Foam sandwich board
By using fiber-reinforced PET surface layer and foam core layer made of recyclable resin, the problem of insufficient flexibility and strength of fiber-reinforced thermoset sandwich sheet is solved, and the high strength, flexibility and recyclability of foam sandwich sheet is achieved, expanding its application range.
Patent Information
- Application Number
- CN202420126319.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-01-18
- Publication Date
- 2025-07-18
- Estimated Expiration
- 2034-01-18
AI Technical Summary
The existing fiber-reinforced thermoset sandwich sheets have poor flexibility, insufficient mechanical strength, and cannot be recycled as a whole, which limits their application scenarios.
The fiber-reinforced PET surface layer and the foam core layer made of recyclable resin are used to form a foam sandwich plate with high mechanical strength and good flexibility.
It realizes the high mechanical strength, good flexibility and overall recyclability of foam sandwich panels, expanding its application scenarios.
Smart Images
Figure CN223116012U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of novel composite materials, in particular to a foam sandwich panel. Background Art
[0002] With the continuous development of the composite materials industry, sandwich panels with fiber-reinforced thermosetting resin as the surface layer are widely used in aerospace, chemical, transportation and other fields due to their excellent properties such as light weight, high specific strength, high specific modulus and corrosion resistance. However, fiber-reinforced thermosetting sandwich panels have poor flexibility and the panels cannot be recycled as a whole, which limits their application scenarios.
[0003] At present, the composite sandwich panels on the market usually use fiber-reinforced PP as the surface layer and PET foam core material to form a sandwich structure. However, the recyclability of the composite sandwich panels still does not reach the ideal level; in addition, the foam sandwich panels using fiber-reinforced PP as the surface layer have poor mechanical strength and weak flexibility. Utility Model Content
[0004] In order to solve the above technical problems, the purpose of the utility model is to provide a foam sandwich panel with high mechanical strength, good flexibility and recyclability.
[0005] In order to achieve the above-mentioned purpose, the utility model adopts the following technical solutions:
[0006] A foam sandwich panel comprises a foam core layer and a first surface layer and a second surface layer respectively arranged on the upper and lower sides of the foam core layer, wherein the first surface layer is a fiber-reinforced PET surface layer, the second surface layer is a fiber-reinforced PET surface layer, and the foam core layer is made of recyclable resin. By setting the first surface layer and the second surface layer as fiber-reinforced PET surface layers, the first surface layer and the second surface layer have good flexibility and increase the mechanical strength of the first surface layer and the second surface layer, so that the foam sandwich panel has the characteristics of good mechanical strength, good flexibility and good recyclability.
[0007] Preferably, the fibers in the first surface layer are one or more of glass fibers, aramid fibers, carbon fibers, basalt fibers, PI fibers, PBO fibers, polyarylate fibers and silicon carbide fibers, and / or the fibers in the second surface layer are one or more of glass fibers, aramid fibers, carbon fibers, basalt fibers, PI fibers, PBO fibers, polyarylate fibers and silicon carbide fibers.
[0008] Preferably, the fiber reinforcement in the first surface layer is in the form of one or more of fiber woven cloth, unidirectional tape, felt, non-woven fabric and staple fiber; and / or, the fiber reinforcement in the second surface layer is in the form of one or more of fiber woven cloth, unidirectional tape, felt, non-woven fabric and staple fiber.
[0009] Preferably, the fiber-reinforced PET surface layer is composed of one or more layers of fiber-reinforced PET single surface layers. The first surface layer includes one or more layers of fiber-reinforced PET single surface layers, and / or the second surface layer includes one or more layers of fiber-reinforced PET single surface layers.
[0010] Preferably, the thickness of each layer of fiber-reinforced PET single surface layer is 0.05 - 1.00 mm; and / or the PET resin content in each layer of fiber-reinforced PET single surface layer is 20% - 80%; and / or the first surface layer includes 2 - 20 layers of fiber-reinforced PET single surface layers; and / or the second surface layer includes 2 - 20 layers of fiber-reinforced PET single surface layers. With such limitations, the mechanical strength, flexibility, and recyclability of the foam sandwich panel can be further improved.
