CN111497357A

CN111497357A - Honeycomb core sandwich composite board and preparation method and equipment thereof

Info

Publication number: CN111497357A
Application number: CN202010463371.9A
Authority: CN
Inventors: 朱华平; 韩德滨; 姚正军; 沃晓剑
Original assignee: Jiangsu Qiyi Technologies Co ltd
Current assignee: Jiangsu Qiyi Technologies Co ltd
Priority date: 2020-05-27
Filing date: 2020-05-27
Publication date: 2020-08-07

Abstract

The invention discloses a honeycomb core sandwich composite plate which comprises a honeycomb core material formed by a plurality of units arranged in a row, wherein the units are hexagonal columns formed by surrounding side walls, the transversely adjacent units are connected through transversely arranged connecting walls, and the adjacent side walls of the longitudinally adjacent units are mutually bonded or attached through an adhesion layer. The upper surface and the lower surface of the honeycomb core material are respectively provided with a panel, the panel comprises a main body layer, an interface layer and a surface layer, the surface layer and the interface layer are respectively arranged on two sides of the main body layer, and the surface layer is made of continuous fiber reinforced thermoplastic material or thermoplastic resin film or metal film added with a modification auxiliary agent. Furthermore, the invention also discloses a preparation method and equipment of the honeycomb core sandwich composite board. The honeycomb core sandwich composite board has more excellent compressive strength and bending strength performance, and has the characteristics of A-level surface treatment, skid resistance, wear resistance, heat transfer and temperature resistance, thermal modification, air permeability and the like.

Description

Honeycomb core sandwich composite board and preparation method and equipment thereof

Technical Field

The invention relates to the technical field of honeycomb core structures, in particular to a honeycomb core sandwich composite plate and a preparation method and equipment thereof.

Background

The honeycomb core sandwich composite board is prepared by taking light and high-strength materials as an upper panel and a lower panel and taking a low-density honeycomb core material as an intermediate through a hot-pressing composite process, has the characteristics of light weight, large ratio of rigidity to mass, good compressive strength and the like, and is widely applied to various fields requiring light weight, such as aramid fiber honeycombs and aluminum honeycombs on airplanes, thermoplastic PP honeycombs in the field of transportation, paper honeycombs in the packaging industry, backing boards of light weight components in the photovoltaic industry and the like.

Most of the existing honeycomb core structure production process technologies are discontinuous production process flows, but more advanced continuous production processes are developed in succession. Similar process technologies are disclosed in patent publication No. CN101084108B, patent publication No. CN105835484A, U.S. BRADFORD company patent nos. US8303744B2, US8663523B2, and US9550336B2, and for specific details, reference is made to the background description of patent application No. 201911365572.9 of the aforementioned scholanzi-odd-science ltd, which is not repeated herein.

At present, a continuous process mode is adopted to produce a honeycomb core material with a thermoplastic resin material as a panel layer and a honeycomb core material as a sandwich layer. The preparation equipment mainly comprises two main types of double-sided steel belt type thermal composite process equipment and double-sided high-temperature-resistant Teflon belt type thermal composite process equipment. The two types of equipment adopt the same process design principle in the overall flow, and mainly comprise an upper contact type heat conduction heating device, a lower contact type heat conduction heating device, one or more groups of hot-pressing composite rollers, and an upper contact type cooling device and a lower contact type cooling device. The configured steel belt or the high-temperature-resistant Teflon belt not only plays a role in continuously conveying products, but also plays a role in pressing surface textures and separating the products after a cooling and shaping process by the textures set on the surface of the steel belt or the high-temperature-resistant Teflon belt, and realizes the production of the honeycomb core sandwich composite plate with the anti-skid surface in a continuous process flow by integrating heating, pressurizing, texture pressing, cooling, conveying and separating. Meanwhile, regarding the design of the heating process, the two production process equipment also adopt the same structural layout, namely the configured heating devices respectively heat the upper panel and the lower panel of the surface anti-slip honeycomb core sandwich composite plate, and the upper panel and the lower panel are heated through the heat transfer path from the outside to the inside at the outer side of the panel, so that the inner side layer surfaces of the upper panel and the lower panel and the connecting surface layers of the upper surface and the lower surface of the honeycomb core material reach the set hot melting temperature in a mixed heat transfer mode of heat conduction and heat convection, and then the required honeycomb core sandwich composite plate is obtained through the continuous hot pressing and cooling process. In addition, the surface of the existing honeycomb core composite board has no characteristics of A-level surface treatment, skid resistance, wear resistance, temperature resistance, heat transfer modification, air permeability and the like.

Disclosure of Invention

In order to overcome the defects of the prior art, the invention provides a honeycomb core sandwich composite plate which is combined with the technical principle of materials and heat transfer science, further improves and optimizes the material, heat transfer and heat recombination process characteristics of a honeycomb core material structure and the connecting interfaces of an upper panel and a lower panel with a honeycomb core material, and has the characteristics of A-level surface treatment, skid resistance, wear resistance, heat transfer temperature resistance, heat modification, air permeability and the like, and further provides a preparation method and equipment of the honeycomb core sandwich composite plate.

In order to achieve the purpose, the invention adopts the following technical scheme:

the invention provides a honeycomb core sandwich composite plate, which comprises a honeycomb core material formed by a plurality of units arranged in a row, wherein the units are hexagonal columns formed by surrounding side walls, the side walls comprise a supporting layer and an adhesion layer, the supporting layer and the adhesion layer are made of different materials, the melting point of the adhesion layer is lower than the softening point of the supporting layer, the transversely adjacent units are connected through transversely arranged connecting walls, and the longitudinally adjacent side walls of the units are mutually bonded or attached through the adhesion layer;

the honeycomb core material comprises a honeycomb core material and is characterized in that panels are respectively arranged on the upper surface and the lower surface of the honeycomb core material, each panel comprises a main body layer and an interface layer, and the interface layers are respectively connected with the upper surface and the lower surface of the honeycomb core material;

the panel also comprises a surface layer, wherein the surface layer and the interface layer are respectively arranged on two sides of the main body layer, and the surface layer is made of continuous fiber reinforced thermoplastic material or thermoplastic resin film or metal film added with a modification auxiliary agent.

In a preferred embodiment, the side walls of the cell are of a three-layer construction, with an adhesive layer on each side of the support layer.

In a preferred embodiment, the six side walls of the unit and the connecting wall are respectively provided with at least one reinforcing rib or rib in a staggered or aligned manner, which is parallel to the plain line of the unit.

As a preferred embodiment, the facing has anti-slip, anti-friction, high temperature resistance, high heat transfer coefficient, and appearance texture features.

In a preferred embodiment, the auxiliary is one or a mixture of two or more of a hardening agent, an anti-wear agent, a heat-resistant agent, and an auxiliary with a high heat transfer coefficient.

In a preferred embodiment, the anti-wear agent is one or a mixture of two or more of teflon, molybdenum disulfide, graphite and wollastonite, and the heat-resistant agent is one or a mixture of two or more of wollastonite, nano-montmorillonite, talcum powder and calcium carbonate.

In a preferred embodiment, the supporting layer of the cells is made of a modified fiber reinforced thermoplastic resin material and/or a metal alloy, and the side walls and the connecting walls of the cells are made of an aluminum or paper material.

As a preferred embodiment, the melting point of the thermoplastic resin of the bulk layer is higher than the melting point of the thermoplastic resin of the interface layer, and the melting point of the interface layer is the same as or compatible with the melting point of the support layer.

In a preferred embodiment, the surface layer, the main body layer and the interface layer are made of the same material, and the fiber content of the surface layer, the main body layer and the interface layer is sequentially from low to high to low;

the weight ratio of the fiber content of each layer forming the surface layer to the corresponding thermoplastic resin is 0-40%, the weight ratio of the fiber content of each layer forming the main body layer to the corresponding thermoplastic resin is 30-80%, the weight ratio of the fiber content of each layer forming the interface layer to the corresponding thermoplastic resin is 20-40%, and the thickness of the film layer of the interface layer is 0.01-0.5 mm.

