Lightweight rigid fiber-added sandwich composite board

Abstract

The utility model relates to the technical field of composite boards, in particular to a light rigid fiber-added sandwich composite board which comprises a first surface layer, a core layer and a second surface layer, and the first surface layer and the second surface layer are connected to a first end face and a second end face which are opposite to each other of the core layer. Each of the first surface layer and the second surface layer comprises at least two glass fiber belt layers; the core layer comprises a plurality of tubular structures which are arranged in a honeycomb shape, the machining forming efficiency is high, no noise is generated in the production process, and cutting chips and machining waste gas in the production process can be completely absorbed by the collecting cloth bag and the dust removal device; good heat insulation and sound insulation performance is achieved, and recycling and reusing are easy; in addition, the plate has the characteristics of light weight, high rigidity, flame retardance and the like, has good heat deformation resistance, and is convenient to transport, process and mount.

Description

Technical Field

[0001] The utility model relates to the technical field of synthetic boards, in particular to a lightweight rigid fiber-reinforced sandwich composite board. Background Art

[0002] There are many varieties of panels on the market, suitable for various scenarios, and can be processed into various supporting materials, decorative materials, flat paving materials, photovoltaic backboard materials, etc.

[0003] The commonly used board materials on the market mainly include gypsum, plywood, bamboo plywood, wood, metal alloy, plastic, stone, glass, etc. Although these materials have their own advantages, they also have some obvious defects and shortcomings;

[0004] For example, gypsum board and plywood are light in weight, easy to cut and install, but have low strength and are easily damaged by moisture, which may lead to functional failure. Wooden boards are light in weight, easy to process and install, but they are easy to crack, get moldy and infested with insects, and rot during use. Metal alloy boards are rigid, strong, sturdy and wear-resistant, but due to their high cost, high density, heavy weight, and difficulty in installation and drilling, they cannot be used for decorative ceilings, have poor decorative properties, and cannot achieve poor insulation effects. Plastic boards are light in weight and relatively easy to transport and install, but are easy to discolor and deform, have poor heat resistance, and are mostly not flame retardant. Boards made of stone are rigid, have good wear resistance, and have good stability, but are heavy, easy to break, difficult to process, have poor decorative properties, and have poor insulation effects. Glass boards have good rigidity and good aging resistance, but they are fragile and difficult to process and install. They are heavy for photovoltaic products and require fixed brackets for support, which has high production costs and inconvenient installation.

[0005] Therefore, it is very necessary to provide a new type of lightweight rigid board to replace the above-mentioned traditional material boards. Utility Model Content

[0006] In view of the technical problems existing in the board materials in the prior art, the first aspect of the utility model proposes a technical solution, a lightweight rigid fiber-reinforced sandwich composite board, comprising a first skin layer, a core layer and a second skin layer, wherein the first skin layer and the second skin layer are connected to the first end face and the second end face opposite to the core layer;

[0007] The first skin layer and the second skin layer each include at least two glass fiber tape layers;

[0008] The core layer comprises a plurality of tubular structures arranged in a honeycomb shape, the axis of the tubular structure is parallel to the thickness direction of the core layer, each of the tubular structures comprises an inner layer and an outer layer, the inner layer comprises a glass fiber tube, and the outer layer comprises a rubber tube;

[0009] Preferably, the ratio of thickness to diameter of the tubular structure is greater than 1:10.

[0010] Preferably, the outer diameter of the tubular structure is 8.8-9.0 mm.

[0011] Preferably, the thickness of the core layer is 10 mm, the weight of the first skin layer and the second skin layer is 1000-1150 g / m2, and the weight of the core layer is 1100 g / m2.

[0012] Preferably, the tubular structures are closely arranged, the inner and outer contour cross-section shapes of the inner layer of the tubular structure are circular, the inner contour cross-section shape of the outer layer of the tubular structure is circular, and the outer contour cross-section shape of the outer layer of the tubular structure is hexagonal.

[0013] Preferably, the first skin layer and the second skin layer include glass fiber unidirectional tapes cross-stacked along a first direction and a second direction, and the first direction and the second direction are perpendicular to each other.

[0014] Preferably, the thickness of the glass fiber unidirectional tape is 0.15-0.17 mm.

[0015] Preferably, a narrow edge-sealing band is provided around the core layer, and the width of the narrow edge-sealing band is greater than the width of the core layer.

