Three-ply panel and method of its production

FIELD: process engineering.

SUBSTANCE: invention relates to production of construction materials, particularly, to light three-ply boards including foamed polymer filler. Proposed board comprises top and bottom plies with filler glued in place there between. Filler reinforced discrete elements shaped to stiffness are arranged at areas to sustain increased loads. Areas reinforced with discrete elements inside shaped plies are composed of hollow cases located in definite order above bottom ply with glue layer. Invention covers also the production of said boards.

EFFECT: higher hardness, longer life.

2 cl, 5 dwg

 

The invention relates to the field of structural panels, and in particular to a lightweight sandwich panels containing foamed polymeric filler. The results of the development can be used as part of a special constructions of aircraft-and shipbuilding, the manufacture of sports training equipment, large collapsible layouts.

Famous sandwich panel with a polymeric binder containing alternating layers of impregnated fiberglass and bars foam, playing the role of a placeholder. After laying the components of the blanks panel is formed by applying a pressing and induction heating (patent RF №2381132). When sufficient complexity of manufacturing the panel does not meet certain requirements, because the foam easily and irreversibly deformed as from chemical and thermal effects. This may be compromised the integrity of the panel and lost some of the initial specified property.

Famous sandwich panel (PM No. 80874), consisting of upper and lower casings and cell glued filler, combined with additional foam filler. The manufacture of the panel is time-consuming. If this panel does not have near the required physical and mechanical properties or stability of these properties in terms of external influences.

Famous sandwich panel (PM No. 105326), the soda is containing the upper and lower casing, between which is mounted on the glue filler. The filler is made of reinforced discrete gas-filled plastic. Increasing the strength of the filler discrete elements are located in the most loaded areas. They have the configuration of the stiffeners. On a number of essential features of the sandwich panel by GR No. 105326 as the closest to the claimed panel adopted as a prototype. Main achieved by the patent of the prototype is reducing the complexity. Reducing the complexity reached by the introduction of discrete elements in the loaded areas of the fill. Used gas-filled plastics based on polystyrene, polyvinyl chloride, polyurethane, phenolic, epoxy, carbamid and silicone resins. The authors of the utility model is recommended to produce gas-filled plastic layer coating composition. However, in the text there is no indication on the modes and conditions of deposition. It is not clear how made themselves discrete elements as required localization chopped fibers, wire, metal, polymer and ceramic particles in the conditions of sputtering gas-filled plastic is problematic. This applies in particular to a vertically positioned regions 7, marked on figure 5 description of the prototype. Thus shatrugna the analysis of allegiance approval of reducing the complexity of the manufacturing panel, how about the main achievable result. In some cases this method of application seems to be difficult and there is little compatible with the installation of discrete elements. If the discrete elements set in advance, how to produce fastening the top and bottom panels on glue? Some technical issues associated with the method of fastening the top panel after filling the rest of the volume.

The whole design of the prototype seems to be working, but practically difficult. However, in the description GR No. 105326 almost do not provide specific data about the operations of the execution of discrete elements in the manufacture of sandwich panels.

The main technical task of the present application is related to design efficient in operation and technologically feasible sandwich panels.

Another technical challenge is the development of a method of manufacturing the panel.

Technical problem in the design of the panel is solved due to the fact that reinforced discrete elements contain shaped shell of appropriate dimensions, geometric configuration, arrangement and composition, and on the inside of the shells is a composite material with the desired combination of properties.

The technical problem according to the method is solved by the fact that when the bottom is th plating on it mounted on the adhesive layer pre-formed shaped shell of discrete elements, filled composite material with the desired content of discrete reinforcing elements, then make the filling the rest of the structural volume of gas-filled plastic, mechanical surface treatment and installation of the upper shell.

To achieve the result is a clear localization of reinforced discrete elements within the required geometrical dimensions, configuration, strength characteristics. This makes it possible to ensure that the composition and structure of three-layer panels structural calculations. Depending on the specified configuration shaped shells of discrete elements they can be produced by the methods of pneumaturia and vacuum molding of thermoplastics, technology blown polymers, installation on melted and soluble models.