[0011] Preferably, the fiber-reinforced PET single surface layer in the first surface layer is a unidirectional tape single surface layer. The first surface layer is formed by laminating multiple layers of unidirectional tape single surface layers, and the included angle θ between the fibers of adjacent two layers of unidirectional tape single surface layers is 0° < θ < 180°; and / or the fiber-reinforced PET single surface layer in the second surface layer is a unidirectional tape single surface layer. The second surface layer is formed by laminating multiple layers of unidirectional tape single surface layers, and the included angle θ between the fibers of adjacent two layers of unidirectional tape single surface layers is 0° < θ < 180°. In this way, while ensuring the mechanical strength of the foam sandwich panel, its flexibility is further improved.
[0012] Preferably, in the first surface layer, the included angle θ between the fibers of adjacent two layers of unidirectional tape single surface layers is 45° - 135°; and / or in the second surface layer, the included angle θ between the fibers of adjacent two layers of unidirectional tape single surface layers is 45° - 135°.
[0013] Preferably, the recyclable resin is one or more of recyclable PU, recyclable PP, PET, PLA, PCL, PBAT, PBS, or PHA.
[0014] Preferably, the thickness of the foam core layer is 1 - 200 mm, and / or the density is 50 - 300 kg / m 3 , the pore diameter is 20 - 500 μm, and the pore density is 10 4 -10 12 per cm 3 . Without affecting the light weight, the mechanical strength of the foam sandwich panel can be further improved.
[0015] Preferably, the first surface layer is a PET surface layer reinforced by a glass fiber unidirectional tape, and the second surface layer is a PET surface layer reinforced by a glass fiber unidirectional tape; the foam core layer is a PET foam core layer. In this way, the resins in the first surface layer, the second surface layer and the foam core board are all PET resins, and the whole board can be recycled integrally, with better overall recyclability.
[0016] Preferably, the diameter of the glass fiber is 3-25 μm, the linear density is 5-10000 tex, and the gram weight of the glass fiber unidirectional tape is 50-1000 g / m 2 . By limiting the diameter, linear density and gram weight of the glass fiber unidirectional tape, the mechanical strength and flexibility of the foam sandwich panel are improved simultaneously.
[0017] Due to the adoption of the above technical solutions, the present utility model has the following advantages: by setting the first surface layer and the second surface layer as fiber-reinforced PET surface layers, the present utility model has better flexibility in the first surface layer and the second surface layer while increasing the mechanical strength of the first surface layer and the second surface layer, so that the foam sandwich panel has the characteristics of good mechanical strength, good flexibility and good recyclability. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 is a schematic structural diagram of the present utility model;
[0019] Figure 2 is an exploded view of the laminated structure of two adjacent unidirectional tape single surface layers.
[0020] REFERENCE SIGNS:
[0021] 1. Foam core layer; 2. First surface layer; 3. Second surface layer; 4. Unidirectional tape single surface layer. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0022] The embodiments of the present utility model will be described in detail below. The examples of the embodiments are shown in the drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary and are intended to explain the present utility model, and should not be construed as limiting the present utility model.
[0023] In the description of the present utility model, it should be understood that the orientation or positional relationship indicated by the terms "thickness", "upper", "lower", "front", "rear", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present utility model.
[0024] In addition, the terms "first" and "second" are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present utility model, unless otherwise specified, the meaning of "a plurality of" is two or more, unless otherwise clearly defined.
[0025] As Figure 1 shown, a foam sandwich panel includes a foam core layer 1, and a first surface layer 2 and a second surface layer 3 respectively disposed on the upper and lower sides of the foam core layer 1. The first surface layer 2 is a fiber-reinforced PET surface layer, and the second surface layer is a fiber-reinforced PET surface layer. The foam core layer 1 is made of recyclable resin.
