Foldable fiber composite board

Abstract

The utility model provides a foldable fiber composite board. The foldable fiber composite board comprises at least one composite structure layer, the composite structure layer comprises a flexible fiber layer and a plurality of rigid structures fixed on the surface of the flexible fiber layer, and each rigid structure comprises at least one rigid fiber layer; the flexible fiber layer can be bent, the rigid structures cannot be bent, and the multiple rigid structures are arranged at intervals so that folding areas can be formed at the intervals. Through the design of joint laying, the folding function is achieved at the preset position, and meanwhile the characteristics of high specific stiffness and high specific strength are achieved.

Description

Technical Field

[0001] The utility model relates to the field of composite materials, in particular to a foldable fiber composite board. Background Art

[0002] Common foldable materials include paper, elastic plastics, and textiles. While these materials offer the advantages of low cost and excellent plasticity, they also have significant disadvantages. Ordinary paper, also a fibrous material, is highly susceptible to moisture absorption and breakage. This is because it lacks a complete, rigid cellulose network structure and has not been specifically treated to remove water-absorbing components. Elastic plastics and textiles are often thin to ensure foldable and deformable properties, thus lacking sufficient rigidity and strength, significantly limiting their ultimate application areas.

[0003] When using high-strength metal as the folding material, if the material itself is folded without additional connectors, the metal thickness at the fold must be significantly reduced. However, metal foil may oxidize and fatigue after repeated folding, and the metal material has a high density, which cannot meet the requirements of lightweighting.

[0004] Compared to traditional materials, composite folding materials offer advantages such as expandability, high space utilization, convenient transportation, and flexible use, and hold promising application prospects in aerospace, automotive, construction, solar energy, and other fields. While the currently mainstream folding materials reinforced with glass fiber or carbon fiber composite materials possess high specific stiffness and strength, their brittle nature makes them susceptible to fracture and breakage when used as folding structures. Summary of the Invention

[0005] In response to the problems in the above-mentioned technology, the present invention provides a foldable fiber composite panel to solve the above-mentioned technical problems. Through the design of the interlaced layering of the rigid structure and the flexible fiber layer, the composite panel has the folding function at the preset position and also has the characteristics of high specific stiffness and high specific strength.

[0006] The utility model provides a foldable fiber composite panel, comprising: at least one composite structure layer; the composite structure layer comprises a flexible fiber layer and a plurality of rigid structures fixed on the surface of the flexible fiber layer, each rigid structure comprises at least one rigid fiber layer; the flexible fiber layer is bendable, the rigid structure is not bendable, and the plurality of rigid structures are arranged at intervals to form folding areas at the intervals.

[0007] Preferably, it comprises multiple composite structural layers, the rigid structure of an upper composite structural layer is fixed to the flexible fiber layer of a lower composite structural layer, and the rigid structures of each layer are aligned with each other.

[0008] Preferably, the folded area is filled with a bondable elastic material.

[0009] Preferably, a rigid resin is laid between each fiber layer.

[0010] Preferably, the rigid structure is a quadrilateral, and the rigid structure is linearly arranged along the transverse or longitudinal direction of the flexible fiber layer, thereby forming a plurality of longitudinal or transverse penetrating folding areas; or the rigid structure is a rectangle, and the rigid structure is arranged in an array along the transverse and longitudinal directions of the flexible fiber layer, thereby forming a plurality of longitudinal and transverse penetrating folding areas at the same time; or the rigid structure is a triangle, and the rigid structure is arranged in an array along the transverse and longitudinal directions of the flexible fiber layer, thereby forming a plurality of transverse and oblique penetrating folding areas at the same time.

[0011] Preferably, the flexible fiber layer adopts unidirectional reinforced fiber material.

[0012] Preferably, the flexible fiber layer is made of densified wood fiber material.

[0013] Preferably, the flexible fiber layer comprises at least a portion of fibers whose extending direction intersects with the through-extending direction of the folding region.

[0014] Preferably, the flexible fiber layer comprises at least a portion of fibers whose extending direction is perpendicular to the through-extending direction of the folding region.

[0015] Preferably, the number of composite structural layers is greater than or equal to the number of through-extension directions of the folding regions, the fiber extension direction of the flexible fiber layer is perpendicular to one of the through-extension directions of the multiple folding regions, and each through-extension direction of the folding region corresponds to at least one flexible fiber layer perpendicular thereto.

