A full-composite deployable thermal insulation large plate for a shelter and a forming method thereof

Abstract

The application discloses a full-composite deployable heat-insulating large plate for a shelter and a forming method thereof. The forming method comprises the following steps: S1, connecting composite material sections by adopting a gluing-riveting fixing mode to obtain a composite material section framework; and S2, hot-pressing and compounding the composite material section framework, a composite material skin and a heat-insulating layer by adopting a hot-pressing and compounding forming method to obtain the full-composite deployable heat-insulating large plate for the shelter. The shelter is integrally hot-compounded by adopting a prefabricated composite material framework, heat-insulating material and composite material skin, the shelter large plate framework is assembled based on the composite material section, and the framework, the heat-insulating material and the composite material skin are integrally formed by hot compounding, so that the development efficiency of the shelter large plate can be effectively improved, and rapid preparation is realized.

Description

Technical Field

[0001] This invention relates to the field of composite material modular housing manufacturing technology, specifically to a fully composite material deployable thermal insulation panel for modular housing and its molding method. Background Technology

[0002] With the development of modern society, modular shelters are increasingly widely used in various fields. Modular shelters offer advantages such as rapid deployment and flexible movement, playing a vital role in medical, emergency rescue, and military applications. Existing modular shelter panels are mostly made of metal, which, while possessing a certain strength, are heavy, hindering transportation and rapid deployment. Meanwhile, some lightweight materials lack sufficient strength to meet the requirements of modular shelter use. Currently, composite material panels for modular shelters are mostly single-layer foam sandwich panels, serving only as insulation layers and lacking deployment and load-bearing capacity, thus failing to meet the needs of deployable modular shelters. Based on the existing problems with modular shelters, this invention aims to provide a fully composite material deployable insulation panel for modular shelters. Summary of the Invention

[0003] The purpose of this invention is to provide a fully composite material deployable thermal insulation panel for modular shelters. It uses composite material profiles as the skeleton, foamed or porous materials as the insulation layer, and composite fiber-reinforced thermoplastic composite material panels on the surface. Through prefabrication of the skeleton assembly and integrated molding of the panel, the load-bearing capacity and stability of the modular shelter panel are improved, the weight of the modular shelter is reduced, and the portability and rapid deployment capability of the modular shelter are improved.

[0004] The composite material profiles and sheet skin for modular shelters provided by this invention use composite material profiles to connect and assemble the profiles to prepare the modular shelter frame, and prepare the modular shelter all-composite material unfoldable heat-insulating large panel through hot-pressing composite molding process.

[0005] The present invention discloses a method for preparing a "modular cabin frame" using an adhesive-riveting method to connect composite material profiles. The profiles are cut according to the frame design structure. Profiles with the same outer diameter as the inner diameter of the profiles to be connected are used as connectors. A thermosetting resin adhesive that cures at room temperature is coated on the surface of the connector. The profiles to be connected are then embedded into the connectors and bonded together. After the adhesive cures, holes are drilled at the joints, and composite rivets are used for riveting to further secure the profiles and enhance the connection strength. The connecting parts are then joined using the same method to obtain the modular cabin frame. The adhesive-riveting process effectively solves the problem of joining thermosetting composite materials, achieving a high-strength connection.

[0006] This invention, "Preparation of Deployable Insulated Panels of All Composite Materials for Container Housing using Hot Press Molding Process," mainly comprises three structures: a composite material profile skeleton, a composite material skin, and a thermal insulation layer. A thermosetting resin adhesive, but not limited to, is used to place the insulation material into the profile skeleton. An adhesive is then applied to the surface, and continuous fiber-reinforced composite panels are placed on the upper and lower sides of the skeleton. The mixture is then heat-sealed using a laminating machine to achieve integrated molding of the deployable insulated panels of all composite materials for container housing.

[0007] Specifically, the molding method of the deployable thermal insulation panel made of all-composite material for modular shelters of the present invention includes the following steps: S1. The composite material profiles are connected by adhesive-riveting to obtain the composite material profile skeleton; S2. Using a hot-pressing composite molding method, the composite material profile skeleton, composite material skin and thermal insulation layer are hot-pressed together to obtain a fully composite material deployable thermal insulation panel for container houses.

[0008] Preferably, the composite material profile is formed from continuous fibers and thermosetting resin; The continuous fibers include carbon fibers and glass fibers; The thermosetting resins include epoxy resins, polyurethanes, and phenolic resins; The molding process includes fiberglass roving arrangement, resin impregnation, fiberglass cloth wrapping, preforming, extrusion molding and curing, traction, and cutting.