[0026] The first surface layer 2 and the second surface layer 3 are respectively fixedly bonded to the upper and lower sides of the foam core layer 1 by means of hot melt lamination, hot melt adhesive film lamination or adhesive. Of course, other bonding methods may also be used.
[0027] In this way, by setting the first surface layer 2 and the second surface layer 3 as fiber-reinforced PET surface layers, while the first surface layer 2 and the second surface layer 3 have good flexibility, the mechanical strength of the first surface layer 2 and the second surface layer 3 is increased, so that the foam sandwich panel 1 has the characteristics of good mechanical strength, good flexibility and good recyclability.
[0028] In the present utility model, the recyclable resin can be stored at room temperature for a long time and can be one or more of recyclable PU, recyclable PP, PET, PLA, PCL, PBAT, PBS or PHA.
[0029] Among them, the thickness of the foam core layer 1 is 1 - 200 mm, the density is 50 - 300 kg / m 3 , the pore diameter is 20 - 500 μm, and the pore density is 10 4 -10 12 per cm 3 . By limiting the pore diameter and pore density of the foam core layer 1, the density of the foam core layer 1 is controlled. While ensuring the light weight of the sandwich panel, its mechanical strength is further improved. If the pore diameter and pore density of the foam core layer 1 are too small, the density of the foam core layer 1 is too high. If the pore diameter and pore density of the foam core layer 1 are too large, the mechanical strength of the foam core layer 1 will decrease. Further, the thickness of the foam core layer 1 is 2 - 150 mm, and / or the density is 50 - 250 kg / m 3 , the pore diameter is 25 - 450 μm, and the pore density is 10 5 -10 11 per cm 3 .
[0030] In the present utility model, the fibers in the first surface layer 2 are one or more of glass fiber, aramid fiber, carbon fiber, basalt fiber, PI fiber, PBO fiber, polyarylate fiber, and silicon carbide fiber, and / or the fibers in the second surface layer 3 are one or more of glass fiber, aramid fiber, carbon fiber, basalt fiber, PI fiber, PBO fiber, polyarylate fiber, and silicon carbide fiber. The fiber compositions in the first surface layer 2 and the second surface layer 3 can be the same or different.
[0031] The fiber reinforcement form in the first surface layer 2 is one or more of fiber woven fabric, unidirectional tape, felt, non-woven fabric, and short fiber; and / or the fiber reinforcement form in the second surface layer 3 is one or more of fiber woven fabric, unidirectional tape, felt, non-woven fabric, and short fiber.
[0032] Furthermore, the first surface layer 2 includes one or more layers of fiber-reinforced PET single surface layers, the thickness of each layer of fiber-reinforced PET single surface layer is 0.05 - 1.00 mm, and the PET resin content in each layer of fiber-reinforced PET single surface layer is 20% - 80%; and / or the second surface layer 3 includes one or more layers of fiber-reinforced PET single surface layers, the thickness of each layer of fiber-reinforced PET single surface layer is 0.05 - 1.00 mm, and the PET resin content in each layer of fiber-reinforced PET single surface layer is 20% - 80%.
[0033] When the first surface layer 2 is formed by laminating multiple layers of fiber-reinforced PET single surface layers, the number of layers of fiber-reinforced PET single surface layers in the first surface layer is preferably 2 - 20 layers, and the fiber reinforcement forms of each layer of fiber-reinforced PET single surface layer can be the same or different. Similarly, when the second surface layer 3 is formed by laminating multiple layers of fiber-reinforced PET single surface layers, the number of layers of fiber-reinforced PET single surface layers in the second surface layer is preferably 2 - 20 layers, and the fiber reinforcement forms of each layer of fiber-reinforced PET single surface layer can be the same or different.
[0034] A unidirectional tape refers to a textile fabric that has a large number of textile yarns or rovings in one direction and only a small amount and usually fine yarns in the other direction, so that almost all the strength of the fabric is in one direction. It has the advantages of high cost performance, high production efficiency, and high mechanical properties in a specific direction.