In a preferred embodiment, the surface layer, the main body layer and the interface layer are made of different materials, the surface layer is made of a continuous fiber reinforced thermoplastic material or a thermoplastic resin film or a metal film added with a modification auxiliary agent, the main body layer is made of a continuous fiber reinforced thermoplastic sheet with higher performance as an outer layer and a continuous fiber reinforced thermoplastic sheet with lower performance as an adjacent inner layer, or is made of a design that the continuous fiber reinforced thermoplastic sheet with higher performance and the continuous fiber reinforced thermoplastic sheet with lower performance are alternately layered in a high-low mode, and the interface layer is made of a continuous fiber reinforced thermoplastic material or a thermoplastic resin film with lower mechanical property than that of the main body layer.

In a preferred embodiment, the surface layer, the main body layer and the interface layer are made of different materials, the surface layer and the main body layer are made of metal films, the interface layer is made of a modified hot melt adhesive film, and the surface layer and the main body layer are bonded by the modified hot melt adhesive film.

The invention also provides a preparation method of the honeycomb core sandwich composite plate, which is used for manufacturing any one of the honeycomb core sandwich composite plates and comprises the following steps:

s1: forming a plurality of connected semi-hexagonal structures longitudinally and transversely on the thermoplastic resin film by a heating compression molding process or a heating vacuum plastic molding process, wherein the plurality of connected semi-hexagonal structures comprise semi-hexagonal unit parts and adjacent connecting parts which are distributed at intervals;

s2: adopting a heating pressing or ultrasonic heating welding process to align, fit and connect two longitudinally continuous and transversely connected connecting parts with a plurality of connected semi-hexagonal structures, so that the two connecting parts are integrally formed into a longitudinally continuous and transversely connected core plate with a plurality of connected hexagonal column structures;

s3: cutting the longitudinally continuous and transversely connected core plates of a plurality of connected hexagonal column structures at intervals up and down to form cuts which are spaced up and down and are partially connected, wherein the longitudinally continuous and transversely connected core plates of the plurality of connected hexagonal column structures are not completely cut off during cutting, but a connecting edge is reserved at the cuts;

s4: folding the core plate with the notch by rotating the core plate by plus 90 degrees or minus 90 degrees according to the notch direction by taking the notch as a folding position and the connecting edge of the notch as a folding rotating shaft, and heating to form an adhesion layer in a hot melting state on adjacent side walls, wherein the adjacent side walls are mutually attached and connected to form a honeycomb core material;

s5: and (3) attaching the panels to the upper surface and the lower surface of the honeycomb core material, heating the interface layer of the panel and the upper surface and the lower surface of the honeycomb core material to reach the set hot melting temperature, forming a hot melting connecting layer on the interface layer of the panel, performing hot pressing, attaching and compounding on the upper surface and the lower surface of the honeycomb core material, heating and pressing textures on the surface layer of the panel, and cooling and forming to prepare the honeycomb core sandwich composite plate.

As a preferred embodiment, the thermoplastic resin films of the preparation units are of a single-layer structure, the single-layer thermoplastic resin film is used as a supporting layer in step S1, a thermal compounding process is used to thermally compound a thermoplastic resin film as an adhesion layer on each of two sides of the supporting layer, and the melting point of the adhesion layer is lower than the softening point of the supporting layer; in step S2, an adhesion layer is arranged on the outer side of the core plate which is longitudinally continuous and transversely provided with a plurality of connected hexagonal columnar structures, the supporting layer and the adhesion layer are made of different materials, and the melting point of the adhesion layer is lower than the softening point of the supporting layer; the adhesive layers of the folded side-by-side connected cell sidewalls are thermally fused by heating at a temperature between the melting point of the adhesive layer and the softening point of the support layer in step S4.

As a preferred embodiment, the panel is of a single structure, and S5 includes the following steps:

s51: adopting extrusion forming or hot-press forming to prepare a hot-melt connecting film, wherein the thickness of the hot-melt connecting film is 0.01-0.5 mm;

s52: at least one layer of continuous fiber reinforced thermoplastic material is used as a main body layer in the panel, and a layer of hot melt connecting film is adhered to the inner side surface of the panel to form an interface layer;

s53: heating the binding surfaces of the upper surface and the lower surface of the honeycomb core material and the interface layer to a required melting point temperature, hot-pressing, binding and compounding the interface layer and the upper surface and the lower surface of the honeycomb core material, heating the interface layer, pressing textures, and cooling and forming to prepare the honeycomb core sandwich composite board.

The invention also provides a preparation device of the honeycomb core sandwich composite plate, which is used for realizing the preparation method of the honeycomb core sandwich composite plate, and the preparation device comprises the following steps:

a first conveyor belt device for realizing continuous conveying from the thermoplastic resin film to the honeycomb core material manufacturing process;

a thermoplastic molding device for thermoplastic molding a thermoplastic resin film;

the first cooling device is used for cooling and laminating to form a hexagonal column-structured core plate which is longitudinally continuous and is formed by laminating a plurality of connected semi-hexagonal structures in the transverse direction;

the cutting device is used for cutting the core plate of the hexagonal column structure which is longitudinally continuous and transversely formed by pressing a plurality of connected semi-hexagonal structures;

an indexing pair roller device for folding the core plate cut by the cutting device;

the hot melting device is used for heating and hot melting the core plates folded by the indexing double-roller device to form a honeycomb core material;

the second conveying belt device is used for realizing continuous conveying from the honeycomb core material to the processes of manufacturing the honeycomb core sandwich composite board;

a heating device for heating the upper and lower surfaces of the honeycomb core material and the face plate;

the preparation apparatus further comprises:

at least one group of hot-pressing composite rollers for hot-pressing the upper surface, the lower surface and the interface layer of the honeycomb core material to form the honeycomb core sandwich composite plate;

a texture pressing device for performing texture pressing molding on the surface layer;

and the second cooling device is used for cooling the honeycomb core sandwich composite plate formed by texture pressing of the texture pressing device and comprises an upper contact type cooling device and a lower contact type cooling device.

In a preferred embodiment, the texture pressing device is a steel belt with texture on the surface, a high-temperature-resistant Teflon belt and a meshing roller.

As a preferred embodiment, the manufacturing apparatus further comprises a plasma emission device for polarity treatment of the upper and lower surfaces of the honeycomb core and the inner side surface of the face sheet.

Compared with the prior art, the invention further improves and optimizes the material, heat transfer and thermal recombination process characteristics of the honeycomb core structure and the connection interfaces of the upper and lower panels and the honeycomb core by combining the technical principles of materials and heat transfer. The honeycomb core sandwich composite board designed and manufactured is more excellent in compressive strength and bending strength, has the characteristics of A-level surface treatment, skid resistance, wear resistance, temperature transmission resistance, thermal modification, air permeability and the like, is applied to the fields of aerospace, rail transit, home decoration and the like, and has great advantages compared with traditional materials.

Drawings

FIG. 1 is a schematic structural view of a honeycomb core of an embodiment of the invention;

FIG. 1a is a schematic structural view of a honeycomb core provided with reinforcing ribs or ridges according to an embodiment of the present invention;

FIG. 2 is a schematic diagram of a cell structure with two sidewalls according to an embodiment of the present invention;

FIG. 3 is a schematic flow chart of a process for preparing a honeycomb core sandwich composite panel using a two-layer structure of thermoplastic resin films according to an embodiment of the present invention;

FIG. 4 is a schematic illustration of the formation of a core sheet during the fabrication of a honeycomb core sandwich composite panel in accordance with an embodiment of the present invention;

FIG. 4a is a schematic representation of one structural design of a core sheet having reinforcing ribs or ridges formed during the fabrication of a honeycomb core sandwich composite panel in accordance with an embodiment of the present invention;

FIG. 4b is a schematic illustration of an alternative structural design for forming a core sheet with reinforcing ribs or ridges during the fabrication of a honeycomb core sandwich composite panel in accordance with an embodiment of the present invention;

FIG. 5 is a schematic flow diagram of an embodiment of the present invention for preparing a honeycomb core sandwich composite panel using a panel of unitary construction;

FIG. 6 is a schematic view of an apparatus for preparing a honeycomb core according to an embodiment of the present invention;

fig. 6a is a schematic structural diagram of an indexing roll-to-roll device in the honeycomb core material preparation equipment according to the embodiment of the invention;

FIG. 7 is a schematic structural view of a continuous fiber reinforced unidirectional sheet of an embodiment of the present invention;