[0009] Preferably, in step S1, the adhesive-riveting fixing method includes using thermosetting resin adhesives to bond the composite material profile and connectors and using composite material rivets to rivet them.

[0010] The outer diameter of the connector is the same as the inner diameter of the composite material profile.

[0011] Preferably, the adhesive-riveting fixing method includes the following steps: The thermosetting resin adhesive is coated on the surface of the connector, and then the connector is embedded into the composite material profile to bond the composite material profile. After the thermosetting resin adhesive has cured, holes are drilled at the joint, and the composite rivets are used for riveting to further fix the joint and enhance its strength.

[0012] Preferably, the composite material skin is obtained by a layup-hot pressing process of glass fiber and polypropylene resin through glass fiber reinforced polypropylene prepreg tape, wherein the layup angle is 0 / 90° cross layup, the hot pressing temperature is 180-220℃, the hot pressing pressure is 80-100 Bar, and the traction speed is 1m / min.

[0013] Preferably, the two surfaces of the composite material skin are respectively laminated with non-woven fabric and PET film. The non-woven fabric can increase the surface roughness of the board, which is beneficial to the adhesion between the board and the insulation material. The PET film serves as the outer surface of the cabin skin, and the surface can be coated with paint.

[0014] Preferably, in step S2, the conditions for hot-pressing composite are as follows: The temperature is 60-80℃, the pressure is 60-100 Bar, and the time is 60-120 min.

[0015] The modular cabin panels of this invention use fiber-reinforced composite material profiles as the skeleton, which offers better strength and stability compared to non-deployable modular cabin panels. This allows for high load-bearing capacity on the cabin surface. Compared to deployable modular cabin panels, the composite skeleton provides higher strength and lighter weight, effectively reducing the weight of the cabin while maintaining stability.

[0016] The surface of the modular cabin panel of this invention uses fiber-reinforced composite material panels as the skin. Compared with traditional metal modular cabin skins, it is lighter, stronger, and can be integrally molded with the composite material skeleton, realizing the rapid preparation of lightweight modular cabin panels.

[0017] The modular cabin of this invention adopts a prefabricated composite material frame, insulation material and composite material skin integrated thermal composite molding. Based on the composite material profile assembly of the modular cabin large panel frame, the frame, insulation material and composite material skin are integrated into a single molding through thermal composite molding, which can effectively improve the development efficiency of the modular cabin large panel and realize rapid preparation. Attached Figure Description

[0018] Figure 1 This is a structural diagram of the deployable thermal insulation panel made of all composite materials for the modular shelter of the present invention. Figure 2 This is a diagram of the connection structure of composite material profiles.

[0019] The markings in the diagram are as follows: 1. Fiber-reinforced composite skin; 2. Composite profile; 3. Thermal insulation material; 4. Fiber-reinforced composite skin; 5. Composite rivet; 6. Composite connector. Detailed Implementation The present invention will be further described below with reference to the accompanying drawings, but the present invention is not limited to the following embodiments.

[0020] The molding method for deployable thermal insulation panels made of all-composite materials for shelters provided by this invention mainly includes the following steps: 1. Preparation of composite material profiles for modular shelters; 2. Based on the connection and assembly of composite material profiles, fabricate the large panel frame of the modular cabin; 3. Preparation of composite material sheet skin for modular shelters; 4. By using a hot-pressing composite molding process, composite material profile skeleton, composite material skin and thermal insulation layer are hot-pressed together to develop a fully composite material deployable thermal insulation panel for modular shelters.

[0021] Example 1: Molding of deployable thermal insulation panels made of all-composite materials for modular shelters 1. Preparation of composite material profiles for modular shelters The composite material profiles for the modular shelters utilize continuous fibers and thermosetting resins. The molding process involves: fiberglass roving arrangement – ​​epoxy resin impregnation – fiberglass cloth wrapping – preforming – extrusion molding and curing – traction – cutting. The resin solution content is 20%, the molding temperature is 150℃, and the traction speed is 0.1 m / min. Composite material profiles with an outer diameter of 60 mm and an inner diameter of 40 mm, and those with an outer diameter of 40 mm and an inner diameter of 30 mm, are produced using 60×40 and 40×30 molds.

[0022] 2. Preparation of the modular cabin frame The modular cabin frame is made by connecting and assembling composite material profiles.

[0023] The modular cabin frame is constructed using an adhesive-riveting method for connection and fabrication, such as... Figure 2 As shown.

