阅读说明：本技术 一种连续纤维增强复合材料、工字梁型材、格栅及光伏组件边框 (Continuous fiber reinforced composite material, I-beam profile, grating and photovoltaic module frame ) 是由 陈湛 朱旭华 许嘉浚 于 2019-11-27 设计创作，主要内容包括：本发明提供一种连续纤维增强复合材料、工字梁型材、格栅及光伏组件边框,所述复合材料包括基体材料和增强材料,基体材料包括无机凝胶材料、有机聚合物材料或金属材料,增强材料包含有连续的单向纤维材料；复合材料具有不均匀的单向纤维含量分布,其在承受弯曲载荷时受压的部分的单向纤维含量大于受拉的部分的单向纤维含量。所述工字梁型材具有上翼板、下翼板和腹板,上翼板和下翼板通过腹板连接,型材具有工字型截面；上翼板中的单向纤维体积含量大于腹板中的单向纤维体积含量。所述格栅由多个工字梁、凸销和凹销相互扣接制成,所述工字梁采用前述的连续纤维增强复合材料制备而成。所述光伏组件边框采用前述的连续纤维增强复合材料制备而成。(The invention provides a continuous fiber reinforced composite material, an I-beam profile, a grid and a photovoltaic module frame, wherein the composite material comprises a base material and a reinforcing material, the base material comprises an inorganic gel material, an organic polymer material or a metal material, and the reinforcing material comprises a continuous unidirectional fiber material; the composite material has a non-uniform distribution of unidirectional fiber content with the unidirectional fiber content of the portion in compression being greater than the unidirectional fiber content of the portion in tension when subjected to a bending load. The I-beam section is provided with an upper wing plate, a lower wing plate and a web plate, wherein the upper wing plate is connected with the lower wing plate through the web plate, and the section has an I-shaped section; the unidirectional fiber volume content in the upper wing panel is greater than the unidirectional fiber volume content in the web. The grid is formed by mutually buckling a plurality of I-beams, convex pins and concave pins, and the I-beams are prepared from the continuous fiber reinforced composite material. The photovoltaic module frame is prepared from the continuous fiber reinforced composite material.)

1. A continuous fibre reinforced composite material, characterised in that the composite material comprises a matrix material comprising an inorganic cementitious material, an organic polymeric material or a metallic material and a reinforcing material comprising a continuous unidirectional fibrous material; the composite material has a non-uniform distribution of unidirectional fiber content with the unidirectional fiber content of the portion in compression being greater than the unidirectional fiber content of the portion in tension when subjected to a bending load.

2. The continuous fiber-reinforced composite material of claim 1, wherein the unidirectional fiber volume content of the compressed portion of the composite material is 40 to 65% when subjected to bending load; the unidirectional fiber volume content of the tensioned portion is 20-60%.

3. The continuous fiber reinforced composite of claim 1, wherein the unidirectional fiber volume content of the composite decreases progressively as the distance between the central axis of the portion of the composite and the neutral axis of the overall composite in the direction of bending decreases.

4. The continuous fiber reinforced composite of claim 1, wherein the reinforcement comprises one or more of unidirectional fibers in a bundle, a fiber mat, and an axial cloth of fibers.

5. A matrix material for use in the manufacture of a continuous fibre reinforced composite, characterised in that the matrix material comprises a phenolic resin and in that the raw materials from which the cured precursor composition of the phenolic resin is formulated comprise the following components:

100 parts by weight of phenolic resin;

3-10 parts of resorcinol;

0.1-10 parts by weight of PVB (polyvinyl butyral) powder.

6. The matrix material for manufacturing a continuous fiber reinforced composite of claim 5, wherein the PVB (polyvinyl butyral) powder has a fineness greater than 20 mesh.

