Multilayer structural material and method of its production

FIELD: construction.

SUBSTANCE: method for production of multilayer structural material includes mould filling, subsequent supply of layer materials, moulding, soaking, withdrawal from mould. At the same time serial filling of layer materials is carried out through placement of basalt cloth layers impregnated with epoxide resin onto mould bottom, placement of foam polyurethane layer onto layers of basalt-plastic with further laying of basalt cloth layers impregnated with epoxide resin onto foam polyurethane layer, with intermediate arrangement of carbon threads in between. Ends of carbon threads are taken outside. Moulding and soaking of all layers is carried out simultaneously in process of heating up to temperature of 60C and pressure of 0.5-1.0 MPa until resin hardens. At the same time ratio of foam polyurethane layer thickness to basalt-plastic layer thickness makes 20-80:0.5-1.5.

EFFECT: improved mechanical properties and reduced process cycle.

2 cl, 2 dwg, 1 tbl

 

The invention can be used in wall and roof sandwich panels for aircraft skin and deep-diving vehicles, river and sea vessels as a structural heat - and sound insulating material.

Known multilayer construction element consisting of a Central layer (strips of mineral wool) and surface layers located on two opposite major surfaces of the Central layer, obtained by gluing surface layers to the opposite main surfaces of the Central layer. The surface of the middle layer is made of profiled with grooves, and the surface layers repeat the circuit surface of the middle layer [1].

Profiling of facing sheets and mineral wool boards with exactly match the ledge with hollow sheet and plate, the adhesive on the outer layers and bonding complicate the process.

Known multilayer structural material used in sandwich panels, including two of the surface layer of the metal and the Central part, assembled from pieces of strips of mineral wool, between which there are longitudinal strips of molding foam (polyurethane and the like), where the Central layer of mineral wool strips alternated with a foam obtained by Gulf pieces of mineral wool is spininng mass polyurethane foam and the resulting structure are bonded sheets of metal [2].

The disadvantages of this design is the complexity of manufacturing, use as the outer layer of expensive metal sheets.

Known multilayer structural material used in the production of wall panels, characterized in that it consists of medium polyurethane foam insulation layer, the surface of which is shaped grooves, and the outer layers, made of galvanized steel with thickness of 0.5-0.7 mm with protective and decorative paint coating or without it.

Multilayer structural material obtained by pouring the foamed mass polyurethane foam in the mold, the profiled outer surface of the polyurethane layer grooves and bonding polyurethane foam blanks with pre-shaped sheet metal of the car [3].

The disadvantages of this design is the poor compatibility of the materials of the layers, low adhesion and Flexural strength, stiffness, multi-stage process.

Known multilayer structural material used in the production of wall panels, taken as a prototype, characterized in that it consists of two lateral sliced bars and located between the plates of polyurethane foam density 25-70 kg/m3while the front and rear side plates of panopolis the Tana closed layer of protective material, of paper, foil or plastic film, is fixed through the adhesive properties of the polyurethane foam. The material obtained by the Gulf of foamed mass in the mold, the bottom of which lay a protective material on the sides of the wooden blocks. On foam mass placed on protective material, after which the resulting structure is maintained under pressure [4].

Structural strength is provided by the properties of the polyurethane foam, the surface protective layers do not improve the mechanical characteristics of the material.

A known method of manufacturing a multi-layer building blocks containing cladding, insulation and structural layers, including installation in the form of technological partitions, form a consistent supply solutions cladding, insulation and structural layers, molding, extract, and eject from the mold. At the bottom of the form is placed plates of flexible resilient material, the dimensions and configuration of which correspond to the size and configuration of manufactured units, as technological partitions use plates located along their bottom ends and side surfaces of a film of an elastic flexible material, which set after completing the form, enter their bottom ends into the gap between the plates of ELAS the ranks of the material, the extract produced before setting solutions, and then remove the plate technological partitions, leaving the film is fixed between the ends of plates made of an elastic material prior to complete solidification of solutions.

The disadvantages of this method is a multistage process.

The objective of the invention is to improve the mechanical characteristics, the reduction process.

Unlike the prototype created in the multilayer structural material, the inner layer consists of polyurethane foam, and the surface layers are made of basaltoplastica, consisting of several layers of basalt fabric impregnated with resin or basaltoplastica, consisting of several layers of basalt fabric impregnated with resin and laid between them carbon fibers, used a combination of well-interoperable components - polyurethane foam and basaltoplastica and placement of carbon filament in basalt plastic, providing electric heating.

To achieve the mentioned technical result in the production method of the multilayer structural material including filling in forms consistent supply of material layers, forming, self-control, demoulding, consistent flow of the mother of the crystals of the layers is performed in the following sequence: place at the bottom of the shaped layers of basalt fabric, impregnated with epoxy resin, or layers of basalt fabric impregnated with epoxy resin, and between them is placed carbon filament, the ends of which are output. Then place a layer of polyurethane foam, preformed in identical form, it is placed layers of basalt fabric impregnated with epoxy resin, or layers of basalt fabric impregnated with epoxy resin, and between them is placed carbon filament, the ends of which are output. The formation and exposure of all of the layers takes place simultaneously when heated to 60C and a pressure of 0.5-1.0 MPa to curing resin.

To achieve this technical result in the multilayer structural material containing a Central polyurethane foam layer and the surface layers, the surface layers are made of basaltoplastica or layer basaltoplastica with stacked inside carbon fibers, the ends of which are brought out, when the ratio of the thickness of the layer of polyurethane foam to the thickness of basaltoplastica 20-80: 0.5 to 1.5.

To create the layered structural material used:

polyurethane foam stamps T-PN TU-011-43862634-07;

basalt fabric BT-12 TU 5952-031-00204949-95;

epoxy resin grade ED-20 GOST 10587-76;

carbon fiber - Balakovo fiber.

Figure 1 presents the scheme of formation of the multilayer construction is about material without carbon fibers inside basaltoplastica.

Figure 2 presents the scheme of formation of the multilayer structural material containing carbon filament inside basaltoplastica.

Table 1 shows the physico-mechanical characteristics of the prototype and the inventive multilayer structural material depending on the ratio of the thickness of the inner layer to the outer.

Example 1. Multilayer structural material (figure 1) consists of a lower layer of basaltoplastica 1 in the form of resin-impregnated layers of basalt fabric, a middle layer of polyurethane foam 2, the top layer of basaltoplastica 3 in the form of resin-impregnated layers of basalt fabric. The number of layers of basalt fabric layer 1 is two and layer 3 is equal to two.

Way to obtain is as follows. At the bottom of the mold stacked basalt plastic 1 - resin-impregnated layers of basalt fabric, which lay in advance obtained by forming a layer of polyurethane foam 2 identical forms, and laid on top of the basalt plastic 3 - resin-impregnated layers of basalt fabric. The resulting structure is crimped outer part press tooling, which can be smooth or with ridges. Order to shorten the curing resin raise the temperature of the outer layer of the multilayer structural material up to t=60C due to external source of heat and withstand dauvergne resin. The layer thicknesses are (20:0,5) mm

Example 2. The same as in example 1 at a ratio of layer thicknesses (50:1,0) mm

Example 3. The same as in example 1 at a ratio of layer thicknesses (80:1,5) mm

Example 4. Multilayer structural material (2) consists of a layer of basalt fabric 1, impregnated with resin, which laid carbon fiber 2 with facing outward ends 3, a layer of basalt fabric 4, the resin-impregnated layer of polyurethane foam 5, a layer of basalt fabric 6, impregnated with resin, which laid carbon fiber 7 with facing outward ends 8, a layer of basalt fabric 9 impregnated with resin.

Multilayer structural material obtained by the sequential filling of the components of the mold: at the bottom of press equipments stacked resin-impregnated basalt fabric 1, which put a carbon fiber 2 from coming out all 3, and cover basalt fabric 4 impregnated with resin. Next place a layer of polyurethane foam 5, preformed in identical form, on which the stacked resin-impregnated basalt fabric 6, it put a carbon fiber 7 with facing outward ends 8 and cover basalt cloth 9 impregnated with resin. The resulting structure is crimped outer part press tooling, which can be smooth or with ridges. Order to shorten the approval of the resin increase temperature to t=60C, why carbon filaments noise electric current, power and voltage which is determined by the size and configuration of the element. The curing process of the resin in the basalt plastic accelerated several times. Further heating elements of carbon fibers can be used as heat sources for heating the interior space. The layer thicknesses are (20:0,5) mm

Example 5. The same in example 4, when the thickness ratio of layers (50:1,0) mm

Example 6. The same in example 4, when the thickness ratio of layers (80:1,5) mm

Data defining the physical-mechanical characteristics of the material in comparison with the prototype, shown in table 1.

The advantage of the developed technology is.

High strength adhesive compound between the layers of basaltoplastica and polyurethane, which ensures penetration of epoxy resin into the surface of the polyurethane layer and filling a void, creates a solid adhesive layer. The presence of basaltoplastica as the outer layers significantly improves the strength characteristics of the structure, giving it the strength qualities of both materials. Low coefficient of thermal conductivity design provides a combination of materials. The presence of the layer of basaltoplastica electrically conductive carbon fibers, the cat is the second electric current, allows you to adjust the heating layer basaltoplastica, which contributes to the acceleration of the hardening process of the resin. Improving the efficiency of the insulation. Further heating elements of carbon fibers can be used as heat sources for heating the interior space.

In addition, profiling of the lower and upper surface of the element and pressing the snap, it is possible to obtain a multilayer structural element with ribs, while reducing transaction profiling as a separate, allowing you to create waste-free technology, further enhances the strength of the structure.

Used sources of information

1. Pat. 2270902, RF IPC E04C 2/26, 2/292. Sandwich-panel / Abulashvili SG, Kisielius BTW, Bobryshev VV // bul. - 2006. No. 6.

2. Pat. UM 65920, RF IPC E04C 2/292. Sandwich-panel / Khafizov MR // bul. - 2007. No. 24.

3. THE 5768-116-02495282-01.

4. Utility model 65919, Russia IPC IS 2/10. Wall polyurethane foam panel / Vasilets SV // bul. - 2007, No. 24.

1. The method of obtaining the multilayer structural material including filling in forms consistent supply of material layers, forming, self-control, removing from the mold, characterized in that the consistent flow of material layers perform the placement at the bottom of the form layer b is salloway fabric, impregnated with epoxy resin, placing a foam layer on the layers of basaltoplastica and piling on penopoliuretanovuju layer of basalt layers of fabric impregnated with epoxy resin with an intermediate location between the carbon fibers, the ends of which are output, molding and extract all of the layers takes place simultaneously when heated to a temperature of 60C and a pressure of 0.5-1.0 MPa to curing of the resin at the ratio of the thickness of the layer of polyurethane foam to the thickness of basaltoplastica 20-80: 0.5 to 1.5.

2. Multilayer structural material obtained according to claim 1, containing a Central polyurethane foam layer and the surface layers, wherein the surface layers are made of basaltoplastica or layer basaltoplastica with stacked inside carbon fibers, the ends of which are brought out, when the ratio of the thickness of the layer of polyurethane foam to the thickness of basaltoplastica 20-80:0.5 to 1.5.



 

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