin from penetrating into the interior of the porous core material from the source, thus preventing the composite material product from becoming too heavy, achieving lightweighting of the composite material product, and improving product performance.

[0006] The porous core material of this invention includes a porous core board, a first film, and a second film. The porous core board has a first surface and a second surface, both of which have pores communicating with the internal space of the porous core board. The first film covers the first surface and is connected to the porous core board, and the second film covers the second surface and is connected to the porous core board, so as to seal the pores on the first surface and the second surface using the first film and the second film.

[0007] In some embodiments, the thickness of the first film is 0.03 mm to 1 mm; and / or, the thickness of the second film is 0.03 mm to 1 mm; and / or, at least one of the first film and the second film is made of polyurethane film.

[0008] In some embodiments, the first plate surface and / or the second plate surface have grooves, and the first film and / or the second film adhere to the groove wall to form a flow channel on the first plate surface and / or the second plate surface.

[0009] In some embodiments, the flow channel includes a plurality of first guide sections extending in a first direction, and the plurality of first guide sections are arranged sequentially at intervals in a second direction; and / or, the flow channel includes a plurality of second guide sections extending in the second direction, and the plurality of second guide sections are arranged sequentially at intervals in the first direction; wherein the first direction intersects the second direction.

[0010] In some embodiments, the spacing between two adjacent first guide sections is 5mm to 500mm; and / or, the spacing between two adjacent second guide sections is 5mm to 500mm.

[0011] In some embodiments, the thickness of the porous core material is 1mm to 20mm, the width of the flow channel is 0.5mm to 12mm, and / or the depth of the flow channel is 0.5mm to 3mm.

[0012] In some embodiments, the thickness of the porous core material is 20mm to 50mm, the width of the flow channel is 0.5mm to 15mm, and / or the depth of the porous core material is 0.5mm to 5mm.

[0013] The composite material of this invention includes a porous core material, a first reinforcing layer, a second reinforcing layer, and a matrix resin. The porous core material is the porous core material described in any of the above embodiments. The first reinforcing layer, the porous core material, and the second reinforcing layer are arranged sequentially. The first reinforcing layer, the porous core material, and the second reinforcing layer are connected by the matrix resin.

[0014] The method for forming a porous core material according to an embodiment of the present invention includes the following steps:

[0015] S1: The first film is attached to the cavity wall of the first half mold, the second film is attached to the cavity wall of the second half mold, and the first half mold and the second half mold are joined together; S2: Inject foaming material into the foaming mold, heat the foaming mold to a preset temperature and keep it at that temperature for a preset time, so that the foaming material foams and forms the porous core board, while the first film and the second film are connected to the porous core board. S3: Cool the foaming mold to form the porous core material inside the foaming mold.

[0016] In some embodiments, the cavity wall of the first half mold and / or the cavity wall of the second half mold includes protrusions, and in step S2, the protrusions are used to form the grooves on the first and / or second surfaces of the porous core plate.

[0017] The porous core material of this invention, by respectively setting a first film and a second film on the two surfaces (including a first surface and a second surface) of the porous core board, can block the pores on the surface of the porous core board and form a sealing layer on the surface of the porous core board. Furthermore, when the porous core material is used in a high-pressure resin transfer molding process to form a composite material product, during the resin injection process, the sealing layer formed by the first film and the second film can fundamentally prevent the resin from penetrating into the interior of the porous core material, thereby preventing the composite material product from becoming too heavy, achieving lightweighting of the composite material product, and improving product performance. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the layer structure of a composite material according to an embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the structure of a porous core material according to an embodiment of the present invention.

[0020] Figure 3 This is a schematic diagram of the flow channel arrangement of a porous core material according to an embodiment of the present invention.

