Lightweight composite steel plate

Abstract

The utility model relates to the technical field of composite plates, in particular to a lightweight composite steel plate which comprises a lower two-way steel surface layer, a lower structural adhesive layer, an aluminum alloy honeycomb core layer, an upper structural adhesive layer and an upper two-way steel surface layer which are sequentially laminated from bottom to top, and a circle of stainless steel covered edge is welded and sealed along the peripheral contour of the laminated structure. Sealant and an insulating ceramic fiber belt are filled in the joint positions of the stainless steel covered edge and the lower bidirectional steel surface layer and the upper bidirectional steel surface layer. Petroleum corrosion media are directly resisted through the dual-phase steel panel, the weight is effectively reduced through the aluminum alloy honeycomb core structure, a continuous closed structure is formed through stainless steel covering edges and sealing filling on the edges, external corrosion media are prevented from invading, and the long-term corrosion resistance reliability of the material in a harsh petroleum environment is improved while the structural strength is guaranteed; and the maintenance dependence of the traditional anti-corrosion coating is reduced.

Description

Technical Field

[0001] This utility model mainly relates to the field of composite material technology, specifically a lightweight composite steel plate. Background Technology

[0002] The petroleum industry faces extremely harsh operating environments, including high concentrations of hydrogen sulfide (H2S), carbon dioxide (CO2), immersion in brine / seawater, high temperature and pressure, and corrosion from crude oil and chemicals. This places stringent demands on structural materials for corrosion resistance (especially resistance to sulfide stress corrosion cracking), wear resistance, high strength, and high rigidity. Furthermore, particularly for offshore platforms, the weight of the superstructure directly translates into enormous construction costs and engineering complexity. Lightweighting has become a crucial and rigid requirement for reducing platform load, increasing payload, and improving the efficiency of mobile equipment.

[0003] Currently, widely used single-layer thick steel plates (carbon steel or low-alloy steel) are excessively heavy due to strength requirements, and their inherent corrosion resistance is severely insufficient. They are highly susceptible to corrosion failure in petroleum environments, making them heavily reliant on thick anti-corrosion coatings or linings. These protective layers are fragile and easily damaged; once damaged, they trigger severe localized corrosion, forcing companies to invest heavily in frequent and high-risk maintenance, creating a continuous burden. While high-grade stainless steel offers excellent corrosion resistance, its extremely high cost and density limit its lightweighting effect, making large-scale application uneconomical. Non-metallic composite materials suffer from insufficient high-temperature resistance, susceptibility to hydrocarbon swelling, poor fire resistance, and difficulties in connection reliability and industry certification. Generally, it is difficult to simultaneously achieve lightweighting, long-term protection in extreme environments, high strength and rigidity, and reasonable total lifecycle costs. Utility Model Content

[0004] The purpose of this invention is to provide a lightweight composite steel plate to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a lightweight composite steel plate, comprising a lower bidirectional steel surface layer, a lower structural adhesive layer, an aluminum alloy honeycomb core layer, an upper structural adhesive layer, and an upper bidirectional steel surface layer stacked sequentially from bottom to top, and a stainless steel edging is welded and sealed around the perimeter of the stacked structure. The joint between the stainless steel edging and the lower bidirectional steel surface layer and the upper bidirectional steel surface layer is filled with sealant and then filled with insulating ceramic fiber tape.

[0006] Preferably, the thickness of the aluminum alloy honeycomb core layer accounts for 70% of the overall thickness of the composite laminate structure, the diameter of any one honeycomb cell in the aluminum alloy honeycomb core layer is 50% of the total thickness of the layer, the surface of the aluminum alloy honeycomb core layer is anodized to form an oxide film, and an epoxy primer is coated on the surface of the oxide film.

[0007] Preferably, the lower structural adhesive layer is a modified epoxy resin structural adhesive, which contains mica and silica, and the upper structural adhesive layer is the same as the lower structural adhesive layer.