[0035] The fiber-reinforced PET single surface layer in the first surface layer 2 is a unidirectional tape single surface layer 4, and the first surface layer 2 is formed by laminating multiple layers of unidirectional tape single surface layers 4, as Figure 2 shown, the included angle θ between the fibers of adjacent two layers of unidirectional tape single surface layers 4 is 0° < θ < 180°; and / or when the fiber-reinforced PET single surface layer in the second surface layer 3 is a unidirectional tape single surface layer 4, the second surface layer 3 is formed by laminating multiple layers of unidirectional tape single surface layers 4, asFigure 2 As shown, the included angle θ between the fibers of the single-sided layer 4 of unidirectional tape in adjacent two layers is 0° < θ < 180°. Each single-sided layer 4 of unidirectional tape contains a layer of unidirectional tape in the same direction and PET resin. Figure 2 In [description], the arrow on each single-sided layer 4 of unidirectional tape indicates the direction of the fibers in this single-sided layer of unidirectional tape. When multiple single-sided layers 4 of unidirectional tape are laminated, due to the included angle θ between the fibers of adjacent two single-sided layers 4 of unidirectional tape, therefore, a cross-linked network structure is formed in both the entire first surface layer 2 and the second surface layer 3, which can further improve its flexibility while ensuring the mechanical strength of the foam core sandwich panel.
[0036] Furthermore, the number of single-sided layers 4 of unidirectional tape in the first surface layer 2 is 2 - 20 layers; and / or, the number of single-sided layers 4 of unidirectional tape in the second surface layer 3 is 2 - 20 layers. The number of single-sided layers 4 of unidirectional tape in the first surface layer 2 and the second surface layer 3 can be the same or different. In the first surface layer 2, the included angle θ between the fibers of adjacent two single-sided layers 4 of unidirectional tape is 45° - 135°; and / or, in the second surface layer 3, the included angle θ between the fibers of adjacent two single-sided layers 4 of unidirectional tape is 45° - 135°.
[0037] In one embodiment, the first surface layer 2 is a PET surface layer reinforced by glass fiber unidirectional tape, and the second surface layer 3 is a PET surface layer reinforced by glass fiber unidirectional tape; the foam core layer 1 is a PET foam core layer. And, since the foam core layer 1 is made of PET and the resins in the first surface layer 2 and the second surface layer 3 are both PET, therefore, the bonding property between the first surface layer 2 and the foam core layer 1 and between the foam core layer 1 and the second surface layer 3 is good, and the overall recyclability is better.
[0038] The diameter of the glass fiber is 3 - 25 μm, the linear density is 5 - 10000 tex, and the grammage of the glass fiber unidirectional tape is 50 - 1000 g / m 2 . More preferably, the diameter of the glass fiber is 5 - 20 μm, the linear density is 10 - 8000 tex, and the grammage of the glass fiber unidirectional tape is 100 - 800 g / m 2 .
[0039] All features described in the specification, the appended claims and the drawings, whether alone or in any combination thereof, are important features of the present utility model.
[0040] In the description of this specification, the descriptions with reference to the terms "one embodiment", "some embodiments", "one implementation manner", "specific implementation manner", "other implementation manners", "example", "specific example", or "some examples", etc. mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment, implementation manner, or example of the present utility model. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described above can also be combined in a suitable manner in any one or more embodiments, implementation manners, or examples. The technical solutions recorded in the present utility model also include the technical solutions formed by the above-described any one or more specific features, structures, materials, or characteristics alone or in combination.
[0041] Although the embodiments of the present utility model have been shown and described above, it can be understood that the above embodiments are exemplary and should not be construed as limiting the present utility model. Those of ordinary skill in the art can make changes, modifications, substitutions, variations, delete some features, add features, or re-combine features within the scope of the present utility model without departing from the principle and purpose of the present utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the innovative principle of the present utility model still fall within the scope of the technical solutions of the present utility model.