[0021] Figure label: 100. Composite materials; 10. Porous core material; 1. Perforated core board; 11. First board surface; 12. Second board surface; 2. First thin film; 3. Second thin film; 4. Flow channel; 41. First guide section; 42. Second guide section; 20. First reinforcement layer; 30. Second reinforcement layer; 40. Matrix resin. Detailed Implementation

[0022] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0023] like Figure 1As shown, the porous core material 10 of this embodiment includes a porous core plate 1, a first film 2, and a second film 3. The porous core plate 1 has a first plate surface 11 and a second plate surface 12, both of which have pores communicating with the internal space of the porous core plate 1. The first film 2 covers the first plate surface 11 and is connected to the porous core plate 1, and the second film 3 covers the second plate surface 12 and is connected to the porous core plate 1, so as to seal the pores on the first plate surface 11 and the second plate surface 12 using the first film 2 and the second film 3.

[0024] The porous core material 10 of this invention has a first film 2 and a second film 3 respectively provided on the two surfaces of the porous core board 1 (including the first surface 11 and the second surface 12). The first film 2 and the second film 3 can block the pores on the surface of the porous core board 1 and form a sealing layer on the surface of the porous core board 1. Furthermore, when the porous core material 10 is used in a high-pressure resin transfer molding process to form a composite material 100 product, the sealing layer formed by the first film 2 and the second film 3 can prevent the resin from penetrating into the interior of the porous core material 10 at the source during the resin injection process, thereby preventing the composite material 100 product from becoming too heavy. This can achieve the lightweighting of the composite material 100 product and improve product performance.

[0025] As an example, such as Figure 2 As shown, the porous core material 10 of this embodiment of the invention is suitable for forming a composite material 100 using a high-pressure resin transfer molding process. The formed composite material 100 includes a first reinforcing layer 20, a porous core material 10, and a second reinforcing layer 30 arranged sequentially. When producing the composite material 100 using the high-pressure resin transfer molding process, the first reinforcing layer 20, the porous core material 10, and the second reinforcing layer 30 are placed sequentially in a mold. Then, resin is injected into the mold. Under high pressure, the resin penetrates the first reinforcing layer 20 and the second reinforcing layer 30, and further penetrates between the first reinforcing layer 20 and the porous core material 10, as well as between the second reinforcing layer 30 and the porous core material 10, so that the first reinforcing layer 20, the porous core material 10, and the second reinforcing layer 30 are fixed to each other to form an integral structure, thereby satisfying the structural strength of the composite material 100 while achieving lightweighting.

[0026] In addition, in the high-pressure resin transfer molding process, the sealing layer formed by the first film 2 and the second film 3 is used to block the resin from penetrating into the porous core material 10, so that the resin consumption can be precisely controlled, avoiding large fluctuations in the amount of resin in a single composite material 100 product, thereby improving the consistency of the quality and the weight compliance rate of the composite material 100 product.

[0027] Optionally, the porous core board 1 is a foamed core material, which is made using a foaming molding process.

[0028] In some embodiments, the thickness of the first film 2 is 0.03 mm to 1 mm.

[0029] In some embodiments, the thickness of the second film 3 is 0.03 mm to 1 mm.

[0030] By using the first film 2 and the second film 3 to form a sealing layer on the two surfaces of the porous core board 1, the airtightness and strength of the sealing layer on the surface of the porous core material 10 can be improved by limiting the thickness of the first film 2 and the second film 3, and the first film 2 and the second film 3 can be prevented from being damaged in the high-pressure resin transfer molding process.

[0031] In some embodiments, at least one of the first film 2 and the second film 3 is made of polyurethane film.

[0032] Optionally, both the first film 2 and the second film 3 are made of thermoplastic polyurethane film.

[0033] During the process of forming composite material 100 using high-pressure resin transfer molding, the resin exerts extrusion pressure on the porous core material 10 during injection. The thermoplastic polyurethane film has good flexibility, which can prevent the first film 2 and the second film 3 from breaking under the extrusion pressure, ensuring the integrity of the first film 2 and the second film 3, and thus blocking the resin from entering the voids of the porous core material 10.

[0034] Meanwhile, the thermoplastic polyurethane film also has good adhesion, which is beneficial for the first film 2 and the second film 3 to bond with the porous core board 1. For example, during the foaming process of the porous core board 1, with the help of foaming temperature (40℃~160℃) and pressure, the first film 2 and the second film 3 can be tightly bonded to the two surfaces of the porous core board 1, forming a continuous and dense closed layer on the two surfaces of the porous core board 1, completely sealing the pores on the surface of the porous core board 1, blocking the channels for resin to penetrate into the core material, and thus blocking the resin from entering the porous core material 10 from the source.