7. The matrix material for manufacturing continuous fiber reinforced composites as claimed in claim 6, wherein the raw materials for preparing the cured precursor composition of phenolic resin further comprise one or more of the following components:

1-5 parts by weight of an internal mold release agent;

0.1-1 part by weight of a UV stabilizer;

0.1-1 part by weight of a coupling agent;

5-50 parts by weight of aluminum hydroxide;

5-50 parts by weight of a filler;

2-20 parts of whisker;

2-10 parts of urotropin;

1-10 parts by weight of molecular sieve activation powder;

1-15 parts by weight of sodium silicate or sodium metasilicate;

2-15 parts by weight of aluminum dihydrogen phosphate;

5-15 parts by weight of zinc borate;

2-15 parts of red phosphorus;

2-20 parts by weight of calcium chloride;

2-20 parts by weight of magnesium sulfate;

2-20 parts by weight of magnesium oxide;

0.5 to 10 parts by weight of a thermoplastic resin powder;

the thermoplastic resin powder comprises one or more of polyamide and polyvinyl alcohol;

the viscosity of the curing precursor composition is 500 to 4000 mPa.s.

8. The matrix material for manufacturing a continuous fiber-reinforced composite material according to any one of claims 5 to 7, wherein the temperature of the cured precursor composition of the phenolic resin is controlled to be 35 ℃ to 90 ℃ when the fibers are impregnated.

9. An I-beam section made of composite materials, which is characterized in that the I-beam section is made of the composite materials of any one of claims 1 to 8.

10. The composite i-beam section of claim 9, wherein the i-beam section has an upper wing panel, a lower wing panel, and a web, the upper wing panel and the lower wing panel being connected by the web, the section having an i-section; the unidirectional fiber volume content in the upper wing panel is greater than the unidirectional fiber volume content in the web.

11. The composite i-beam profile as claimed in claim 10, wherein the fiber volume content of the whole i-beam profile is 40-65%, the unidirectional fiber volume content of the upper wing plate is 40-70%, and the unidirectional fiber volume content of the web plate is 20-60%, wherein the unidirectional fiber volume content of the compression section of the web plate is 15-60%, and the unidirectional fiber volume content of the tension section of the web plate is 5-55%.

12. The composite i-beam profile of claim 10, wherein the upper wing panel has a unidirectional fiber volume content greater than the unidirectional fiber volume content of the lower wing panel.

13. The composite material I-beam profile as claimed in claim 12, wherein the unidirectional fiber volume content of the upper wing plate is 40-70%, and the unidirectional fiber volume content of the lower wing plate is 35-65%.

14. The composite material grid is characterized in that the grid is formed by mutually buckling a plurality of I-shaped beams, convex pins and concave pins, wherein the convex pins and the concave pins are made of continuous fiber reinforced composite materials; the I-beam section is prepared from the composite material I-beam section as claimed in any one of claims 9-13.

15. A composite grid according to claim 14 wherein the web of the i-beam section is provided with through holes extending through the thickness thereof, the male pins are provided with transverse notches for snap-fitting to the i-beam section, the transverse notches being configured to fit the inner end surface of the through holes in the i-beam section; the convex pins and the transverse notches are provided with longitudinally extending convex blocks in a staggered manner, the structures of the convex blocks are matched with the groove structures of the concave pins, and the extending directions of the convex pins and the concave pins in the assembled grid are perpendicular to the extending direction of the I-shaped beam.

16. The composite grid according to claim 15 wherein the through-holes in the i-beams are circular through-holes and the female pins have an arcuate profile conforming to the circular through-holes; the transverse notches buckled with the I-shaped beam on the convex pins are all towards the direction of a pressure source.

17. A composite material photovoltaic module frame is characterized in that the frame is prepared from the composite material of any one of claims 1-8.

Technical Field

The invention relates to the technical field of composite materials and preparation processes thereof, in particular to a continuous fiber reinforced composite material, an I-beam profile, a grid and a photovoltaic module frame.

Background

Composite materials are materials with distinct phase separation characteristics formed by mixing two or more materials, the morphology and the performance of the composite materials are different from those of any one of the materials alone, the main components of the composite materials are matrix materials and reinforcing materials, and fibers are the most commonly used reinforcing materials. In general, composite materials refer to materials in their final form after molding, while materials in their form before final molding after mixing of matrix materials with reinforcing materials are referred to as composite precursors.