[0008] Preferably, the surface of the upper bidirectional steel surface layer is sprayed with a layer of nano-ceramic anti-slip coating, the four edges of the upper bidirectional steel surface layer are milled with connecting bevels, the sealant and the insulating ceramic fiber tape are located outside the connecting bevels, and the tops of the stainless steel edging, the insulating ceramic fiber tape and the nano-ceramic anti-slip coating are flush.

[0009] Furthermore, the lower bidirectional steel surface layer has the same structure as the upper bidirectional steel surface layer, and the longitudinal section of the stainless steel edging has a U-shaped structure. The two ends of the U-shape extend horizontally and contact the upper and lower connecting inclined surfaces respectively, while the remaining part is welded and sealed to the aluminum alloy honeycomb core layer.

[0010] Compared with existing technologies, the beneficial effects of this utility model are as follows: the panel made of duplex steel material directly resists corrosive media such as hydrogen sulfide in the petroleum environment; the aluminum alloy honeycomb core structure significantly reduces the overall weight; the modified epoxy structural adhesive layer, while bonding the upper and lower layers, uses specific fillers to block the galvanic corrosion channel between the aluminum core and the steel panel; the precisely designed beveled edges, combined with stainless steel edging and sealing fillers, achieve a flat and continuous airtight seal, effectively isolating external corrosive media from entering the core layer. This overall structure, while achieving lightweight, significantly improves the long-term corrosion resistance and structural integrity of the material in the harsh petroleum environment, reduces the dependence on vulnerable coatings and the resulting high maintenance burden.

[0011] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0012] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of the present invention and other related contents, and should not be considered as limitations on the present invention.

[0013] In the accompanying drawings of the instruction manual:

[0014] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the structure at point A of this utility model;

[0016] Figure label:

[0017] 1. Lower bidirectional steel surface layer; 2. Lower structural adhesive layer; 3. Aluminum alloy honeycomb core layer; 4. Upper structural adhesive layer; 5. Upper bidirectional steel surface layer; 6. Nano-ceramic anti-slip coating; 7. Stainless steel edging; 8. Sealant; 9. Insulating ceramic fiber tape. Detailed Implementation

[0018] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying 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 accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0019] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] like Figures 1 to 2 As shown, a lightweight composite steel plate includes a lower bidirectional steel surface layer 1, a lower structural adhesive layer 2, an aluminum alloy honeycomb core layer 3, an upper structural adhesive layer 4, and an upper bidirectional steel surface layer 5 stacked sequentially from bottom to top. A stainless steel edging 7 is welded and sealed around the perimeter of the stacked structure. The joint between the stainless steel edging 7 and the lower bidirectional steel surface layer 1 and the upper bidirectional steel surface layer 5 is filled with sealant 8 and filled with insulating ceramic fiber tape 9.

[0021] The aluminum alloy honeycomb core layer 3 is made of 5052 aluminum alloy with a thickness of 10.5 mm, accounting for 70% of the overall thickness of the composite stacked structure. The diameter of any honeycomb cell in the aluminum alloy honeycomb core layer 3 is 5.25 mm. The surface of the aluminum alloy honeycomb core layer 3 is anodized to form an oxide film, and an epoxy primer is coated on the surface of the oxide film, thereby providing double protection against corrosion for the aluminum alloy honeycomb core layer 3.

[0022] The lower structural adhesive layer 2 is a modified epoxy resin structural adhesive, which contains 40% mica and 10% silica to form an insulating barrier. Its thickness is 0.2 mm. The upper structural adhesive layer 4 is the same as the lower structural adhesive layer 2, in order to isolate the potential difference between the aluminum alloy honeycomb core layer 3 and the upper and lower bidirectional steel panels, and to work together to block galvanic corrosion.

[0023] The surface of the upper bidirectional steel surface layer 5 is sprayed with a layer of nano-ceramic anti-slip coating 6, the thickness of the nano-ceramic anti-slip coating 6 is 0.1 mm, the four edges of the upper bidirectional steel surface layer 5 are milled with connecting bevels, the connecting bevels are surfaces with an angle of 45 degrees, the sealant 8 and the insulating ceramic fiber tape 9 are located outside the connecting bevels to form a "glue-tape" composite sealing layer, the insulating ceramic fiber tape 9 is located on top of the "glue-tape" composite sealing layer, and the tops of the stainless steel edging 7, the insulating ceramic fiber tape 9 and the nano-ceramic anti-slip coating 6 are flush.