[0035] In some embodiments, such as Figure 1 As shown, the first plate surface 11 and / or the second plate surface 12 have grooves, and the film adheres to the groove wall to form a flow channel 4 on the first plate surface 11 and / or the second plate surface 12.

[0036] In the process of forming composite material 100 using high-pressure resin transfer molding, the flow channels 4 on the surface of porous core material 10 can guide the resin to flow rapidly and spread evenly, reducing the local accumulation of resin on the surface of porous core material 10. This prevents the first film 2 and / or the second film 3 from being damaged due to excessive local stress, thereby ensuring the integrity of the first film 2 and the second film 3, blocking the resin from penetrating into the interior of porous core material 10, achieving the lightweighting of composite material 100 products, and improving the product performance of composite material 100.

[0037] In some embodiments, such as Figure 3 As shown, the flow channel 4 includes multiple first guide sections 41, which extend in a first direction and are arranged sequentially at intervals in a second direction, with the first direction intersecting the second direction.

[0038] In some embodiments, such as Figure 3 As shown, the flow channel 4 also includes a plurality of second guide sections 42, which extend in the second direction and are arranged at intervals in the first direction, with the first direction intersecting the second direction.

[0039] Thus, multiple first guide sections 41 and multiple second guide sections 42 interweave to form a grid-arranged flow channel 4. This flow channel 4 can improve the uniformity of resin distribution and guide the resin to quickly cover the entire surface of the porous core material 10, thereby improving the performance of the composite material 100.

[0040] Optionally, the first direction and the second direction are perpendicular to each other.

[0041] Specifically, such as Figure 3 As shown, the flow channel 4 is arranged on the entire surface of the porous core material 10. Multiple first flow guide sections 41 are evenly spaced in the second direction, and multiple second flow guide sections 42 are evenly spaced in the first direction. The distance between two adjacent first flow guide sections 41 is equal to the distance between two adjacent second flow guide sections 42. The intersection positions of the first flow guide sections 41 and the second flow guide sections 42 are interconnected. In the process of forming the composite material 100 using the high-pressure resin transfer molding process, resin is injected into the mold. The resin can cover the entire surface of the porous core material 10 along the multiple first flow guide sections 41 and the multiple second flow guide sections 42. The evenly arranged first flow guide sections 41 and second flow guide sections 42 can improve the uniformity of resin distribution, thereby improving the performance of the composite material 100 product.

[0042] In other embodiments, the flow channel 4 can also be arranged in other ways, such as a serpentine arrangement, as long as it can cover the entire surface of the porous core material 10, which will not be elaborated here.

[0043] In some embodiments, the spacing between two adjacent first guide sections 41 is 5mm to 500mm.

[0044] In some embodiments, the spacing between two adjacent second guide sections 42 is 5mm to 500mm.

[0045] In practical applications, the spacing between two adjacent first guide sections 41 and / or two adjacent second guide sections 42 can be determined based on the width and depth parameters of the flow channel 4, as well as the outer contour and thickness parameters of the porous core material 10. For example, when the width of the flow channel 4 is large, the spacing between two adjacent first guide sections 41 and two adjacent second guide sections 42 can be increased accordingly; when the width of the flow channel 4 is small, the spacing between two adjacent first guide sections 41 and two adjacent second guide sections 42 can be decreased accordingly.

[0046] In some embodiments, the thickness of the porous core material 10 is 1 mm to 20 mm, the width of the flow channel 4 is 0.5 mm to 12 mm, and / or the depth of the flow channel 4 is 0.5 mm to 3 mm.

[0047] In some embodiments, the thickness of the porous core material 10 is 20mm to 50mm, the width of the flow channel 4 is 0.5mm to 15mm, and / or the depth of the porous core material 10 is 0.5mm to 5mm.