The pultrusion process is to solidify or shape the continuous fiber yarn and fabric soaked with liquid base material under the action of traction force through a mould with a constant section cavity to continuously produce the composite material with unlimited length. At present, the length of the composite material pultrusion mold is generally between 600 millimeters and 1000 millimeters, wherein the pultrusion mold with the length of 900-1000 millimeters is widely used.

In the existing pultrusion process of composite materials, a method for impregnating fibers by a resin continuous injection method is an effective method, resin is continuously injected into a cavity of a specially designed glue injection box according to actual demand, so that the fibers passing through the cavity of the glue injection box are quickly soaked and then enter a mold cavity connected with the rear section of the glue injection box for curing or shaping, and in many designs, the glue injection box is designed to be a part of a mold inlet to play the same function. The existing resin continuous injection method has the glue injection opening arranged in the middle of the cavity of the glue injection box, and has the improvement that when matrix resin adopted is high in viscosity or contains more fillers, particularly when fiber felts or fabrics are used, the resin is difficult to permeate into fibers, or the fillers are difficult to permeate into the fibers, so that the performance defects of the composite material are caused.

The key force-bearing part of the composite material fire-resistant grid is a glass fiber reinforced phenolic resin I-beam, the glass fiber reinforced phenolic resin I-beam is manufactured by adopting glass fiber direct yarns, a glass fiber felt and phenolic resin through a pultrusion process, the mechanical strength is low due to the high brittleness of the phenolic resin, meanwhile, the existing process generally adopts the fiber content which is consistent in whole body, and the volume content of the fiber is 40-70%. When the composite material I-beam bears bending load, the upper wing plate can be quickly broken, the due performance of the composite material cannot be fully exerted, and a great improvement space exists.

Meanwhile, in the manufacturing process of the glass fiber reinforced phenolic resin I-beam, a glass fiber continuous felt or a stitch-bonded felt is needed, and if more fillers are added into the phenolic resin, the fibers are difficult to be completely soaked, so that modification of the phenolic resin is limited.

The frame and the support are usually made of aluminum alloy, when the photovoltaic component is used, the frame and the support need to be grounded to prevent lightning strike and electric leakage, meanwhile, the fireproof requirement of the building is difficult to meet, although the frame and the support are insulated, the fireproof grade cannot meet the fireproof requirement of the building, the composite material based on the phenolic resin is an ideal choice, but the traditional phenolic composite material is low in strength and poor in toughness and cannot meet the requirement.

In summary, there are many areas where improvements are needed in the existing continuous fiber reinforced composites and the manner in which they are produced. Only by solving these technical difficulties can such materials be made to meet the requirements of applications such as grids and photovoltaic module borders.

SUMMARY OF THE PATENT FOR INVENTION

In order to solve the problems, the invention provides the continuous fiber reinforced composite material, and the comprehensive performance of the composite material in use is effectively improved by filling the regions with different stress types and stress sizes with different contents of unidirectional fibers. The purpose of the invention is realized by the following technical scheme:

a continuous fibre reinforced composite comprising a matrix material and a reinforcement material, the matrix material comprising an inorganic cementitious material, an organic polymeric material or a metallic material, the reinforcement material comprising a continuous unidirectional fibrous material; the composite material has a non-uniform distribution of unidirectional fiber content with the unidirectional fiber content of the portion in compression being greater than the unidirectional fiber content of the portion in tension when subjected to a bending load. The technical effects are as follows: the unidirectional fiber content of the pressed part is increased, the strength and the modulus of the part are improved, the unidirectional fiber content of the pulled part is reduced, and the strength and the modulus of the part are reduced, so that the strain of each part of the whole composite material under the working condition of bending load is adapted to the allowable strain of the part, the early damage of the pressed part with small allowable strain is avoided, and the bending strength of the whole composite material is improved and the brittleness caused by too high fiber content is avoided under the condition that the unidirectional fiber content is not increased on the whole.