[0016] This utility model proposes a foldable fiber composite panel comprising at least one composite structural layer consisting of a flexible fiber layer and multiple rigid structures fixed to the surface of the flexible fiber layer. The flexible fiber layer is bendable, while the rigid structures are non-bendable, forming a high-rigidity, non-deformable portion. The multiple rigid structures are arranged at intervals to form folding areas at the intervals. The rigid portions exhibit high strength, high modulus, and low density. Through a cross-laminated design, the panel achieves foldability at pre-set locations while also exhibiting high specific stiffness and strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings.

[0018] Figure 1 is a schematic cross-sectional view of a foldable fiber composite panel according to an embodiment of the present invention;

[0019] Figure 2 This is a three-dimensional schematic diagram of the structure of each layer of the composite structure layer of an embodiment of the present utility model;

[0020] Figure 3a , 3b, 3c are schematic structural diagrams of a foldable fiber composite panel according to an embodiment of the present invention;

[0021] Figure 4 It is a structural schematic diagram of a foldable fiber composite panel according to an embodiment of the present invention. DETAILED DESCRIPTION

[0022] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in a variety of forms and should not be construed as limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that the present invention will be comprehensive and complete and will fully convey the concepts of the example embodiments to those skilled in the art. The same reference numerals in the figures represent the same or similar structures, and their repeated descriptions will be omitted. The directions such as up, down, lateral, and longitudinal described in this patent are all descriptions of the relative positional relationships between the components, and do not limit the actual directions, nor constitute limitations on the claims.

[0023] Figure 1 This is a cross-sectional view of a foldable fiber composite panel according to an embodiment of the present invention. Figure 2 This is a three-dimensional schematic diagram of the structure of each layer of the composite structure layer of an embodiment of the present invention. Figure 1 、 Figure 2 As shown, the foldable fiber composite panel in this embodiment includes three composite structure layers 1 and an additional flexible fiber layer 2 fixed thereto.

[0024] Each composite structure layer 1 includes a flexible fiber layer 2 and a plurality of rigid structures 3 fixed on the surface of the flexible fiber layer 2. Each rigid structure 3 includes at least one rigid fiber layer 301 ( Figure 1 In the example, there are 4 layers, Figure 2 (Exemplarily, there are two layers in the figure). A plurality of rigid structures 3 are arranged at intervals to form folding areas 4 at the intervals.

[0025] The flexible fiber layer 2 is made of a soft material with high elongation at break, allowing the folded portion of the flexible fiber layer 2 corresponding to the folding region 4 to be bi-directionally foldable while maintaining a certain degree of durability. The rigid structure 3 is inflexible and constitutes a highly rigid, non-deformable portion. Multiple rigid structures 3 are arranged at intervals to form folding regions 4 at these intervals. During use, the foldable fiber composite panel can be bi-directionally folded along the through-direction of the folding region 4.

[0026] It should be noted that each composite structure layer 1 can be made of a single layer of flexible fiber material or multiple layers of flexible fibers stacked together, and the rigid structure 3 includes at least one rigid fiber layer 301. The thickness of the rigid structure 3 is generally greater than that of the flexible fiber layer 2. The multiple rigid fiber layers 301 can be made of the same material or different materials to achieve different effects.

[0027] When there are more than one composite structure layer 1, the rigid fiber layer 301 at the bottom of each rigid structure 3 in the previous composite structure layer 1 is fixed to the flexible fiber layer 2 of the next composite structure layer 1, and the rigid structures 3 of each layer are aligned with each other, thereby ensuring that the folding regions 4 of each layer are aligned with each other. The thickness and number of flexible fiber layers 2 or rigid structures 3 in the same composite structure layer 1 are the same, while the thickness and number of flexible fiber layers 2 or rigid structures 3 in different composite structure layers 1 can be the same or different. In other embodiments, a composite structure layer 1 with one or more layers can be provided depending on the actual application scenario.

[0028] In a preferred embodiment, the folding region 4 is filled with a bondable elastic material. The cross-linking agent of the folding region 4 can be a highly elastic resin such as a hydroxyl-containing linear polyester resin, polyurethane, thermoplastic elastic urethane, or other bondable elastic materials such as rubber and silicone.

[0029] In a preferred embodiment, a rigid resin 5 is laid between each fiber layer. The resin base can be selected from thermoplastic resins including polyamide, polylactic acid, polyurethane, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer, copolyester and other hot melt adhesive grade polymers, etc., and thermosetting resins including one or more of epoxy resin, unsaturated polyester, polybutadiene resin, phenolic resin and cross-linkable polyurethane can also be selected.