[0048] In other words, the width and depth parameters of the flow channel 4 can be flexibly selected according to the thickness of the porous core material 10. At the same time, the width and depth parameters of the flow channel 4 can also be selected according to the material characteristics of the porous core material 10 to meet the production of composite materials 100 of different thicknesses and types.

[0049] Optionally, the thickness of the porous core material 10 is 2mm to 15mm.

[0050] Preferably, the thickness of the porous core material 10 is 5mm to 10mm.

[0051] like Figure 2 As shown, the composite material 100 of this embodiment includes a porous core material 10, a first reinforcing layer 20, a second reinforcing layer 30, and a matrix resin 40. The porous core material 10 is the porous core material 10 of any of the above embodiments. The first reinforcing layer 20, the porous core material 10, and the second reinforcing layer 30 are arranged sequentially, and the first reinforcing layer 20, the porous core material 10, and the second reinforcing layer 30 are connected by the matrix resin 40.

[0052] The composite material 100 of this invention can increase its structural strength by using the first reinforcing layer 20 and the second reinforcing layer 30, and can achieve lightweighting by using the porous core material 10 as its intermediate structural layer.

[0053] Furthermore, the first film 2 and the second film 3 of the porous core material 10 can seal the pores on the surface of the porous core board 1, forming a sealing layer on the surface of the porous core board 1. In the process of forming the composite material 100 using the high-pressure resin transfer molding process, the sealing layer formed by the first film 2 and the second film 3 can prevent the resin from penetrating into the interior of the porous core material 10 at the source, thereby preventing the composite material 100 product from becoming too heavy, achieving the lightweighting of the composite material 100 product and improving product performance.

[0054] Optionally, the first reinforcing layer 20 is made of glass fiber.

[0055] Optionally, the second reinforcing layer 30 is made of glass fiber.

[0056] In practical applications, during the formation of composite material 100 using high-pressure resin transfer molding, the porous core material 10, the first reinforcing layer 20, and the second reinforcing layer 30 are first placed in a mold in sequence. Then, resin is injected into the mold. Under high pressure, the resin enters the first reinforcing layer 20 and the second reinforcing layer 30, and then penetrates between the first reinforcing layer 20 and the porous core material 10, as well as between the second reinforcing layer 30 and the porous core material 10. This allows the first reinforcing layer 20, the porous core material 10, and the second reinforcing layer 30 to be fixed together by the resin (i.e., the matrix resin 40), forming an integral structure. This satisfies the structural strength requirements of composite material 100 while achieving lightweighting.

[0057] It is understood that the above description of the porous core material 10 also applies to the composite material 100, and will not be repeated here.

[0058] The method for forming the porous core material 10 according to an embodiment of the present invention includes the following steps: S1: The first film 2 is attached to the cavity wall of the first half mold, the second film 3 is attached to the cavity wall of the second half mold, and the first half mold and the second half mold are joined together. S2: Inject foaming material into the foaming mold, heat the foaming mold to a preset temperature and keep it warm for a preset time, so that the foaming material foams and forms a porous core board 1, while the first film 2 and the second film 3 are connected to the porous core board 1. S3: Cool the foaming mold to form a porous core material 10 inside the foaming mold.

[0059] The porous core material 10 forming method of this invention can realize the bonding connection between the porous core board 1 and the first film 2 and the second film 3 during the foaming and forming process of the porous core board 1, thereby simplifying the forming steps of the porous core material 10 and improving the production efficiency of the porous core material 10.

[0060] Optionally, the preset temperature is 40℃~160℃.

[0061] In some embodiments, the cavity wall of the first half mold and / or the cavity wall of the second half mold includes protrusions, and in step S2, grooves are formed on the first plate surface 11 and / or the second plate surface 12 of the porous core plate 1 using the protrusions.

[0062] In practical applications, during the processing of the first and second half molds, protrusions corresponding to the grooves are provided on the cavity walls of both the first and second half molds, thereby forming flow channels 4 on the surface of the porous core material 10. Thus, during the foaming and molding process of the porous core board 1, the connection between the porous core board 1 and the first and second films 2 and 3 can be achieved, and flow channels 4 can be formed on the surface of the porous core material 10. This eliminates the need for additional processing steps for the porous core material 10, significantly simplifying the molding process and improving the production efficiency of the porous core material 10.