Claims
1. A foam sandwich panel, comprising a foam core layer (1) and a first surface layer (2) and a second surface layer (3) respectively disposed on the upper and lower sides of the foam core layer (1), characterized in that, The first surface layer (2) is a fiber-reinforced PET surface layer, the second surface layer (3) is a fiber-reinforced PET surface layer, and the foam core layer (1) is made of recyclable resin; wherein, the fiber-reinforced PET surface layer is composed of one or more fiber-reinforced PET single surface layers, the first surface layer (2) includes one or more fiber-reinforced PET single surface layers, and / or the second surface layer (3) includes one or more fiber-reinforced PET single surface layers.
2. The foam sandwich panel according to claim 1, wherein, The fiber in the first surface layer (2) is one of glass fiber, aramid fiber, carbon fiber, basalt fiber, PI fiber, PBO fiber, polyarylate fiber, and silicon carbide fiber, and / or the fiber in the second surface layer (3) is one of glass fiber, aramid fiber, carbon fiber, basalt fiber, PI fiber, PBO fiber, polyarylate fiber, and silicon carbide fiber.
3. A foam sandwich panel according to claim 1, wherein, The fiber reinforcement form in the first surface layer (2) is one of fiber woven cloth, unidirectional tape, felt, non-woven fabric, and short fiber; and / or the fiber reinforcement form in the second surface layer (3) is one of fiber woven cloth, unidirectional tape, felt, non-woven fabric, and short fiber.
4. A foam sandwich panel according to claim 1, characterized in that, The thickness of each layer of fiber-reinforced PET single surface layer is 0.05 - 1.00 mm; and / or the PET resin content in each layer of fiber-reinforced PET single surface layer is 20% - 80%; and / or the first surface layer (2) includes 2 - 20 layers of fiber-reinforced PET single surface layers; and / or the second surface layer (3) includes 2 - 20 layers of fiber-reinforced PET single surface layers.
5. A foam sandwich panel according to claim 1, characterized in that, The fiber-reinforced PET single surface layer in the first surface layer (2) is a unidirectional tape single surface layer, and the first surface layer (2) is formed by laminating multiple unidirectional tape single surface layers, and the included angle θ between the fibers of adjacent two unidirectional tape single surface layers is 0° < θ < 180°; and / or the fiber-reinforced PET single surface layer in the second surface layer (3) is a unidirectional tape single surface layer, and the second surface layer (3) is formed by laminating multiple unidirectional tape single surface layers, and the included angle θ between the fibers of adjacent two unidirectional tape single surface layers is 0° < θ < 180°.
6. A foam sandwich panel according to claim 5, wherein, In the first surface layer (2), the included angle θ between the fibers of adjacent two unidirectional tape single surface layers is 45° - 135°; and / or in the second surface layer (3), the included angle θ between the fibers of adjacent two unidirectional tapes is 45° - 135°.
7. A foam sandwich panel according to claim 1, characterized in that, The recyclable resin is one of recyclable PU, recyclable PP, PET, PLA, PCL, PBAT, PBS, or PHA.
8. A foam sandwich panel according to claim 7, wherein The thickness of the foam core layer (1) is 1 - 200 mm, and / or the density is 50 - 300 kg / m 3 , the pore diameter is 20 - 500 μm, and the pore density is 10 4 -10 12 per cm 3 .
9. A foam sandwich panel according to claim 1, wherein, The first surface layer (2) is a PET surface layer reinforced by glass fiber unidirectional tape, the second surface layer (3) is a PET surface layer reinforced by glass fiber unidirectional tape; and the foam core layer (1) is a PET foam core layer.
10. A foam sandwich panel according to claim 9, characterized in that, The diameter of the glass fiber is 3 - 25 μm, the linear density is 5 - 10000 tex, and the weight per unit area of the unidirectional glass fiber tape is 50 - 1000 g / m 2 .