[0030] Figure 3a , 3b, 3c are schematic structural diagrams of a foldable fiber composite board according to an embodiment of the present invention. Figure 3a As shown, the rigid structure 3 is a quadrilateral and is arranged linearly along the longitudinal direction of the flexible fiber layer 2, thereby forming a plurality of transversely penetrating folding regions 4. It should be noted that the rigid structure 3 is not limited to a rectangle and can also be other quadrilaterals such as a trapezoid or parallelogram.

[0031] like Figure 3b As shown, the rigid structure 3 is rectangular and is arranged in an array along the transverse and longitudinal directions of the flexible fiber layer 2 , thereby forming a plurality of longitudinally and transversely penetrating folding areas 4 at the same time.

[0032] like Figure 3c As shown, the rigid structure 3 is triangular and is arranged in an array along the transverse and longitudinal directions of the flexible fiber layer 2 , thereby forming a plurality of transverse and oblique through-folded areas 4 at the same time.

[0033] In a preferred embodiment, the flexible fiber layer utilizes a unidirectional reinforced fiber material. Unidirectional reinforced fiber materials are anisotropic, and compared to isotropic fiber materials, they exhibit particularly outstanding strength in a specific direction (the direction in which the fibers extend). Unidirectional fiber materials with a certain degree of toughness can be selected, such as wood fiber paper, wood fiber fabric, linen fabric, aramid cloth, and aramid fiber paper.

[0034] Further preferably, the flexible fiber layer is made of densified wood fiber material. The densified wood fiber material can be obtained by the following method:

[0035] 1) chemically modifying the unidirectional veneer to obtain the unidirectional veneer from which some substances such as lignin and hemicellulose are removed;

[0036] 2) The unidirectional veneer from which some substances have been removed is subjected to shrinkage treatment in at least one direction, and is flattened by flat hot pressing under a negative pressure exhaust environment to obtain a densified wood fiber material.

[0037] The densified wood fiber material obtained by the above method can reach a thickness of no more than 0.3 mm, but a strength greater than 150 MPa, a Young's modulus greater than 20 GPa, and an elongation at break greater than 1%, thereby ensuring that the flexible fiber layer 2 has a very good folding function, making it foldable while having excellent load-bearing capacity and anti-destructive force.

[0038] The rigid fiber layer 301 preferably adopts high strength, high modulus, low density material. The fiber of the rigid part does not need to provide folding function, so unidirectional reinforced fiber material can be selected, and can also include conventional glass fiber, carbon fiber, etc.

[0039] Figure 4 This is a schematic structural diagram of a foldable fiber composite panel according to an embodiment of the present invention. Figure 4As shown, when the composite structure layer 1 is a single layer, the flexible fiber layer 2 includes at least part of the fibers extending in a direction B that intersects with the folding region through-extension direction A, and preferably, the two are perpendicular. Since unidirectional reinforced fiber materials have particularly high strength in the fiber extension direction, when the fiber extension direction B intersects with the folding region through-extension direction A, when the foldable fiber composite panel is folded along the folding region through-extension direction A, at least part of the fibers in the flexible fiber layer 2 are mainly subjected to force in the extension direction, thereby being able to withstand greater forces and support the strength requirements of multiple folds. In particular, when the fiber extension direction B is perpendicular to the folding region through-extension direction A, the fibers in the flexible fiber layer 2 are subjected to almost all forces in the extension direction, thus having a better effect. If an isotropic fiber material is used, since there is no directional reinforcement effect, when the flexible fiber layer is folded, the fibers are evenly distributed in the folding direction, and the supporting effect is limited. Therefore, the unidirectional reinforced fiber material used in this patent is more durable.

[0040] When the number of folding regions 4 extending in different directions is greater than one, the number of composite structural layers 1 is greater than or equal to the number of folding regions 4 extending in these directions. The flexible fiber layers 2 extend in a direction perpendicular to one of the multiple folding region 4 extending directions, and each folding region 4 extending in this direction corresponds to at least one flexible fiber layer 2 extending perpendicularly thereto. This structure ensures that at least one flexible fiber layer 2 can provide support for folding in one direction, thereby achieving folding toughness and strength in multiple directions for the foldable fiber composite panel.

[0041] The foldable fiber composite panel provided in this embodiment divides the folding material into two parts: a rigid portion and a flexible portion. The rigid structure 3 can be designed with a desired layup structure based on the stress characteristics of the designed structure. The unidirectional fibers in the folding portion are provided by a complete unidirectional reinforced fiber material, with the unidirectional fibers preferably oriented crosswise or perpendicular to the folding direction to improve mechanical properties.