[0063] It is understood that the above description of the porous core material 10 and the composite material 100 also applies to the molding method of the porous core material 10, and will not be repeated here.

[0064] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0065] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0066] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0067] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0068] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0069] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A porous core material (10), characterized in that, It includes a porous core plate (1), a first film (2) and a second film (3). The porous core plate (1) has a first plate surface (11) and a second plate surface (12). Both the first plate surface (11) and the second plate surface (12) have pores that communicate with the internal space of the porous core plate (1). The first film (2) covers the first plate surface (11) and is connected to the porous core plate (1), and the second film (3) covers the second plate surface (12) and is connected to the porous core plate (1), so as to use the first film (2) and the second film (3) to seal the pores on the first plate surface (11) and the second plate surface (12).

2. The porous core material (10) according to claim 1, characterized in that, The thickness of the first film (2) is 0.03 mm to 1 mm; and / or, The thickness of the second film (3) is 0.03 mm to 1 mm; and / or, At least one of the first film (2) and the second film (3) is made of polyurethane film.

3. The porous core material (10) according to claim 1 or 2, characterized in that, The first plate surface (11) and / or the second plate surface (12) have grooves, and the first film (2) and / or the second film (3) are attached to the groove wall to form a flow channel (4) on the first plate surface (11) and / or the second plate surface (12).

4. The porous core material (10) according to claim 3, characterized in that, The flow channel (4) includes a plurality of first guide sections (41), the first guide sections (41) extending in a first direction, and the plurality of first guide sections (41) arranged sequentially at intervals in a second direction; and / or, The flow channel (4) includes a plurality of second guide sections (42), which extend in the second direction and are arranged at intervals in the first direction. Wherein, the first direction intersects with the second direction.

5. The porous core material (10) according to claim 4, characterized in that, The spacing between two adjacent first guide sections (41) is 5mm to 500mm; and / or, The distance between two adjacent second guide sections (42) is 5mm to 500mm.

6. The porous core material (10) according to claim 3, characterized in that, The thickness of the porous core material (10) is 1mm to 20mm, the width of the flow channel (4) is 0.5mm to 12mm, and / or the depth of the flow channel (4) is 0.5mm to 3mm.

7. The porous core material (10) according to claim 3, characterized in that, The thickness of the porous core material (10) is 20mm~50mm, the width of the flow channel (4) is 0.5mm~15mm, and / or the depth of the porous core material (10) is 0.5mm~5mm.

8. A composite material (100), characterized in that, include: Porous core material (10), wherein the porous core material (10) is the porous core material (10) according to any one of claims 1-7. A first reinforcing layer (20) and a second reinforcing layer (30) are provided sequentially, wherein the first reinforcing layer (20), the porous core material (10), and the second reinforcing layer (30) are provided sequentially; The matrix resin (40), the first reinforcing layer (20), the porous core material (10) and the second reinforcing layer (30) are connected through the matrix resin (40).

9. A method for forming a porous core material (10) as described in any one of claims 1-7, characterized in that, Includes the following steps: S1: The first film (2) is attached to the cavity wall of the first half of the foaming mold, the second film (3) is attached to the cavity wall of the second half of the foaming mold, and the first half of the mold and the second half of the mold are joined together; S2: Inject foaming material into the foaming mold, heat the foaming mold to a preset temperature and keep it warm for a preset time, so that the foaming material foams and forms the porous core board (1), while the first film (2) and the second film (3) are connected to the porous core board (1). S3: Cool the foaming mold to form the porous core material (10) inside the foaming mold.

10. The method for forming the porous core material (10) according to claim 9, characterized in that, For the porous core material (10) as described in any one of claims 3-7, the cavity wall of the first half mold and / or the cavity wall of the second half mold includes protrusions, and in step S2, the grooves are formed on the first plate surface (11) and / or the second plate surface (12) of the porous core plate (1) using the protrusions.

Images