[0016] Compared with the prior art, the advantages of the utility model are:

[0017] The utility model has the advantages of high processing efficiency, easy recycling and reuse, light weight (2.2kg / ㎡), strong rigidity (unidirectional tape tensile strength reaches 1000MPa), flame retardancy (can produce flame retardant unidirectional tape and flame retardant honeycomb core), good heat deformation resistance (can ensure no deformation for 60 minutes at a temperature of 130°C), easy transportation, convenient processing and installation; it can be effectively used as a backboard on photovoltaic modules to manufacture lightweight and rigid solar photovoltaic modules, so that lightweight panels can be combined with the photovoltaic industry to create a new generation of photovoltaic module products. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings are not intended to be drawn to scale. In the accompanying drawings, each identical or nearly identical component shown in various figures may be represented by the same reference numeral. For the sake of clarity, not every component is labeled in each figure. Now, embodiments of various aspects of the utility model will be described by way of example and with reference to the accompanying drawings, in which:

[0019] Figure 1 It is a structural schematic diagram of a lightweight rigid fiber-reinforced sandwich composite board shown in the utility model;

[0020] Figure 2It is a schematic diagram of the cross-over and superposition state of the glass fiber unidirectional tapes shown in the utility model;

[0021] Figure 3 It is a schematic diagram of the tubular structures shown in the utility model being closely arranged;

[0022] Figure 4 It is a honeycomb structure formed by closely arranging the tubular structures shown in the utility model and then heat-treating;

[0023] Figure 5 It is a processing flow chart of the core layer shown in the utility model;

[0024] Figure 6 It is a processing flow chart of the one-way belt shown in the utility model;

[0025] Figure 7 It is a schematic diagram of the lamination process of the first skin layer, the second skin layer and the core layer shown in the utility model;

[0026] Figure 8 It is a schematic diagram of edge sealing of a plate shown in the utility model. DETAILED DESCRIPTION

[0027] In order to better understand the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.

[0028] The sheet material proposed in the utility model is especially used as the back sheet of the photovoltaic module. It should be understood that the back sheet of the photovoltaic module should first have the characteristics of heat resistance and flame retardancy. Secondly, in order to facilitate transportation and have considerable reliability, the back sheet should have strong rigidity and light weight. Currently, metal alloys and plastics are suitable for photovoltaic back sheets, but metal alloy sheets are high in cost, high in density, and heavy in weight, and plastic sheets are easy to discolor, easy to deform, have poor heat resistance, and are mostly not flame retardant.

[0029] Based on the above, if Figure 1 As shown, the first aspect of the utility model proposes a technical solution, a lightweight rigid fiber-reinforced sandwich composite panel, comprising a first skin layer 11, a core layer 20 and a second skin layer 12, wherein the first skin layer 11 and the second skin layer 12 are connected to the first end face and the second end face opposite to the core layer 20.

[0030] Furthermore, the first skin layer 11 and the second skin layer 12 each include at least two glass fiber tape layers.

[0031] In an optional embodiment, the first skin layer 11 and the second skin layer 12 include glass fiber unidirectional tapes cross-stacked along a first direction and a second direction, and the first direction and the second direction are perpendicular to each other.

[0032] Preferably, the thickness of the glass fiber unidirectional tape is 0.15-0.17 mm.

[0033] Combination Figure 2 As shown, the first unidirectional tape 101 along the first direction and the second unidirectional tape 102 along the second direction are cross-stacked. After the two layers of unidirectional tapes are heat-treated, the resin between the two layers of glass fiber unidirectional tapes melts together to form a composite tape. The surface of the tape is smooth and has good connectivity.

[0034] Furthermore, the core layer 20 includes a plurality of tubular structures 21 arranged in a honeycomb shape, the axis of the tubular structure 21 is parallel to the thickness direction of the core layer 20, each tubular structure 21 includes an inner layer 201 and an outer layer 202, the inner layer 201 includes a glass fiber tube, and the outer layer 202 includes a rubber tube.

[0035] The ratio of thickness to diameter of the tubular structure 21 is greater than 1:10, the glass fiber content in the first skin layer 11 and the second skin layer 12 is 65-70%, and the glass fiber content in the core layer 20 is 30%.