[0042] In a preferred embodiment, both the flexible fiber layer 2 and the rigid fiber layer 301 use unidirectional densified wood fiber paper. According to the designed folding method and force direction, the unidirectional densified wood fiber paper is cut into the designed shape. The flexible fiber layer 2 uses a whole sheet of unidirectional densified wood fiber paper, and the cross-linking agent is attached to the position fixed to the rigid structure 3 by brushing or laminating. The rigid structure 3 is laid in the order of a layer of rigid resin 5 and a layer of rigid fiber layer 301 for the designed number of layers, and then the densified wood fiber paper of the last rigid structure 3 is connected to the whole sheet of unidirectional densified wood fiber paper by the rigid resin 5. Repeat the above steps until all the layers are laid. The board is pressed together as a whole by pressure. The above-mentioned foldable fiber composite board combines a soft, foldable base material with a high-strength, tough and oriented unidirectional reinforced fiber material, so that its foldable part can be folded in both directions, and it has excellent load-bearing capacity and anti-destructive force while being foldable.

[0043] The forming method for the foldable fiber composite panel provided by this invention is similar to conventional composite material forming. After all layers are laid, the panel is pressed together using pressure. This pressure can be applied using a variety of molding equipment, such as vacuum bags, hot presses, and hot rollers. If the resin is a thermoplastic resin, the temperature must be raised above the melting point of the resin during pressing, held for a period of time, and then cooled to room temperature. If a thermosetting resin is used, the temperature can be adjusted based on the specific resin curing conditions. Once the resin is fully cured, the panel is removed to obtain the foldable fiber composite material.

[0044] The foldable fiber composite panel provided in this practical information has a composite structure composed of a flexible fiber layer and a plurality of rigid structures fixed on the surface of the flexible fiber layer, thereby achieving the bending function at a specific position while providing sufficient rigidity and strength.

[0045] The above content is a further detailed description of the present invention in conjunction with specific preferred embodiments, and the specific implementation of the present invention cannot be considered to be limited to these descriptions. For those skilled in the art of the present invention, without departing from the concept of the present invention, several simple deductions or substitutions can be made, which should be considered to fall within the scope of protection of the present invention.

Claims

1. A foldable fiber composite panel, characterized in that: include: at least one composite structural layer; The composite structure layer includes a flexible fiber layer and a plurality of rigid structures fixed on the surface of the flexible fiber layer, each of the rigid structures includes at least one rigid fiber layer; The flexible fiber layer is bendable, and the rigid structure is non-bendable. A plurality of the rigid structures are arranged at intervals to form folding areas at the intervals.

2. The foldable fiber composite panel according to claim 1, wherein: It comprises multiple layers of the composite structure layer, wherein the rigid structure of the upper composite structure layer is fixed to the flexible fiber layer of the lower composite structure layer, and the rigid structures of each layer are aligned with each other.

3. The foldable fiber composite panel according to claim 1, wherein: The folded area is filled with a bondable elastic material.

4. The foldable fiber composite panel according to claim 1, wherein: A rigid resin is laid between each fiber layer.

5. The foldable fiber composite panel according to claim 1, wherein: The rigid structure is a quadrilateral, and is arranged linearly along the transverse or longitudinal direction of the flexible fiber layer, thereby forming a plurality of longitudinally or transversely penetrating folding areas; or The rigid structure is rectangular and arranged in an array along the transverse and longitudinal directions of the flexible fiber layer, thereby forming a plurality of longitudinally and transversely penetrating folding areas; or The rigid structure is triangular and is arranged in an array along the transverse and longitudinal directions of the flexible fiber layer, thereby forming a plurality of transversely and obliquely penetrating folding areas at the same time.

6. The foldable fiber composite panel according to any one of claims 1 to 5, characterized in that: The flexible fiber layer is made of unidirectional reinforced fiber material.

7. The foldable fiber composite panel according to claim 6, wherein: The flexible fiber layer is made of densified wood fiber material.

8. The foldable fiber composite panel according to claim 7, wherein: The flexible fiber layer comprises at least a portion of fibers whose extending direction intersects with the through-extending direction of the folding region.

9. The foldable fiber composite panel according to claim 7, wherein: The flexible fiber layer comprises at least a portion of fibers whose extending direction is perpendicular to the through-extending direction of the folding region.

10. The foldable fiber composite panel according to claim 7, wherein: The number of composite structure layers is greater than or equal to the number of through-extension directions of the folding regions, the fiber extension direction of the flexible fiber layer is perpendicular to one of the through-extension directions of the folding regions, and each through-extension direction of the folding region corresponds to at least one flexible fiber layer perpendicular thereto.

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