[0024] According to the frame design structure, the profiles are cut, and a 40 mm outer diameter profile is used as the composite connector 6. An epoxy resin adhesive that can cure at room temperature is coated on the surface of the composite connector 6. Then, the 40 mm composite connector 6 is embedded into the 60 mm composite profile 2 that needs to be connected, and the composite profile 2 is bonded together. After standing for 12 hours to allow the adhesive to cure, holes are drilled at the connection points, and composite rivets 5 are used for riveting to further fix the profiles and enhance the connection strength. The right-angle connections are made using the same method, thus preparing the modular cabin frame.

[0025] 3. Preparation of composite material panels for modular shelter skin Glass fiber and polypropylene (PP) resin were selected, and the material was prepared using a layup-hot pressing process with glass fiber reinforced polypropylene prepreg tape. The glass fiber reinforced polypropylene prepreg tape was laid up at a 0 / 90° cross-layup angle to ensure high strength in both the 0° and 90° directions. The prepreg tape was then hot-pressed at 200℃, 100 Bar, and 1 m / min to obtain a continuous fiber-reinforced composite material sheet. Different thicknesses of continuous fiber-reinforced composite material sheets could be obtained by adjusting the number of prepreg tape layers. During this process, a non-woven fabric or PET film was thermally laminated onto the surface. Thermally laminating a layer of non-woven fabric to the sheet surface increases its roughness, which is beneficial for adhesion between the sheet and the insulation material. The PET film, after thermal lamination, serves as the outer skin of the shelter, and the surface can be coated with paint.

[0026] 4. Hot-pressed composite fabrication of deployable thermal insulation panels made of all-composite materials for modular shelters. Cut the PET foam to the dimensions of the gaps in the profile skeleton and then place it into the skeleton of composite profile 2. Coat the surface with two-component polyurethane adhesive, then place the continuous fiber reinforced composite panel (skin) on the upper and lower sides of the skeleton and heat-bond it using a laminating machine. The heat-bonding temperature is 65℃, the heat-bonding pressure is 70 Bar, and the time is 90 minutes. After heat-bonding, remove the panel from the laminating machine to obtain a large, deployable, all-composite thermal insulation panel for shelters. Figure 1 As shown.

[0027] The large plate prepared in this embodiment has a size of 6 m × 2.5 m and a total mass of 160 kg.

Claims

1. A molding method for a deployable thermal insulation panel made of all-composite materials for use in shelters, comprising the following steps: S1. The composite material profiles are connected by adhesive-riveting to obtain the composite material profile skeleton; S2. Using a hot-pressing composite molding method, the composite material profile skeleton, composite material skin and thermal insulation layer are hot-pressed together to obtain a fully composite material deployable thermal insulation panel for container houses.

2. The molding method according to claim 1, characterized in that: The composite material profile is formed from continuous fibers and thermosetting resin; The continuous fibers include carbon fibers and glass fibers; The thermosetting resins include epoxy resins, polyurethanes, and phenolic resins.

3. The molding method according to claim 1 or 2, characterized in that: In step S1, the adhesive-riveting fixing method includes using thermosetting resin adhesives to bond the composite material profiles and connectors and using composite material rivets to rivet them.

4. The molding method according to claim 3, characterized in that: The outer diameter of the connector is the same as the inner diameter of the composite material profile.

5. The molding method according to claim 4, characterized in that: The adhesive-riveting fixing method includes the following steps: The thermosetting resin adhesive is coated on the surface of the connector, and then the connector is embedded into the composite material profile to bond the composite material profile. After the thermosetting resin adhesive has cured, holes are drilled at the joint, and the composite rivets are used for riveting to further fix it in place.

6. The molding method according to any one of claims 1-5, characterized in that: The composite material skin is obtained by a layup-hot pressing process of glass fiber and polypropylene resin through glass fiber reinforced polypropylene prepreg tape, wherein the layup angle is 0 / 90° cross layup, the hot pressing temperature is 180-220℃, the hot pressing pressure is 80-100 Bar, and the traction speed is 0.5-1.5 m / min.

7. The molding method according to any one of claims 1-6, characterized in that: The two surfaces of the composite material skin are respectively laminated with non-woven fabric and PET film.

8. The molding method according to any one of claims 1-7, characterized in that: In step S2, the conditions for hot-pressing composite are as follows: The temperature is 60-80℃, the pressure is 60-100 Bar, and the time is 60-120 min.

9. A deployable thermal insulation panel made of all composite materials for use in shelters, prepared by the method described in any one of claims 1-8.

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