[0036] In this way, the tubular structure 21 formed by double-layer co-extrusion of glass fiber-containing particles has a larger thickness-to-diameter ratio, making the core layer 20 lightweight. Since the inner layer of the tubular structure is a glass fiber tube and the outer layer is a rubber tube, the connection between them is reliable and has both strength and hardness.

[0037] Furthermore, the skin layer composed of the glass fiber tape layer covers the surface of the core layer 20 having a tubular structure arranged in a honeycomb shape. The formed board has the characteristics of light weight (2.2kg / ㎡), strong rigidity (unidirectional tape tensile strength reaches 1000MPa), flame retardancy (flame retardant unidirectional tape and flame retardant honeycomb core can be made), good heat deformation resistance (can ensure that it remains unchanged for 60 minutes at a temperature of 130°C), easy transportation, and convenient processing and installation.

[0038] Furthermore, the tubular structures 21 are closely arranged, the inner and outer cross-sectional shapes of the inner layer 201 of the tubular structure 21 are circular, the inner cross-sectional shape of the outer layer 202 of the tubular structure 21 is circular, and the outer cross-sectional shape of the outer layer 202 of the tubular structure 21 is hexagonal.

[0039] like Figure 3 As shown, the tubular structure 21 is firstly arranged in a honeycomb shape. Since the outer layer 202 is a rubber tube, after being heated, the rubber tube of the outer layer 202 of the tubular structure 21 melts, and the rubber tubes of adjacent tubular structures 21 are melted and connected together, as shown in FIG. Figure 4 As shown, all the tubular structures 21 are made into an integral structure.

[0040] like Figure 7-8 As shown, a method for manufacturing the above-mentioned lightweight rigid fiber-reinforced sandwich composite board comprises the following steps:

[0041] Step S1, preparing a first skin layer 11, a second skin layer 12 and a core layer 20, and storing the prepared first skin layer 11 and the second skin layer 12 in rolls, and cutting the prepared core layer 20 into a predetermined size;

[0042] Step S2, pressing the first skin layer 11, the core layer 20 and the second skin layer 12 together to form a plate shape, during the pressing process, the first skin layer 11 and the second skin layer 12 are respectively located above and below the core layer 20, and the first skin layer 11 and the second skin layer 12 are bonded and fixed to the upper and lower surfaces of the core layer 20 by heating treatment, pressurization treatment and cooling treatment in sequence, so as to form a first plate;

[0043] Step S3, edge sealing the laminated plates: after trimming and polishing one side of the first plate, a narrow edge sealing band is arranged on the side, and the narrow edge sealing band is fixed to the side of the first plate by heating and rolling;

[0044] Step S4, cutting the first skin layer 11, the second skin layer 12 and the edge banding narrow strip on the periphery of the edge-sealed board according to the length of the core layer 20;

[0045] Step S5, trimming the remaining edges of the plate according to step S3 to complete the production of the plate;

[0046] In the manufacturing process, each core layer 20 cut into a predetermined size is fed along the direction of the assembly line, and the first skin layer 11, the second skin layer 12 and the edge band are unrolled along the direction of the assembly line.

[0047] Specifically, in the process of pressing the first skin layer 11, the core layer 20 and the second skin layer 12 together, a Teflon tape laminating machine is used, such as Figure 7 As shown, the Teflon belt laminating machine includes a lower conveyor belt and an upper conveyor belt, and a heating zone, a pressurizing zone and a cooling zone are provided between the lower conveyor belt and the upper conveyor belt. The core layer 20 is laid on the second skin layer 12 and is brought into the laminating machine together with the operation of the lower conveyor belt. During the heating process in the heating section, the second skin layer 12 and the first skin layer 11 are melted, and the second skin layer 12 and the first skin layer 11 are pressurized and adhered to the upper and lower surfaces of the core layer 20 through the pressurizing area, and then enter the cooling section for curing and pressurizing molding. The molded product is the first skin layer 11, the second skin layer 12 and the core layer 20 bonded.

[0048] Furthermore, during the edge banding process, one side is edge banded first, and then all the edge banded boards are rotated 90 degrees to perform edge banding on the second side. After the edge banding is completed, all the boards are rotated 90 degrees to perform edge banding on the third side, until all four sides are edge banded. A total of four edge banding operations are required.