[0024] The lower bidirectional steel surface layer 1 has the same structure as the upper bidirectional steel surface layer 5. The longitudinal section of the stainless steel edging 7 is U-shaped, with its two ends extending horizontally to contact the upper and lower connecting slopes respectively. The remaining part is welded and sealed to wrap the outer wall of the aluminum alloy honeycomb core layer 3, so as to fully protect the composite stacked structure.

[0025] The implementation principle of this application embodiment is as follows: When this product is used, the lower bidirectional steel surface layer 1 and the upper bidirectional steel surface layer 5 directly resist corrosive media such as hydrogen sulfide in the petroleum environment. The nano-ceramic anti-slip coating 6 located on the top further improves the wear resistance and corrosion resistance of the surface and increases the surface friction to prevent slipping. The aluminum alloy honeycomb core layer 3 is bonded between the two steel surface layers by the lower structural adhesive layer 2 and the upper structural adhesive layer 4. The mica and silica filler in the structural adhesive form an insulating barrier, thereby blocking the galvanic corrosion channel between the aluminum alloy honeycomb core layer 3 and the two steel panels. The oxide film and epoxy primer on the surface of the aluminum alloy honeycomb core layer 3 provide double protection against corrosion and effectively isolate external corrosive media from entering the aluminum alloy honeycomb core layer 3. The thickness of the aluminum alloy honeycomb core layer 3 accounts for 70% of the total thickness. On the basis of achieving lightweight, it significantly improves the long-term corrosion resistance reliability and structural integrity of the material in the harsh petroleum environment, and reduces the high dependence on vulnerable coatings and the resulting high maintenance burden.

[0026] It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that this application can be implemented in other specific forms without departing from its essential characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this application. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A lightweight composite steel plate, characterized in that: The structure consists of a lower bidirectional steel surface layer (1), a lower structural adhesive layer (2), an aluminum alloy honeycomb core layer (3), an upper structural adhesive layer (4), and an upper bidirectional steel surface layer (5) stacked sequentially from bottom to top. A stainless steel edging (7) is welded and sealed around the perimeter of the stacked structure. The joint between the stainless steel edging (7) and the lower bidirectional steel surface layer (1) and the upper bidirectional steel surface layer (5) is filled with sealant (8) and filled with insulating ceramic fiber tape (9).

2. The lightweight composite steel plate according to claim 1, characterized in that: The thickness of the aluminum alloy honeycomb core layer (3) accounts for 70% of the overall thickness of the composite stacked structure. The diameter of any one of the honeycomb holes in the aluminum alloy honeycomb core layer (3) is 50% of the thickness of the whole layer. The surface of the aluminum alloy honeycomb core layer (3) is anodized to form an oxide film, and an epoxy primer is coated on the surface of the oxide film.

3. The lightweight composite steel plate according to claim 1, characterized in that: The lower structural adhesive layer (2) is a modified epoxy resin structural adhesive, which contains mica and silica. The upper structural adhesive layer (4) is the same as the lower structural adhesive layer (2).

4. The lightweight composite steel plate according to claim 1, characterized in that: The surface of the upper bidirectional steel surface layer (5) is sprayed with a layer of nano-ceramic anti-slip coating (6). The edges of the upper bidirectional steel surface layer (5) are milled with connecting bevels. The sealant (8) and the insulating ceramic fiber tape (9) are located outside the connecting bevels. The tops of the stainless steel edging (7), the insulating ceramic fiber tape (9) and the nano-ceramic anti-slip coating (6) are flush.

5. A lightweight composite steel plate according to claim 4, characterized in that: The lower bidirectional steel surface layer (1) has the same structure as the upper bidirectional steel surface layer (5). The longitudinal section of the stainless steel edging (7) is U-shaped. Its two ends of the U-shape extend horizontally and contact the upper and lower connecting slopes respectively. The remaining part is welded and sealed to the aluminum alloy honeycomb core layer (3).

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