Further, as an optimized case, the composite material has a unidirectional fiber volume content of 40 to 65% in a pressed portion when subjected to a bending load; the unidirectional fiber volume content of the tensioned portion is 20-60%.

Further, the unidirectional fiber volume content of the composite material decreases progressively as the distance between the central axis of the portion of the composite material and the neutral axis of the overall composite material in the direction of bending decreases.

Further, the reinforcing material comprises one or more of bundled unidirectional fibers, fiber felt, and fiber axial cloth.

A matrix material for use in the manufacture of a continuous fibre reinforced composite, the matrix material comprising a phenolic resin, the components of the raw materials used to formulate the cured precursor composition of the phenolic resin comprising:

100 parts by weight of phenolic resin;

3-10 parts of resorcinol;

0.1-10 parts by weight of PVB (polyvinyl butyral) powder.

Further, the fineness of the PVB (polyvinyl butyral) powder is more than 20 meshes.

Further, the raw materials for preparing the curing precursor composition of the phenolic resin also comprise one or more of the following components:

1-5 parts by weight of an internal mold release agent;

0.1-1 part by weight of a UV stabilizer; 0.1-1 part by weight of a coupling agent; 5-50 parts by weight of aluminum hydroxide; 5-50 parts by weight of a filler; 2-20 parts of whisker; 2-10 parts of urotropin; 1-10 parts by weight of molecular sieve activation powder; 1-15 parts by weight of sodium silicate or sodium metasilicate; 2-15 parts by weight of aluminum dihydrogen phosphate; 5-15 parts by weight of zinc borate; 2-15 parts of red phosphorus; 2-20 parts by weight of calcium chloride; 2-20 parts by weight of magnesium sulfate; 2-20 parts by weight of magnesium oxide; 0.5-10 parts of thermoplastic resin powder; the viscosity of the curing precursor composition is 500 to 4000 mPa.s.

Preferably, the thermoplastic resin powder comprises one or more of polyamide, polyvinyl alcohol;

further, when the fiber is impregnated, the temperature of the cured precursor composition of the phenol resin is controlled to be 35 to 90 ℃.

The technical effects are as follows: the PVB (polyvinyl butyral) powder is added to replace a traditional method that an alcohol solution of the PVB (polyvinyl butyral) is added, so that the phenomenon that a large amount of alcohol is introduced to cause formation of a large number of pores in the composite material due to volatilization of the alcohol in the curing process to reduce the strength is avoided, meanwhile, the PVB (polyvinyl butyral) powder exists in a slightly soluble fine solid state in the phenolic resin, the phenomenon that the resin has high viscosity and cannot permeate fibers is avoided, meanwhile, the PVB (polyvinyl butyral) with high molecular weight and the phenolic resin are cured together, the toughness of the composite material is greatly enhanced, meanwhile, the temperature of a curing precursor composition of the phenolic resin is controlled to be 35-90 ℃, the viscosity of the curing precursor composition is reduced, and the good fiber infiltration quality of the curing precursor composition of the phenolic resin can be guaranteed.

The invention also provides an I-beam section made of the composite material, which is prepared from the composite material.

Further, the I-shaped beam section is provided with an upper wing plate, a lower wing plate and a web plate, the upper wing plate and the lower wing plate are connected through the web plate, and the section has an I-shaped section; the unidirectional fiber volume content in the upper wing panel is greater than the unidirectional fiber volume content in the web.

Further, the fiber volume content of the whole I-beam profile is 40-65%, the unidirectional fiber volume content of the upper wing plate is 40-70%, the unidirectional fiber volume content of the web plate is 20-60%, the unidirectional fiber volume content of the compression section of the web plate is 15-60%, and the unidirectional fiber volume content of the tension section is 5-55%.

Further, the unidirectional fiber volume content of the upper wing plate is greater than the unidirectional fiber volume content of the lower wing plate.

Furthermore, the unidirectional fiber volume content of the upper wing plate is 40-70%, and the unidirectional fiber volume content of the lower wing plate is 35-65%.