[0049] It should be understood that the edge banding uses strips cut to a certain width. For example, if the thickness of the core layer 20 is 10 mm, the edge banding is cut to a width of 12 to 14 mm. The edge banding is rolled into a roll and bonded to the edge of the core layer 20 through an edge banding device to achieve a good edge seal and a right-angled edge.

[0050] Specifically, Figure 8 As shown, when the plate is linearly conveyed by the conveying device 47, the grinding device 41 grinds the side to make the side end surface flat and smooth, the pressure roller 42 presses the narrow strip unwound by the narrow strip roller 45 against the side, and the narrow strip is fit with the side end surface through the heat treatment of the heating device 43 to complete the edge sealing, wherein the guide roller 44 plays a guiding role for the narrow strip.

[0051] Taking a plate with a core layer 20 of 10 mm thickness as an example, the weight of the first skin layer 11 and the second skin layer 12 is about 1000-1150 g / ㎡, the core layer 20 is 1100 g / ㎡, and its area weight is about 2.2 kg / ㎡.

[0052] like Figure 5 As shown, the steps of preparing the core layer 20 include:

[0053] Step C1, preparing fiber-added particles, mixing the fiber-added particles with PP resin, and extruding them together with POE film, and forming a tubular structure 21 after cooling;

[0054] Step C2: After cutting the multiple tubular structures 21 into suitable lengths, they are closely placed together to form a rectangular honeycomb core mass;

[0055] Step C3: drying and curing the honeycomb core mass so that adjacent tubular structures 21 are bonded together, and then the honeycomb core mass is cut to a predetermined thickness to form a core layer 20 .

[0056] In a specific embodiment, the fiber-reinforced granular material is stirred with the PP material, the molten fiber-reinforced material is extruded through the 65 extruder, and the POE rubber material is co-extruded with the auxiliary machine 35 extruder, the co-extruded molten material passes through a round tube mold and enters a cooling water tank, and the negative pressure of the cooling water tank is maintained by the operation of a vacuum system, so that the extruded circular honeycomb tube forms a round tube under negative pressure, the formed round tube enters the second stage of cooling and then enters the cutting device to be cut into a specified size.

[0057] Furthermore, the cut multiple tubular structures 21 are neatly placed on a swing tube rack, and the length of the swing tube rack is adjusted according to the length required for actual production; after the personnel have neatly placed the honeycomb core tubes, they confirm that there are no leaking tubes between the swing tubes, and if a leaking tube occurs, they are promptly repaired; then the arranged honeycomb core tube rack is pushed into a curing and baking chamber for baking, and all the honeycomb core tubes are baked and bonded together to form an overall rectangular lump.

[0058] The baking temperature is set to 110-130° C., and the outer POE layer of the tubular structure 21 is melted and bonded together through a heating cycle.

[0059] Furthermore, the honeycomb core lump is placed on a slicer for honeycomb core slicing. The thickness of the slice is set according to the actual required thickness of the honeycomb board. Finally, the cut honeycomb core slices are placed on a push table saw for trimming, and finally honeycomb core slices with consistent length, width and thickness are formed.

[0060] Furthermore, the ingredients of the fiber-added particles include PP, PP-G, antioxidants, lubricants and glass fibers. PP, PP-G, antioxidants, lubricants and glass fibers are mixed by a mixer and then processed into the desired fiber-added particles by a granulator.

[0061] Specifically, according to the raw material formula, the required materials are placed in the high-speed mixer. After the materials are fully stirred, the lower hopper is opened, and the materials enter the screw extruder. The extrusion component is heated, and the material passes through the heated component through the operation of the extrusion motor. The screw pushes the molten material and passes through the cooling water tank and the cooling and dewatering fan in turn. The cooled material strips are cut and finally processed into the required fiber-added particles.

[0062] Furthermore, the preparation of the first skin layer 11 and the second skin layer 12 includes making a unidirectional tape and a composite unidirectional tape.

[0063] like Figure 6 As shown, making a unidirectional belt includes the following steps:

[0064] Step A1, fully unfold the glass fiber material;

[0065] Step A2, impregnating the spread glass fiber material with molten PP resin, and performing impregnation twice;

[0066] Step A3, rolling the impregnated glass fiber material, and winding it after cooling;

[0067] Wherein, in step A1, the glass fiber material is spread out by a plurality of spreading rollers, and one of the spreading rollers heats all the glass fiber materials.

[0068] The glass fibers formed in this way have low water content, will not stick to each other, and have good dispersion. Therefore, after the PP resin is impregnated, fewer bubbles are formed and the fibers are relatively dense, so the quality of the unidirectional tape is good.

[0069] The composite unidirectional tape comprises the following steps:

[0070] Step B1, cross-stack two or more layers of unidirectional tapes in a first direction and a second direction;

[0071] Step B2, sequentially heating, pressurizing and cooling the stacked unidirectional tapes to melt the resins in the multiple layers of unidirectional tapes together to form a composite unidirectional tape;

[0072] The included angle between the first direction and the second direction is 90°.

[0073] In a specific embodiment, the wound unidirectional tape is cut transversely, the cut tapes are cross-stacked at 0° and 90°, and enter a compounding machine to synthesize two or more skin layers. The compounding machine is a forming device with heating, cooling and pressurizing functions. Heating is at the entrance, cooling is at the exit, and pressurizing is at the middle position. After the multiple layers of unidirectional tapes are stacked, they enter from the heating section, and the heat is transferred to the unidirectional tape through the electrically heated aluminum square tube. After the unidirectional tape is heated and fully melted, the molten multi-layer unidirectional tape is pressurized and formed by the intermediate pressure roller, and then enters the cooling device for cooling and forming.

[0074] The glass fiber content in the formed cortex is about 65%-70%.

[0075] In combination with the above embodiments, the board material of the utility model has high processing and forming efficiency, is easy to recycle and reuse, and has the characteristics of light weight (2.2kg / ㎡), strong rigidity (unidirectional tape tensile strength reaches 1000MPa), flame retardant (can produce flame retardant unidirectional tape and flame retardant honeycomb core), etc. It has good heat deformation resistance (can ensure that it remains unchanged for 60 minutes at a temperature of 130°C), is easy to transport, and is convenient to process and install; it can be effectively used as a backplane on photovoltaic modules to manufacture lightweight and rigid solar photovoltaic modules, so that lightweight boards can be combined with the photovoltaic industry to create a new generation of photovoltaic module products.

[0076] Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. A person with ordinary knowledge in the technical field to which the present invention belongs may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be determined by the definition of the claims.

Claims

1. A lightweight rigid fiber-reinforced sandwich composite panel. It is characterized in that It comprises a first skin layer (11), a core layer (20) and a second skin layer (12), wherein the first skin layer (11) and the second skin layer (12) are connected to a first end surface and a second end surface opposite to the core layer (20); The first skin layer (11) and the second skin layer (12) each include at least two glass fiber tape layers; The core layer (20) comprises a plurality of tubular structures (21) arranged in a honeycomb shape, wherein the axis of the tubular structure (21) is parallel to the thickness direction of the core layer (20), and each of the tubular structures (21) comprises an inner layer (201) and an outer layer (202), wherein the inner layer (201) comprises a glass fiber tube, and the outer layer (202) comprises a rubber tube.

2. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that The ratio of thickness to diameter of the tubular structure (21) is greater than 1:

10.

3. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that The outer diameter of the tubular structure (21) is 8.8-9.0 mm.

4. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that The thickness of the core layer (20) is 10 mm, the weight of the first skin layer (11) and the second skin layer (12) is 1000-1150 g / m2, and the weight of the core layer (20) is 1100 g / m2.

5. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that The tubular structures (21) are closely arranged, the inner and outer cross-sectional shapes of the inner layer (201) of the tubular structure (21) are circular, the inner cross-sectional shape of the outer layer (202) of the tubular structure (21) is circular, and the outer cross-sectional shape of the outer layer (202) of the tubular structure (21) is hexagonal.

6. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that The first skin layer (11) and the second skin layer (12) comprise glass fiber unidirectional tapes that are cross-stacked along a first direction and a second direction, wherein the first direction and the second direction are perpendicular to each other.

7. The lightweight rigid fiber-reinforced sandwich composite board according to claim 6, It is characterized in that The thickness of the glass fiber unidirectional tape is 0.15-0.17 mm.

8. The lightweight rigid fiber-reinforced sandwich composite board according to claim 1, It is characterized in that Narrow edge-sealing bands are provided around the core layer (20), and the width of the narrow edge-sealing bands is greater than the width of the core layer (20).

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