The design of the inventive panel is illustrated in figure 1, figure 2, figure 5. The inventive method of manufacturing a panel is illustrated in figure 3, figure 4.

Figure 1. Shaped shell discrete elements

1 - Sheath in the form of a cylinder

2 - Shell in the form of a truncated cone

3 - Shell in the form of a truncated pyramid

4 - Shell-form structures of 2 truncated cones

5 - Shell-form structures of 2 truncated pyramids

6 - Shell in the form of a rectangular lattice

Figure 2. Obolo the key, filled with material containing discrete reinforcing elements

1 - In the form of a truncated cone

2 - as a combination of 2 truncated pyramids

Figure 3. Installation and placement of the membrane on the lower cladding

3.1 Installation in the form of a rectangular lattice

3.2 - Installation in the form of vertical shells

1 lower hull

2 - Shell in the form of a rectangular lattice

3 - Shell in the form of vertically

4 - Adhesive layer

Figure 4. The filling of established buildings of the composite material and the panel Assembly

1 lower hull

3 is a Molded shell of discrete elements

4 - Adhesive layer

5 - Material filler (gas-filled plastic)

6 - Composite material with discrete elements

Figure 5. The sandwich panel Assembly

1 lower hull

2 - Upper cladding

3 is a Molded shell of discrete elements

4 - Adhesive layer

5 - Material filler (gas-filled plastic)

6 - Composite material with discrete elements

Declare the sandwich panel and method of reception are illustrated by examples 1 to 4.

Example 1

Form upper and lower trim panels made of composite materials in accordance with the drawings on the panel. Perform casting hollow cylindrical shaped shell by ilaci made of composite material based on glass fibers and polyester resin. Set the shell on the bottom of the casing, having them in accordance with the drawings on the panel and fix with adhesive on polyester basis. Fill shell material based on polyester resin and fine ceramics (discrete elements). Stand up to the complete loss of yield strength of the material with the formation of discrete elements. Fill the space between the reinforcing discrete gas-filled plastic, for example by spraying. After full curing materials shall conduct the required machining of the entire surface, fix the upper casing with adhesive on polyester basis, applying pressure, and can withstand up to full curing of all members of the panel materials.

Example 2

Form upper and lower trim panels made of composite materials in accordance with the drawings on the panel. Perform hollow-shaped membrane in the form of truncated cones by vyklicky of composite material based on epoxy resin and basalt fibers. Set the shell on the bottom of the casing, having them in accordance with the drawings on the panel and fix with glue based on epoxy resin. Fill the hollow shell material based on epoxy resin and a mixture of fine aluminum with hollow steklosfera (discrete elements). Stand up for what Noah loss of yield strength of the material with the formation of discrete elements. Fill the space between the discrete reinforcing elements lightweight polymer foam (gas-filled plastic). After curing materials shall conduct the required machining of the entire surface. Fix the upper casing with an adhesive based on epoxy resin, applying pressure, and can withstand up to full curing of all members of the panel materials.

Example 3

Form upper and lower trim panels made of composite materials in accordance with the drawings on the panel. Carry out a method of blow molded shell made of polypropylene in the form of two opposing truncated cones. Set the shell on the bottom of the casing, having them in accordance with the drawings on the panel, and fixed with adhesive based on polyurethane. Fill the hollow shell with polyurethane powder mixed with PIM and short fiber (discrete elements). Stand up to the complete loss of yield strength of the material with the formation of discrete elements. Fill the space between the discrete reinforcing elements lightweight polymer foam, for example gas-filled plastic. After curing materials shall conduct the required machining of the entire surface. Fix the upper casing with an adhesive based on polyurethane, applying pressure, and you shall eribaum to complete curing of all members of the panel materials.

Example 4

Form upper and lower trim panels made of composite materials in accordance with the drawings on the panel. Perform hollow-shaped membrane in the form of pyramids vacuum-formed from ABS plastic. Set the shell on the bottom of the casing, having them in accordance with the drawings on the panel and fix with glue based on epoxy resin. Fill the hollow shell material based on epoxy resin with fragments of metal particles, including spiral shape (discrete elements). Stand up to the complete loss of yield strength of the material with the formation of discrete elements. Fill the space between the discrete reinforcing elements lightweight polymer foam. After curing materials shall conduct the required machining of the entire surface. Fix the upper casing with an adhesive based on epoxy resin, applying pressure, and can withstand up to full curing of all members of the panel materials.

Example 5

Form upper and lower trim panels made of composite materials in accordance with the drawings on the panel. To the top covering adhesive based on epoxy resin pre-fixed shaped hollow shell in the form of a lattice. Performed in the shape of pyramid shaped hollow shell by vacuum molding from polika is Bonita. Set the chassis on the bottom of the casing, having them in accordance with the drawings on the panel and fix with glue based on epoxy resin. Fill the hollow shell material based on epoxy resin with fragments of metal particles, including spiral shape (discrete elements). A lattice-shaped upper shell casing filled with the same material. Stand up to the complete loss of yield strength of the material with the formation of discrete elements. Fill the space between the discrete reinforcing elements on the lower cladding lightweight polymer foam. After curing materials shall conduct the required machining of the entire upper surface. Fix the upper hull is located on it filled lattice shell with glue based on epoxy resin, applying pressure, and can withstand up to full curing of all members of the panel materials.

From the above examples sandwich panels, as well as from figure 1, figure 2, figure 5, illustrating the design panel, you can make the following conclusions.

Declare the sandwich panel like panel analogs and prototypes contains the upper and lower cladding, and filled the space between them, in particular containing discrete elements creating additional strength and having a con is Horatio stiffeners. However, the inventive three-layer panel further comprises a reinforced discrete elements in the form of hollow shaped shells required configuration, the filled composite material containing discrete elements located on the lower trim panel in a certain way in accordance with structural calculations and fixed on the casing by means of the adhesive layer. When this is achieved, the result is a clear localization of the discrete elements, the provision of the necessary design of the geometric dimensions, configuration and structural characteristics of the panel. Shaped shell discrete elements can be performed with the use of serial techniques and lead manufacturing technology panel in accordance with structural calculations. Thus, it can be considered solved the set technical problem in the design of the panel.

In the manufacture of panels in accordance with the inventive method is carried out in a specific sequence of operations to form structural elements, namely:

The formation of the upper and lower facing panels and shaped shells reinforced discrete elements.

Localization shaped shells reinforced discrete elements by attaching them to the hull.

The filling of the shells is filled composite polymer material to form discrete elements.

Filling the remaining volume between the skins and the discrete elements of a lightweight polymer foam, for example gas-filled plastic.

Processing of all utverzhdenii surface mechanically.

Pinning on the treated surface of the upper cladding panels, in particular containing discrete elements.

Only the specified sequence of operations allows obtaining three-layer panel, the corresponding structural calculations and from materials with the necessary combination of physical, mechanical and performance properties. Thus can be considered solved the technical task of the method of manufacturing a sandwich panel.

The sandwich panel in the form of various, as well as the panel as a whole, was manufactured and tested in the CTS.

1. The sandwich panel with an aggregate of gas-filled plastic containing the upper casing and the lower casing, between which is mounted on the glue filler and reinforced discrete area of the filler having the configuration of the stiffening elements and located in the most loaded areas, characterized in that the reinforced discrete area elements inside the shaped shells made in the form of hollow shells, localized in a specific order on top of the lower clapboard and with an adhesive layer.

2. A method of manufacturing sandwich panels, consisting in forming in the most loaded areas filler reinforced discrete elements having the configuration of the stiffening elements, characterized in that after forming the upper covering, a lower covering, shaped shells on top of the lower casing in a specific order to localize the adhesive layer is shaped membrane in the form of hollow shells filled shell material with a high content of discrete reinforcing elements, produce filling the space between the shells lightweight gas filler, conduct mechanical processing of the received surface and install the upper trim panel through the adhesive layer.



 

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