FIG. 8 is a schematic structural diagram of a panel according to an embodiment of the present invention;

FIG. 9 is a schematic structural view of a honeycomb core sandwich composite panel in accordance with an embodiment of the present invention;

FIG. 9a is a schematic view of the honeycomb core sandwich composite plate of an embodiment of the present invention subjected to a force during thermal compounding;

FIG. 10 is a schematic view of an apparatus for making a honeycomb core sandwich composite panel in accordance with an embodiment of the present invention;

FIG. 10a is a schematic view of another apparatus for making honeycomb core sandwich composite panels in accordance with embodiments of the present invention;

wherein, 1 unit, 2 side walls, 21 adjacent side walls, 211 supporting layer, 212 adhesion layer, 3 connecting wall, 4 half hexagonal unit part, 4a, 4b half hexagonal unit part containing reinforcing ribs or reinforcing ridges, 5 connecting part, 5a, 5b connecting part containing reinforcing ribs or reinforcing ridges, 6a, 6b reinforcing ribs or reinforcing ridges, 61 first conveying belt device, 62 thermoplastic forming device, 63 cutting device, 64 indexing pair roller device, 641 roller, 65 hot melting device, 66 extruding device, 67 pressing device, 68 first cooling device, 69 honeycomb core material, upper and lower surfaces of 69a honeycomb core material, 70 surface layer, 71 main body layer, 72 interface layer, inner side layer of 72a interface layer, 73 panel, 73a panel in roll shape, 74 thermoplastic resin, 75 continuous fiber, 76 continuous fiber reinforced unidirectional sheet material, 79 heating device, 80 hot pressing composite roller, 82 texture pressing device, 83 plasma emission device.

Detailed Description

The present invention is further illustrated by the following specific examples, which are, however, not intended to limit the scope of the invention. In this specification, the honeycomb core sandwich composite plate has the characteristics of surface skid resistance, appearance texture and the like, and is not described in detail below.

Example 1

As shown in fig. 1, the honeycomb core 69 includes a plurality of cells 1 arranged in rows, and the cells 1 are columns surrounded by side walls 2, wherein laterally adjacent cells are connected by a laterally disposed connecting wall 3, and longitudinally adjacent cells are attached or bonded to each other by adjacent side walls 21. In the present embodiment, the cells are hexagonal columns, but it should be understood that the cross-sectional shape of the cells in the honeycomb core material can be selected as desired, and for example, the cells can be polygonal, preferably even-numbered polygonal. The side walls 2 and the connecting walls 3 of the cells 1 are not limited to polymer resin materials, and can be made of aluminum or paper materials, so that the compressive strength of the honeycomb core material is improved.

As shown in fig. 2, the side wall 2 of the unit is a two-layer structure including a support layer 211 and an adhesive layer 212, wherein the inner layer is the support layer 211 and the outer layer is the adhesive layer 212. Of course, it will be understood by those skilled in the art that the present invention is not particularly limited in the number and distribution of the side walls, so long as it is ensured that the adjacent side walls of longitudinally adjacent cells can be thermally fused together by adhesive layers, for example, the side walls of the cells of the present invention may also be of a three-layer structure in which an adhesive layer is provided on each side of the support layer.

In the embodiment, the support layer 211 and the adhesion layer 212 in the side wall 2 of the unit are made of different materials, wherein the support layer 211 is made of polypropylene material, and the softening point of the support layer 211 is 130 ℃; the adhesive layer 212 is made of ethylene-vinyl acetate (EVA) material with 28 Vinyl Acetate (VA), and the melting point of the adhesive layer 212 is 60 ℃. When the adjacent lateral wall of vertical adjacent unit is connected in the hot melt, can be with heating temperature control between 80 ~ 100 ℃, make the adhesion layer be in melting state and realize the hot melt and connect, the heat that the supporting layer accepted still is less than the softening point simultaneously, mechanical properties under the normal atmospheric temperature has, thereby make the supporting layer can provide required holding power when the folding laminating of adjacent unit, realize effectively keeping the unit geometry while, obtain the joint strength of higher adjacent lateral wall, promote the compressive strength of honeycomb core by a wide margin.

Preferably, the adhesion layer is made of a material with a melting point temperature of 40-80 ℃, and the supporting layer is made of a material with a softening point temperature of 150-160 ℃.

The adhesive layer 212 is made of ethylene copolymer, such as EVA (ethylene vinyl acetate), EAA (ethylene acrylate), EMA (ethylene maleic anhydride-acrylate), and the support layer 211 is made of polymer material which can be cast, such as PP (polypropylene), PA (polyamide), PC (polycarbonate), PET (polyethylene terephthalate), and the like, and the support layer can also be made of modified resin materials such as fiber-reinforced thermoplastic resin materials and metal alloys, and suitable reinforcing fibers include, but are not limited to, fiber-reinforced thermoplastic resin materials such as L FT (long fiber thermal molding) and L FT-D, and suitable reinforcing fibers include, but are not limited to, glass fibers, carbon fibers, and the like, and fiber-reinforced thermoplastic resins suitable for the fiber-reinforced thermoplastic resins, such as PP, PET, PA6 or PA66, PC resins, PEEK resins, PET resins, PPS resins, and the like.

As shown in fig. 4 to 4b, in fig. 4, the upper and lower half hexagonal cell structures constituting the core plate include half hexagonal cell portions 4 and adjacent connecting portions 5; in fig. 4a, the upper and lower half hexagonal unit structures include half hexagonal unit portions 4a containing reinforcing ribs or ridges and adjacent connecting portions 5a containing reinforcing ribs or ridges, reinforcing ribs or ridges 6a may be provided on the side walls 2 and connecting walls 3 of the units, and at least one reinforcing rib or ridge 6a parallel to the plain line may be provided on each of the six side walls 2 and connecting walls 3 of the unit 1. In fig. 4b, the upper and lower half hexagonal unit structures comprise half hexagonal unit parts 4b containing reinforcing ribs or ridges and adjacent connecting parts 5b containing reinforcing ribs or ridges, reinforcing ribs or ridges 6b may be arranged on the adjacent or corresponding side walls 2 and connecting walls 3 of the unit 1 in an aligned or staggered manner, and the same or different number of reinforcing ribs or ridges 6b may be arranged on each side wall 2 and connecting wall 3 of the unit. As shown in fig. 1a, the side walls of the honeycomb core are provided with stiffening ribs or

ridges

6a, 6 b. In this embodiment, at least one reinforcing rib or

rib

6a, 6b is provided on six side walls 2 and a connecting wall 3 disposed transversely of the unit 1, and the reinforcing ribs or

ribs

6a, 6b may be disposed in alignment with each other or in a staggered manner on the adjacent or corresponding side walls 2 or connecting walls 3, and may be disposed in the same number or in different numbers. It should be understood that the geometry of the ribs or ridges includes semicircular, arcuate, angular, sinusoidal, but is not limited to those described herein. The side walls and the connecting walls of the units are provided with reinforcing ribs or reinforcing ribs, so that the compression strength of the honeycomb core material can be improved by using less materials under the condition that the thickness of the hexagonal film layer is not increased.

As shown in fig. 7, a continuous fiber reinforced unidirectional sheet 76 (abbreviated as UD-Tape) is made of a plurality of bundles of continuous fibers 75 aligned in a single direction and a thermoplastic resin 74 by a hot melt process, where the direction along the running direction of the process equipment is defined as a 0 degree direction, and the direction of the continuous fiber reinforced unidirectional sheet 76 layered perpendicular thereto is defined as a 90 degree direction. A component made from two layers of continuous fiber reinforced unidirectional sheet material 76 according to an 0/90 degree ply design. The continuous fiber-reinforced unidirectional sheet 76, in which the fiber length direction coincides with the running direction of the process equipment, is defined as a 0-degree-oriented ply, and a 90-degree-oriented ply, which is vertically stacked therewith. The body layer may be composed of at least one layer of continuous fiber reinforced unidirectional sheet material depending on the mechanical property requirements desired. And according to the definition convention of the ply angle, the designed main body layer of the panel can be a group of 0/90-degree ply designs, a plurality of groups of 0/90-degree ply designs or a ply design between 0 and 90 degrees according to the mechanical property requirement of the required direction. The continuous fiber reinforced thermoplastic material is manufactured from at least one layer of continuous fiber reinforced unidirectional sheet material according to the method.

As shown in fig. 8, the face plate 73 of the honeycomb core sandwich composite plate is made of a face layer 70, a body layer 71 and an interface layer 72 by a heating composite process through an up-down stacking layer design. The surface layer 70 and the interface layer 72 are provided on both sides of the main body layer 71, respectively, and the interface layer 72 is a layer connected to the upper and lower surfaces 69a of the honeycomb core.

The surface layer 70 with the functions of skid resistance, wear resistance, high temperature resistance, high heat transfer coefficient and the like is the outer layer of the panel 73, the surface layer 70 has the characteristics of skid resistance, friction resistance, high temperature resistance, high heat transfer coefficient, appearance texture and the like, and is manufactured by adopting a continuous fiber reinforced thermoplastic material or a thermoplastic resin film or a metal film added with a modification auxiliary agent. Metallic materials include, but are not limited to, those disclosed hereinStated as aluminum, copper, iron, and the like. The auxiliary agent is one or the mixture of more than two of hardening agent, wear-resisting agent, heat-resisting agent and auxiliary agent with high heat transfer coefficient, the wear-resisting agent is one or the mixture of more than two of teflon, molybdenum disulfide, graphite and wollastonite, and the heat-resisting agent is one or the mixture of more than two of wollastonite, nano-montmorillonite, talcum powder and calcium carbonate. 1-3% of hardening agent is added into the conventional plastic resin, so that the surface hardness of the resin is improved by 5-15%, and the effect of improving the wear resistance is achieved; teflon (polytetrafluoroethylene) has the lowest friction coefficient of all the anti-wear agents, and the Teflon molecules ground out in the friction process can form a lubricating film on the surface of a part. The teflon has good lubricating property and wear resistance under friction and shearing force, and is the best wear-resistant additive in high-load applications, such as hydraulic piston ring seals and thrust washers. The most suitable content of the teflon is that the non-crystalline teflon contains 15 percent of the teflon, and the crystalline plastic contains 20 percent of the teflon; another common name for molybdenum disulfide is "Moly," a wear additive used primarily for nylon plastics. The molybdenum disulfide acts as a crystallizing agent to increase the crystallinity of the nylon, resulting in a harder and more abrasion resistant surface of the nylon material. Molybdenum disulfide has a high affinity for metals, and once adsorbed on the surface of a material, the molecules of molybdenum disulfide plug the pores of the material surface that are visible with a microscope and make the surface of the material more slippery. This makes molybdenum disulfide an ideal wear additive for applications where nylon and other materials rub against each other; the chemical structure of graphite is a unique lattice structure which allows graphite molecules to easily slide over each other with little friction, and this wear resistance is especially important in a water-containing environment. This property makes graphite an ideal wear-resistant additive for many water-borne applications such as water-laid housings, vanes, and closures; wollastonite is added, so that the wear resistance of the thermoplastic material can be improved, the compression deformation is improved, and the scratch resistance is improved; PA6 filled with 5% nano montmorillonite can be raised from 70 deg.C to 150 deg.C, PBT filled with 30% talcum powder, and its heat distortion temperature can be raised from 55 deg.C to 150 deg.C₃The heat distortion temperature of EP modified PP can be increased from 102 ℃ to 150 DEG CDEG C; the thermal conductivity of general heat-conducting plastics is more than 1w/(m.k), and the thermal conductivity of high-purity fine MgO developed by JPN Co-Ltd.

The main body layer 71 is an intermediate layer of the panel 73, is made of a continuous fiber reinforced thermoplastic material or a metal film with high mechanical properties and melting point, and is used as a main bearing part of the mechanical properties.

The interface layer 72 is an inner layer of the panel 73 and is made of a continuous fiber reinforced thermoplastic material or a thermoplastic resin film or a modified hot melt adhesive film with a low melting point.

The face sheet 73 comprises at least one layer of continuous fiber reinforced thermoplastic sheet 76, the thermoplastic resin of the body layer 71 having a melting point higher than the thermoplastic resin of the interface layer 72, the interface layer 72 having a melting point that is the same as or compatible with the melting point of the support layer 211. Due to the advantages, the honeycomb core sandwich composite board can be widely applied to the fields of aerospace, transportation, construction, military and the like, and is used for manufacturing fairings of rockets, wings and cargo holds of airplanes, bulkheads and floors of trains, skins and doors of automobiles, ceilings and curtain walls of buildings and the like. The wings, vertical tails and the like manufactured by the cellular boards, the floor of a cabin or a cargo hold, a cabin door partition plate and the like effectively reduce the weight of the airplane and improve the operation sensitivity of moving parts.

The honeycomb core sandwich composite board of this embodiment is the sandwich composite board product with skid-proof panel and honeycomb core hot pressing composite forming, and product specification is various, and there are multiple processing such as five muscle, three muscle, pointer flower on the surface, can satisfy the application demand in multiple place.

As shown in fig. 9, the honeycomb core sandwich composite plate comprises a honeycomb core 69 and panels 73, wherein interface layers 72 of the upper and lower panels 73 are respectively connected with the upper and lower surfaces 69a of the honeycomb core in a hot melting manner, and then the surface layer 70 is heated and pressed by a belt (steel belt or high temperature resistant teflon belt) or a meshing roller with texture on the surface, and the surface layer is made into the honeycomb core sandwich composite plate with anti-slip characteristics through cooling and molding.

The surface layer, the main body layer and the interface layer of the panel are made of different materials. Wherein,the outer layers of the upper panel and the lower panel of the honeycomb core sandwich composite board manufactured by the thermal compounding process are the surface layers 70, and the honeycomb core sandwich composite board is manufactured by adopting a continuous fiber reinforced thermoplastic material or a thermoplastic resin film or a metal film which has appearance texture characteristics and is added with a modification auxiliary agent, and can be one layer or a plurality of layers. Thermoplastic resin materials include, but are not limited to, those set forth herein, such as: resins or resin mixtures such as polycarbonate, polyvinyl chloride, polymethyl methacrylate, polyethylene terephthalate, polyphenylene oxide, polyphenylene sulfide, polyether ether ketone and the like; abrasion resistant, temperature resistant, high heat transfer coefficient aids include, but are not limited to, those set forth herein, such as: plastic hardening agents, temperature and high heat transfer coefficient aids suitable for plastics such as PP, PE, PVC, PA, POM, PBT, and the like, as well as polyesters, epoxies, and phenolics, including but not limited to those set forth herein, such as: heavy calcium carbonate, light calcium carbonate, precipitated calcium carbonate, calcined pottery, barium sulfate, red mud, titanium self-powder, AlN, SiC and Al₂O₃Graphite, fibrous carbon powder with high thermal conductivity, scaly carbon powder with high thermal conductivity and the like.

The main body layer 71 of the panel 73 is made of at least one layer of continuous fiber reinforced thermoplastic material with different material properties, the main body layer 71 of the panel 73 is made of a continuous fiber reinforced thermoplastic sheet with higher performance as an outer layer and a continuous fiber reinforced thermoplastic sheet with lower performance as an adjacent inner layer, or is made of a design that the continuous fiber reinforced thermoplastic sheet with higher performance and the continuous fiber reinforced thermoplastic sheet with lower performance are alternately layered in a high-low mode.

The inner layers of the upper and lower panels of the honeycomb core sandwich composite board manufactured by the thermal compounding process, namely the interface layers 72 contacted with the upper and lower surfaces of the honeycomb core material, can adopt a thermoplastic resin with a lower melting point to be used as a hot melt adhesive layer between the adhesive interfaces of the panel and the upper and lower surfaces of the honeycomb core material by an extrusion film process or a film made of the thermoplastic resin with the lower melting point is adhered with the main body layer 71 of the panel, the melting point of the thermoplastic resin of the interface layers 72 is lower than that of the thermoplastic resin of the main body layer 71, and the proper thickness range of the thermoplastic resin is 0.01-0.5 mm. Combinations of low melting thermoplastic resin materials meeting the characteristics set forth in the present design include, but are not limited to, the panels set forth herein as comprising a continuous fiber reinforced PP as the bulk layer with POE (ethylene octene copolymer), dadmax (propylene octene copolymer of exxon meifu), EAA (ethylene acrylate copolymer), EMA (ethylene acrylate maleic anhydride terpolymer), EVA (ethylene vinyl acetate copolymer) as the interfacial layer; or a panel which is composed of a main body layer of continuous fiber reinforced PA6 and an interface layer of modified PP, wherein the modified PP is a PP-g-MAH maleic anhydride graft or a PP-g-GMA (glycidyl methacrylate) graft, and a monomer with polar anhydride or epoxy functional groups can form covalent bonds with nylon to have high bonding strength; or a panel which takes continuous fiber reinforced PET as a main body layer and modified PP as an interface layer.

The surface layer, the main body layer and the interface layer are made of different materials, the surface layer and the main body layer are made of metal films, the interface layer is made of modified hot melt adhesive films, and the surface layer and the main body layer are bonded through the modified hot melt adhesive films. The modified hot melt adhesive film used between the surface layer and the main body layer can be selected according to the material of the surface layer and the main body layer, and includes but is not limited to the PP/aluminum adhesive film, the PP/stainless steel adhesive film, the PET/aluminum adhesive film and the like.

The low-melting-point hot-melt adhesive layer and the upper and lower surfaces of the honeycomb core material are subjected to thermal compound bonding in advance through a thermal compound process, and the production of the honeycomb core sandwich composite plate with a continuous process flow is completed according to the design of thermal compound process equipment. The material design characteristics of the panel designed according to the materials and the heat transfer technology are that the hot melting adhesive layer with low resin melting point from outside to inside has the characteristic that the corresponding melting point temperature is gradually reduced from high to low, so that the design requirements of hot melting and hot pressing procedures of the upper panel, the lower panel and the honeycomb core material in the thermal compounding process are met by less heat, the inertia of heat transfer in the heating procedure is reduced, the bearing force of the honeycomb core material in the heating and pressurizing procedures of the thermal compounding process along the parallel direction of the cylindrical surfaces of six-sided cylinders of the honeycomb core material is improved, namely the compressive strength required by the hot pressing and laminating of the thermal compounding process is improved, the data of the composite plate not only is an important index for measuring the technical reliability of the thermal compounding process of the honeycomb core sandwich core, but also directly influences the performance of the compressive strength and the bending strength of a honeycomb.

The surface layer, the main body layer and the interface layer of the panel are made of the same material. Wherein, each layer of the upper and lower panels 73 of the honeycomb core sandwich composite panel made by the thermal compounding process can be a continuous fiber reinforced thermoplastic sheet made of continuous fibers 75 of the same material, but adopting a design in which the fiber content of each adjacent layer is differentiated. The addition of fibers to plastics provides a strong mechanical bond between polymers, so that the fibers can increase the structural integrity and improve the wear resistance of the thermoplastic, and can also increase the thermal conductivity and thermal deformation of the plastic, thereby significantly improving the load resistance and wear resistance of the plastic. The fiber content from the outer layer to the inner layer is from low to high to low, and the addition of the auxiliary agent with high heat transfer coefficient in the surface layer is more beneficial to heat transfer, so that the heat transfer coefficient of the corresponding layer is from high to low. According to the principle of material mechanics, the outermost surface layer 70 of the honeycomb core sandwich plate structure is made of continuous fiber reinforced thermoplastic resin sheets or thermoplastic resin films, so that the resin content is high, and the anti-skid texture with the properties of wear resistance, temperature resistance, high heat transfer coefficient and the like can be conveniently formed by pressing. The main body layer 71 is made of continuous fiber reinforced thermoplastic material with relatively high content of continuous fibers and relatively high mechanical property, so that the bending strength of the honeycomb core sandwich composite plate can be effectively improved, and meanwhile, the relatively high heat transfer efficiency is utilized, so that the hot melting process temperature of the connecting interfaces of the upper panel, the lower panel and the honeycomb core material can be obtained by using relatively less heat. The innermost interface layer 72 is made of a continuous fiber reinforced thermoplastic material with a low content of continuous fibers, i.e., a high content of thermoplastic resin can improve the bonding strength between the interface layer 72 and the honeycomb core 69, suitable continuous fibers include, but are not limited to, those mentioned above, made of inorganic mineral materials such as carbon fibers, glass fibers, basalt fibers, etc., the heat conductivity coefficient is higher than that of the compounded thermoplastic resin, and the fiber content accounts for 30-60% of the volume percentage of the continuous fiber reinforced thermoplastic sheet. The weight ratio of the fiber content of the surface layer 70 to the corresponding thermoplastic resin is 0-40%, the weight ratio of the fiber content of each layer of the main body layer 71 to the corresponding thermoplastic resin is 30-80%, and the weight ratio of the fiber content of the interface layer 72 to the corresponding thermoplastic resin is 20-40%. The face layer, the body layer and the interface layer are made of the same material, but the continuous fiber content is designed to be different, so that the face layer 73 is formed from the face layer 70 to the body layer 71 to the interface layer 72, and the corresponding continuous fiber content is from low to low. Wherein the bulk layer 71 is a high fiber content layer and the face layer 70 and interface layer 72 are lower fiber content layers.

The structure of the panel 73 may be a combination of at least one layer of a continuous fiber reinforced thermoplastic material having a relatively high content of continuous fibers and at least one layer of a continuous fiber reinforced thermoplastic material having a relatively low content of continuous fibers, depending on the mechanical properties required for the product design. The design can meet the design requirements of hot melting and hot pressing procedures of the upper panel, the lower panel and the honeycomb core material in the thermal compounding process with less heat, reduces the inertia of heat energy transfer of the heating procedure, and improves the bearing pressure of the honeycomb core material in the heating and pressurizing procedures of the thermal compounding process along the parallel direction of the cylindrical surfaces of the six-sided cylinders of the honeycomb core material, namely the compressive strength required by the hot pressing and laminating of the thermal compounding process. Simultaneously, the higher main part layer of mechanical properties has optimized the mechanical structure design of honeycomb core sandwich composite sheet.

The plies of the upper and lower face sheets 73 of the honeycomb core sandwich composite panel made by the thermal compounding process may be continuous fiber reinforced thermoplastic sheets made from continuous fibers 75 of different materials. The continuous fiber reinforced thermoplastic sheet material is characterized in that the fiber content from the outer layer to the inner layer and the performance of the continuous fiber reinforced thermoplastic sheet material prepared by compounding are from low to high to low, the mechanical properties of the corresponding layers are also from low to high to low, the heat conduction coefficient is from high to low, and the effective heat transfer is convenient. The material and layer structure is designed by adopting high-performance continuous fiber reinforced thermoplastic material, such as material with better heat transfer and mechanical property made of continuous carbon fiber reinforced thermoplastic material, for the main body layer 71 of the panel, and the inner layer interface layer 72 is made of more economical continuous fiber reinforced thermoplastic material with mechanical property lower than that of the adjacent layer, such as glass fiber reinforced thermoplastic material layer or thermoplastic resin film layer, namely, the mechanical property of each layer corresponding to the interface layer to the main body layer is from low to high and is in a step-rising state. Suitable high performance fiber materials include, but are not limited to, combinations set forth herein such as carbon fibers and glass fibers, high strength, high modulus glass fibers and lower performance glass fibers, and other suitable combinations of continuous fibers reinforced with thermoplastic materials designed to differ from one another in mechanical properties. High-performance continuous fibers such as carbon fiber reinforced thermoplastic materials are adopted to prepare the material with better mechanical properties, such as high modulus and high tensile strength, the material is taken as a main body layer 71 of a panel 73, the thermoplastic plastics are engineering plastics or special engineering plastics such as PA6, PA66, PET, PC, PPS, PPO, PPSU, PEEK, PEKK and the like, the interface layer 72 selects more economical fibers such as a glass fiber reinforced thermoplastic material layer, the thermoplastic plastics are general plastics such as PP, PE, PVC and the like, and the surface layer 70 selects PP, PE, PVC and the like added with wear-resistant, temperature-resistant and high-transmission-coefficient filler additives. A bonding transition layer is arranged between the continuous fibers 75 and the thermoplastic resin 74, the bonding transition layer mainly serves to bond two continuous fiber reinforced thermoplastic materials together to form a whole, the economical thermoplastic plastics are polyolefin materials, so that the thermoplastic plastics have good bonding performance with polyolefin materials, the high-strength high-modulus continuous fiber reinforced thermoplastic materials have polar functional groups, such as amido bonds, ester bonds and ether ketone bonds, and the polar functional groups have good bonding performance with acid anhydrides, epoxy bonds or ester bonds, so the bonding transition layer is a film made of EMA (ethylene acrylic acid maleic anhydride copolymer) and ethylene glycidyl acrylate copolymer. Continuous fibers 75 of different performance materials are used, with the bulk layer 71 being a high performance continuous carbon fiber reinforced thermoplastic material and the interface layer 72 being a more economical continuous fiber reinforced thermoplastic material. The structure of the panel 73 may be a combination of at least one layer of high performance continuous carbon fiber reinforced thermoplastic material and a more economical continuous fiber reinforced thermoplastic material, depending on the mechanical properties required for the product design. The design is characterized in that the excellent heat transfer characteristic of the carbon fiber of the continuous carbon fiber reinforced thermoplastic material layer is used as a main body layer 71 of the panel 73, and the surface layer 70 with high transfer coefficient and other filler additives is added, so that the heat required by the hot melting process of the upper surface and the lower surface of the panel and the honeycomb core material in the thermal compounding process can be effectively reduced, the inertia of heat energy transfer of the heating process can be reduced, and the bearing pressure of the honeycomb core material in the heating and pressurizing process of the thermal compounding process along the parallel direction of the cylindrical surfaces of six-sided cylinders of the honeycomb core material is improved, namely the compressive strength required by the hot-pressing and laminating. Meanwhile, according to the principle of material mechanics, the honeycomb core sandwich composite board manufactured by adopting the design of the layer structure that the mechanical properties of the middle layer in the thickness direction of the honeycomb core material are continuously increased from the inner layer to the outer layer has the characteristics of more optimized material mechanics, the mechanical properties of the honeycomb core sandwich composite board are increased in a stepped manner, and the honeycomb core sandwich composite board with better mechanical properties can be manufactured by using less materials and a more economic method.

Example 2

As shown in fig. 3 and 5, a honeycomb core sandwich composite panel is manufactured using a thermoplastic resin film having a two-layer structure including a support layer 211 and an adhesive layer 212 made of different materials, the adhesive layer 212 having a melting point lower than a softening point of the support layer 211. The supporting layer 211 is made of polyethylene terephthalate (PET), the adhesive layer 212 is made of EMA, and the EMA is prepared by heating and polymerizing ethylene and methyl acrylate serving as raw materials under high pressure by taking oxygen or peroxide as an initiator. The softening temperature of the supporting layer 211 is 160 ℃, the melting point of the bonding layer 212 is 80 ℃, the heating temperature is controlled to be 100-150 ℃, and the preparation method comprises the following steps:

s1: the two layers of thermoplastic resin films respectively pass through an upper forming die and a lower forming die simultaneously, and form a plurality of connected semi-hexagonal structures which are separated from each other vertically, continuously and horizontally by a heating compression molding process or a heating vacuum plastic molding process, wherein the plurality of connected semi-hexagonal structures comprise semi-hexagonal unit parts 4 which are distributed at intervals and adjacent connecting parts 5.

S2: two longitudinally continuous and transversely connected parts with a plurality of connected semi-hexagonal structures are aligned, attached and connected by adopting a heating pressing or ultrasonic heating welding process, so that a longitudinally continuous and transversely connected core plate with a plurality of connected hexagonal column structures is integrally formed, the outer side of the core plate is an adhesion layer 212, and the inner side of the core plate is a supporting layer 211.

S3: the longitudinally continuous and transversely connected core plates of a plurality of connected hexagonal cylinder structures are cut at intervals up and down to form cuts which are spaced up and down and are connected partially, the longitudinally continuous and transversely connected core plates of a plurality of connected hexagonal cylinder structures are not completely cut off during cutting, but connecting edges are reserved at the cuts, wherein the cutting mode can be carried out according to actual needs by adopting a method known in the prior art to meet the production requirements of the honeycomb core material 69 with different thicknesses, and for example, the cutting mode can be one of the following modes: metal or non-metal blade cutting, laser cutting, high pressure hydraulic cutting, wire cutting, resistance wire cutting, plasma cutting, or the like.

S4: the cut is taken as a folding position, the connecting edge of the cut is taken as a folding rotating shaft, the core plate with the cut is rotated by plus 90 degrees or minus 90 degrees according to the cutting direction to fold the core plate, the side walls 2 of the adjacent units are formed by the hot melting adhesion layer 212 and are mutually jointed and connected to form a honeycomb core material 69, the mutually jointed and connected connecting parts 5 in the folded core plate form connecting walls 3 for connecting the units 1 which are transversely adjacent, the adjacent side walls between the longitudinally adjacent units are mutually jointed, the adhesive layers 212 of the adjacent sidewalls of the folded longitudinally adjacent cells are thermally fused by heating, forming a honeycomb core 69, wherein the heating temperature is between the melting point of the adhesion layer 212 and the softening point of the support layer 211, so that while effectively maintaining the cell geometry, the higher bonding strength of the adjacent side walls is obtained, and the compressive strength of the honeycomb core material 69 is improved.

S5: the upper surface 69a and the lower surface 69a of the honeycomb core material are jointed with the interface layer 72 of the panel 73, the interface layer 72 of the panel 73 and the upper surface 69a and the lower surface 69a of the honeycomb core material are heated to reach the set hot melting temperature, the interface layer 72 of the panel 73 forms a hot melting connecting layer to be hot-pressed and compounded with the upper surface 69a and the lower surface 69a of the honeycomb core material, meanwhile, the surface layer 70 of the panel 73 is heated, textures are pressed, and the honeycomb core sandwich composite plate is manufactured through cooling and forming.

Further, the panel 73 is of a single structure, the single structure being a composite structure of at least one layer of the same continuous fiber reinforced thermoplastic material, and S5 includes the steps of:

s52: at least one layer of continuous fiber reinforced thermoplastic material is used as a main body layer 71 in the panel 73, and a layer of hot melt connecting film is adhered to the inner side surface of the panel 73 to form an interface layer 72;

s53: the upper surface 69a and the lower surface 69a of the honeycomb core material are jointed with the interface layer 72 of the panel 73, the interface layer 72 of the panel 73 and the upper surface 69a and the lower surface 69a of the honeycomb core material are heated to reach the set hot melting temperature, the interface layer 72 of the panel 73 forms a hot melting connecting layer to be hot-pressed and compounded with the upper surface 69a and the lower surface 69a of the honeycomb core material, meanwhile, the surface layer 73 is heated, textures are pressed, and the honeycomb core sandwich composite plate is manufactured through cooling forming.

In one embodiment, the thermoplastic resin film of the preparation unit 1 is a single-layer structure, the single-layer thermoplastic resin film is used as the support layer 211 in the honeycomb core 69, and a thermal compounding process is used to thermally compound a layer of thermoplastic resin film as the adhesion layer 212 on each side of the support layer 211; in step S2, an adhesion layer 212 is arranged outside the core plate which is longitudinally continuous and transversely provided with a plurality of connected hexagonal columnar structures, the supporting layer and the adhesion layer are made of different materials, and the melting point of the adhesion layer is lower than the softening point of the supporting layer; the sidewall 2 adhesive layers of the unit 1 connected side by side after being folded are thermally fused by heating at a temperature between the melting point of the adhesive layer 212 and the softening point of the support layer 211 in step S4. Wherein the melting point of the thermoplastic resin of the bulk layer 71 is higher than the melting point of the thermoplastic resin of the interface layer 72, and the melting point of the interface layer 72 is the same as or compatible with the melting point of the support layer 211.

In another embodiment, S1 further includes forming the thermoplastic resin film into a half-hexagonal structure including ribs or reinforcing

ribs

6a, 6b by a thermoforming process or a vacuum forming process, the half-hexagonal structure including ribs or reinforcing

ribs

6a, 6b including half-hexagonal unit portions 4 and adjacent connecting portions 5, ribs or reinforcing

ribs

6a, 6b spaced apart, the ribs or reinforcing

ribs

6a, 6b being disposed on the half-hexagonal unit portions 4 and on the adjacent connecting portions 5.

In another embodiment, the surface layer 70 with characteristics of skid resistance, wear resistance, temperature resistance, high heat transfer coefficient, etc. is pre-attached by hot pressing during the preparation of the panel 73 (without the surface layer), or the surface layer 70 is attached to the upper and lower surfaces of the honeycomb core sandwich composite plate (without the surface layer) by a secondary heating and hot pressing process.

In another embodiment, the surface layer 70 and the main body layer 71 are made of metal films, and the surface layer 70 and the main body layer are bonded by hot melting using a modified hot melt adhesive film, and the interface layer 72 made of the modified hot melt adhesive film is connected with the honeycomb core material 69 by hot melting. Or forming a surface layer metal film on the surface of the main body layer by hot-pressing the modified hot melt adhesive film for the second time.

Example 3

Fig. 6 shows an embodiment of the apparatus for manufacturing a honeycomb core material according to the present invention, which includes a first conveyor belt device 61, a thermoforming device 62, a slitting device 63, an indexing roll device 64, and a heat-melting device 65.

The first belt conveyor 61 is used for continuous conveyance from the thermoplastic resin film to the honeycomb core material formation step.

The thermoplastic forming device 62 can comprise an upper forming die, a lower forming die and an infrared heating device, two layers of thermoplastic resin films respectively pass through the upper forming die and the lower forming die, a heating compression molding process or a heating vacuum plastic molding process are formed into two longitudinally continuous structures with separated upper and lower parts, and a plurality of connected semi-hexagonal structures are transversely formed and comprise semi-hexagonal unit parts 4 and adjacent connecting parts 5 which are distributed at intervals; the two sheets are longitudinally continuous, a plurality of connected semi-hexagonal structures transversely enter the meshing position of the upper and lower pressing forming dies, the pair roller pressure pressing formed by the set gap at the meshing position of the upper and lower pressing forming dies is longitudinally continuous, the connecting parts of the plurality of connected semi-hexagonal structures transversely form longitudinally continuous core plates of a plurality of connected hexagonal column structures transversely. Suitable processing techniques include, but are not limited to, the thermoplastic forming techniques set forth herein, including heated roll-to-roll thermoforming techniques, and the like.

The slitting device 63 cuts the longitudinally continuous and transversely connected core plates of the hexagonal cylinder structures which are formed by pressing and integrating a plurality of connected semi-hexagonal cylinder structures at intervals up and down to form slits which are spaced up and down and are partially connected, and the core plates are not completely cut off during cutting, but a connecting edge is reserved at the slits; optionally, the cutting device may be a device that performs cutting by means of metal or nonmetal blade cutting, laser cutting, high-pressure hydraulic cutting, wire cutting, resistance wire cutting, or plasma cutting.

As shown in fig. 6a, the indexing roll-to-roll device 64 includes a set of rollers 641 with indexing teeth, which can press the honeycomb core 69 at the notch with the thickness of the core as the indexing reference, and the difference between the speed of the first belt conveyor 61 and the linear speed of the indexing wheel on the indexing roll-to-roll device 64 is set, so that the horizontal unit after the notch is folded and rotated by about 90 degrees, and the unit is folded to form a continuous unit connected in parallel front and back. The indexing folding requirements of honeycomb cores with different notch intervals and different hexagonal section sizes are met by setting the teeth of the indexing double rollers and the centers of the indexing double rollers in the horizontal direction and the vertical direction.

The hot melting device 65 can heat the folded units connected side by side to connect adjacent side walls between the units in a hot melting mode to form the honeycomb core material 69, the heating temperature can be controlled between the melting point of the adhesion layer 212 of the side wall 2 and the softening point of the supporting layer 211, so that the geometric shape of the units is effectively maintained, the higher attaching strength of the adjacent side walls is obtained, and the compressive strength of the honeycomb core material is improved.

As shown in fig. 6, the honeycomb core manufacturing apparatus of the present invention may further include an extrusion device 66 for preparing a thermoplastic resin film for extrusion-forming the thermoplastic resin film used as a raw material.

The honeycomb core material preparation equipment of the invention can also comprise a pressing device 67 used for pressing and combining two formed sheets of longitudinally continuous and transversely connected semi-hexagonal structures to form the core plate with the hexagonal column structure with the complete unit part.

The honeycomb core material manufacturing equipment can further comprise a first cooling device 68, wherein the first cooling device can be an air cooling device and is used for cooling the core plates of the hexagonal column structures formed by pressing.

The honeycomb core material preparation equipment can also comprise a belt type pressing device which is used for jointly acting with the indexing double-roller device 64 to extrude adjacent units after the processes of cutting, folding and heating so as to realize the adhesion of the side wall of the honeycomb core material, and the two devices are jointly used for extruding the operation direction of a honeycomb core production line so as to realize the effective adhesion of the side wall of the honeycomb core material.

As shown in FIG. 9a, the upper and lower face plates 73 of the honeycomb core sandwich composite plate are thermally combined with the upper and lower faces 69a of the honeycomb core to generate the required force F and reaction force F^,Are key process design parameters for producing high performance honeycomb core sandwich composite panels according to fig. 10 or fig. 10a, or similar thermal compounding equipment.

Fig. 10 shows an embodiment of the apparatus for manufacturing a honeycomb core sandwich composite panel from a honeycomb core material according to the present invention, which includes a heating device 79, a hot-pressing composite roll 80, and a texture pressing device 82.

The heating device 79 includes upper and lower contact type heat conduction heating devices, which heat the upper and lower panels 73, respectively, and heat the interface layer 72 of the panel 73 to a predetermined temperature through the outer layer main body layer 71 of the panel 73 and the heat transfer path from the outside to the inside by a mixed heat transfer method of heat conduction and heat convection, thereby forming a hot-melt connection layer.

And one or more sets of thermocompression bonding rollers 80 for thermocompression bonding the interface layer 72 of the face sheet 73 and the upper and lower surfaces 69a of the honeycomb core material.

Texture pressing apparatus 82 is used to apply texture pressing to the facing layer, including but not limited to those described herein, such as: a Teflon belt or a steel belt with set textures, an engaging double roller with set textures on the surface, and the like. The honeycomb core sandwich composite board is high-temperature resistant, prevents hot melt adhesive from being adhered, and can be continuously conveyed from the honeycomb core material to the processes of manufacturing the honeycomb core sandwich composite board.

And the second cooling device comprises an upper contact type cooling device and a lower contact type cooling device and is used for cooling and molding the honeycomb core sandwich composite plate subjected to hot-pressing compounding.

As shown in fig. 10a, the apparatus for manufacturing a honeycomb core sandwich composite plate of the present invention may further include a plasma emission device 83, which performs surface polarity treatment on the interface layers 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core by using a plasma process technology, so as to increase the surface energy of the interfaces where the interface layers 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core sandwich composite plate are connected, thereby increasing the bonding strength between the interface layers 72 of the upper and lower panels 73 and the upper and lower surfaces 69a of the honeycomb core. The plasma emission device 83 arranged at the inlet end of the thermal composite process equipment respectively carries out plasma treatment on the interface layers 72 of the upper and lower face plates 73 and the upper and lower face layers 69a of the honeycomb core material, so that the compressive strength of the honeycomb core material is ensured to the maximum extent while the heat required by the fusion state of the joint interfaces of the interface layers 72 of the upper and lower face plates 73 and the upper and lower face layers 69a of the honeycomb core material is effectively controlled. The process techniques for increasing the polarity of the surface of the thermoplastic material may be, but are not limited to, those set forth herein, including plasma emission devices, corona devices for surface treatment of plastics, and high heating value gas-like flame combustion devices, among others. The process technology apparatus suitable for increasing the interfacial surface energy of the thermoplastic material to achieve rapid thermal fusion may be, but is not limited to, those set forth herein, including natural gas nozzle heating process apparatus, acetylene gas nozzle heating process apparatus, infrared heating process apparatus, laser heating process apparatus, and the like.

The working principle of the invention is as follows:

the two thermoplastic resin films enter the thermoplastic forming device 66, and are respectively and simultaneously pressed into a forming die from top to bottom, and are thermally formed by a heating compression molding process or a heating vacuum plastic-absorbing process to form two longitudinally continuous and transversely connected semi-hexagonal structures. Two sheets are longitudinally continuous, a plurality of connected semi-hexagonal structures are transversely arranged at the meshing position of the upper pressing forming die and the lower pressing forming die, the two sheets are longitudinally continuous through the pressure of a pair roller formed by the set gap at the meshing position of the upper pressing forming die and the lower pressing forming die, and the plurality of connected semi-hexagonal structures are transversely arranged to form the core plate of the hexagonal cylinder structure. The core plates of the hexagonal cylinder structures are cooled by the first cooling device 68 and then conveyed to the notching device 63 for cutting, the notching device 63 longitudinally and continuously cuts the core plates of the plurality of connected semi-hexagonal cylinder structures at intervals up and down to form notches which are at intervals up and down and are partially connected, and the core plates are not completely cut off during cutting, but connecting edges are reserved at the notches. After cutting, the core board is conveyed to the indexing double-roll device 64 by the first conveying belt device 61, a roller 641 with indexing teeth in the indexing double-roll device 64 applies pressure to the notch, the notch is used as a folding position, the connecting edge of the notch is used as a folding rotating shaft, the core board with the notch rotates by plus 90 degrees or minus 90 degrees according to the notch direction to fold the core board, the core board is folded to form continuous units which are connected in parallel front and back, then the core board is conveyed to the hot melting device 65 by the first conveying belt device 61, the hot melting device 65 can heat the units which are connected in parallel after being folded, the heating temperature is controlled between the melting point of the adhesion layer 212 and the softening point of the supporting layer 211, and the adjacent side walls 2 between the units are connected in. The surface layer 70 is hot pressed and attached in advance in the manufacturing process of the panel 73, the panel 73a which is coiled is continuously conveyed, the honeycomb core material 69 and the panel 73a synchronously enter thermal compounding process equipment, the interface layers 72 of the upper and lower face plates 73 and the upper and lower faces 69a of the honeycomb core are subjected to surface polarity treatment by the plasma emitter 83, the upper and lower face plates 73 are heated by the heater 79, and through the face layer 70, the body layer 71 of the face plate 73, and the heat transfer path from the outside to the inside, the upper and lower surfaces 69a of the honeycomb core and the inner layer 72a of the interface layer of the face sheet 73 are heated to a set temperature by a mixed heat transfer method of heat conduction and heat convection, immediately, the process proceeds to a hot press process, and the inner layers 72a of the interface layers of the upper and lower face plates 73 and the upper and lower faces 69a of the honeycomb core are hot press-bonded by a pair of hot press bonding rollers 80. Meanwhile, the texture pressing device 82 presses textures on the surface layer, and then the textures are conveyed to a second cooling device, and after a cooling process, the honeycomb core sandwich composite plate of the continuous process flow is produced. Or the surface layers 70 with textures are secondarily hot-pressed and attached to the upper surface 69a and the lower surface 69a of the honeycomb core sandwich composite plate formed by cooling to form the more attractive honeycomb core sandwich composite plate.

While specific embodiments of the present invention have been described in detail above, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to these embodiments. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.

Claims

1. A honeycomb core sandwich composite plate comprises a honeycomb core material formed by a plurality of units arranged in a row, wherein the units are hexagonal columns formed by surrounding side walls, the side walls comprise a supporting layer and an adhesion layer, the supporting layer and the adhesion layer are made of different materials, the melting point of the adhesion layer is lower than the softening point of the supporting layer, the units which are transversely adjacent are connected through a connecting wall which is transversely arranged, and the adjacent side walls of the units which are longitudinally adjacent are mutually bonded or attached through the adhesion layer;

the panel is characterized by further comprising surface layers, wherein the surface layers and the interface layers are respectively arranged on two sides of the main body layer, and the surface layers are made of continuous fiber reinforced thermoplastic materials or thermoplastic resin films or metal films added with modification aids.

2. The honeycomb core sandwich composite panel of claim 1 wherein the side walls of the cells are of a three layer construction with an adhesive layer on each side of the support layer.

3. The honeycomb core sandwich composite plate according to claim 1, wherein the six side walls of the unit and the connecting wall are provided with at least one reinforcing rib or rib, respectively, in a staggered or aligned manner in parallel with the plain line thereof.

4. The honeycomb core sandwich composite panel of claim 1, wherein the facing layer has slip, abrasion, heat, high heat transfer coefficient, and appearance texture characteristics.

5. The honeycomb core sandwich composite plate of claim 1, wherein the additive is one or a mixture of two or more of a hardening agent, an anti-wear agent, a heat-resistant agent and an additive with high heat transfer coefficient.

6. The honeycomb core sandwich composite plate of claim 5, wherein the wear-resistant agent is one or a mixture of more than two of teflon, molybdenum disulfide, graphite and wollastonite, and the heat-resistant agent is one or a mixture of more than two of wollastonite, nano-montmorillonite, talcum powder and calcium carbonate.

7. The honeycomb core sandwich composite panel according to claim 1, wherein the supporting layers of the cells are made of a modified fiber reinforced thermoplastic resin material and/or a metal alloy, and the sidewalls of the cells and the connecting walls are made of an aluminum or paper material.

8. The honeycomb core sandwich composite panel of claim 1 wherein the bulk layer has a higher melting point of the thermoplastic resin than the interface layer, the interface layer having a melting point that is the same as or compatible with the melting point of the support layer.

9. The honeycomb core sandwich composite plate according to claim 1, wherein the face layer, the bulk layer and the interface layer are made of the same material, and the fiber content of the face layer, the bulk layer and the interface layer is sequentially from low to high to low;

10. The honeycomb core sandwich composite plate according to claim 1, wherein the surface layer, the main body layer and the interface layer are made of different materials, the surface layer is made of a continuous fiber reinforced thermoplastic material or a thermoplastic resin film or a metal film added with a modification aid, the main body layer is made of a continuous fiber reinforced thermoplastic sheet with higher performance as an outer layer and a continuous fiber reinforced thermoplastic sheet with lower performance as an adjacent inner layer, or is made of a design that the continuous fiber reinforced thermoplastic sheet with higher performance and the continuous fiber reinforced thermoplastic sheet with lower performance are alternately layered at high and low levels, and the interface layer is made of a continuous fiber reinforced thermoplastic material or a thermoplastic resin film with lower mechanical properties than the main body layer.

11. The honeycomb core sandwich composite plate according to claim 1, wherein the surface layer, the bulk layer and the interface layer are made of different materials, the surface layer and the bulk layer are made of metal films, the interface layer is made of modified hot melt adhesive films, and the surface layer and the bulk layer are bonded by the modified hot melt adhesive films.

12. A method of making a honeycomb core sandwich composite panel for use in making a honeycomb core sandwich composite panel according to any one of claims 1 to 11, comprising the steps of:

13. The method of manufacturing a honeycomb core sandwich composite panel according to claim 12, wherein the thermoplastic resin films of the manufacturing units are of a single-layer structure, the single-layer thermoplastic resin film is used as a supporting layer in step S1, a thermal lamination process is used to thermally laminate a thermoplastic resin film as an adhesive layer on each of two sides of the supporting layer, respectively, and the melting point of the adhesive layer is lower than the softening point of the supporting layer; in step S2, an adhesion layer is arranged on the outer side of the core plate which is longitudinally continuous and transversely provided with a plurality of connected hexagonal columnar structures, the supporting layer and the adhesion layer are made of different materials, and the melting point of the adhesion layer is lower than the softening point of the supporting layer; the adhesive layers of the folded side-by-side connected cell sidewalls are thermally fused by heating at a temperature between the melting point of the adhesive layer and the softening point of the support layer in step S4.

14. The method of manufacturing a honeycomb core sandwich composite plate according to claim 12, wherein the panel is a single structure, and the step of S5 comprises the steps of:

15. A honeycomb core sandwich composite panel manufacturing apparatus for implementing a honeycomb core sandwich composite panel manufacturing method according to any one of claims 12 to 14, comprising:

it is characterized in that the preparation equipment further comprises:

16. The apparatus for preparing a honeycomb core sandwich composite panel according to claim 15, wherein the texture pressing means is a steel belt having a texture on a surface thereof, a teflon belt having a high temperature resistance, and a mesh roller.

17. The apparatus of claim 15, further comprising a plasma emission device for polarity treatment of the upper and lower surfaces of the honeycomb core and the inner surface of the face sheet.