The technical effects are as follows: under the working condition of bearing bending load, the I-shaped beam is prevented from failing in advance due to the fact that the upper wing plate and the compression web plate are crushed in advance.

The invention further provides a composite material grid which is formed by mutually buckling and connecting a plurality of I-shaped beams, convex pins and concave pins, wherein the I-shaped beam section is prepared from the composite material I-shaped beam section.

Furthermore, a through hole penetrating through the thickness of the web plate of the I-beam section is formed in the web plate of the I-beam section, a transverse notch used for being buckled with the I-beam section is formed in the convex pin, and the structure of the transverse notch is matched with the structure of the inner end face of the through hole in the I-beam section; the convex pins and the transverse notches are provided with longitudinally extending convex blocks in a staggered manner, the structures of the convex blocks are matched with the groove structures of the concave pins, and the extending directions of the convex pins and the concave pins in the assembled grid are perpendicular to the extending direction of the I-shaped beam.

Furthermore, the through hole on the I-beam is a circular through hole, and the concave pin is provided with an arc-shaped outline matched with the circular through hole; the transverse notches buckled with the I-shaped beam on the convex pin are all towards the direction of a pressure source, namely when the transverse notches are used in a flat laying state, the transverse notches on the convex pin are all upwards.

The technical effect is that when the grid bears bending load and impact load of a falling hammer, all I-beams in the grid can be cooperatively stressed, so that the damage of the whole grid caused by the fact that a certain I-beam is damaged in advance is avoided.

The invention also provides a photovoltaic frame or support, which is prepared from the composite material.

The photovoltaic frame has the technical effects that the photovoltaic frame can meet the bearing requirement and has insulating and fireproof performance, induced power generation capacity attenuation (PID) of the photovoltaic module caused by frame leakage is reduced, the workload of grounding is reduced or even avoided, the installation and maintenance cost is reduced, the service life of the photovoltaic module is prolonged, and the safety of the photovoltaic module is improved.

The invention has the following advantages:

1. the bearing capacity of the composite material is greatly improved under the conditions of unchanged geometric dimension and unchanged total fiber content;

2. the toughness of the I-beam and the grid of the glass fiber reinforced phenolic composite material is improved creatively by adding thermoplastic resin powder into phenolic resin;

3. the composite material is manufactured by using the high-viscosity phenolic resin in a mode of heating the phenolic resin, so that the modification space of the phenolic resin is expanded;

4. creatively enables all I-beams in the grating to be stressed cooperatively through a special concave-convex pin and I-beam interlocking structure, and greatly improves the bending strength and the impact strength of the grating.

5. The photovoltaic module is applied to the photovoltaic module, so that the cost is reduced, and the service life and the safety are improved.

In the present description, the directions listed are opposite to each other, and upper means a direction toward a compressive stress under a bending load, and lower means a direction opposite to upper under a bending load.

Drawings

FIG. 1 is a force analysis diagram of a composite profile of example 2 of the present invention;

FIG. 2 is a schematic cross-sectional view showing the structure of a composite material according to example 2 of the present invention;

FIG. 3 is a perspective view of a grid according to embodiment 3 of the present invention;

FIG. 4 is a schematic view of the male and female pins of FIG. 3 mated together;

fig. 5 is a schematic front view of a photovoltaic module frame according to embodiment 4 of the present invention;

fig. 6 is a schematic top view of fig. 5.

Wherein:

1: an I-beam profile; 1-5: a web; 2-1: a first support point;

1-1: surfacing felt; 1-51 web compression section; 2-2: a second support point;

1-2: a continuous felt; 1-52 web tension segments; 3: an action point;

1-3: a unidirectional fiber; 1-6: a lower wing plate; 4: a boss pin;

1-4: an upper wing plate; 1-7 neutral axis; 4-1: a transverse groove;

4-2: a boss; 5: a female pin; 5-1: and (4) a groove.

Detailed Description

The preferred embodiments of the present invention will be described below with reference to the accompanying drawings: