SANDWICH COMPOSITE BOARD AND PREPARATION METHOD THEREOF

Abstract

The disclosure relates to a sandwich composite board and a preparation method thereof. The sandwich composite board includes, from top to bottom, an upper panel layer, a core material layer, and a lower panel layer, wherein the upper panel layer and the lower panel layer are glass or fiber reinforced resin-based composite sheets; and the core material layer is composed of an aerogel, a resin, and an expandable microsphere foaming agent. Method (1) includes: heating and melting the resin to obtain slurry A, cooling the same, adding the aerogel and the expandable microsphere foaming agent thereto, and uniformly mixing the same to obtain slurry B, then flat-laying the lower panel layer, coating or printing with the slurry B, then laying the upper panel layer and hot press molding the same. Method (2) includes: uniformly mixing an aerogel, a resin and an expandable microsphere foaming agent to obtain mixture A, placing the mixture A into a non-woven bag, sealing to obtain a core material B, flat-laying the lower panel layer, flat-laying the core material B, then laying the upper panel layer, and hot press molding the same.

Claims

1. A sandwich composite board, comprising an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom, wherein the upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed; the upper panel layer and the lower panel layer are glass or fiber-reinforced resin-based composite sheets; and the core material layer consists of 30-70 parts by mass of aerogel, 10-35 parts by mass of a resin, and 2-4 parts by mass of an expandable microsphere foaming agent.

2. The sandwich composite board of claim 1, wherein the glass is selected from the group consisting of tempered glass, semi-tempered glass, ultra-white glass, float glass, coated glass, and film covered glass.

3. The sandwich composite board of claim 1, wherein fibers of the fiber-reinforced resin-based composite sheets are selected from the group consisting of glass fibers, carbon fibers, boron fibers, and aramid fibers; and the resin of the fiber-reinforced resin-base composite sheet is selected from the group consisting of a unsaturated polyester resin, a vinyl resin, a polyurethane resin, an epoxy resin, a polycarbonate resin, a polyamide resin, and a phenolic resin.

4. The sandwich composite board of claim 1, wherein the aerogel is selected from the group consisting of silicon dioxide aerogel, aluminum oxide aerogel, titanium dioxide aerogel, and zirconium dioxide aerogel.

5. The sandwich composite board of claim 1, wherein the resin of the core material layer is a thermosetting resin or a thermoplastic resin.

6. The sandwich composite board of claim 5, wherein the thermosetting resin is selected from the group consisting of a phenolic resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, an epoxy resin, a unsaturated resin, a polyurethane, and a polyimide; and the thermoplastic resin is selected from the group consisting of a polyethylene resin, a polypropylene resin, a polycarbonate resin, a polyvinyl chloride resin, a polystyrene resin, a polyamide resin, a polyformaldehyde resin, a polyphenyl ether resin, and a polysulphone resin.

7. The sandwich composite board of claim 1, wherein the expandable microsphere foaming agent has a particle size of 10-50 .Math.m.

8. A method for preparing the sandwich composite board of claim 1, comprising the steps of: (1) adding the resin of the core material layer in a container and heating at 110-160° C. to allow the resin of the core material layer to melt and obtain slurry A, then cooling the slurry A to 25-70° C. by standing; (2) adding the aerogel and the expandable microsphere foaming agent to the slurry A obtained in step (1), and mixing uniformly to obtain slurry B; (3) flatly placing the lower panel layer, spreading the slurry B obtained in step (2) uniformly on the lower panel layer, and then placing the upper panel layer on the slurry B to obtain a sandwich composite layer; and (4) hot-press molding the sandwich composite layer obtained in step (3) to obtain the sandwich composite board.

9. A method for preparing the sandwich composite board of claim 1, comprising the steps of: (1) adding the aerogel, the resin, and the expandable microsphere foaming agent according to compositions of the core material layer in a container and mixing uniformly to obtain a mixture A; (2) placing the mixture A obtained in step (1) into a nonwoven bag and sealing the nonwoven bag to obtain a core material B; (3) flatly placing the lower panel layer, spreading the core material B obtained in step (2) on the lower panel layer, and then placing the upper panel layer on the core material B to obtain a sandwich composite layer; and (4) hot-press molding the sandwich composite layer obtained in step (3) to obtain the sandwich composite board.

10. The method of claim 8, wherein in the hot-press molding of step (4), temperature is 100-180° C., the pressure is 2-5 MPa, and the time is 30 minutes - 8 hours.

11. The method of claim 9, wherein in the hot-press molding of step (4), temperature is 100-180° C., the pressure is 2-5 MPa, and the time is 30 minutes - 8 hours.

Description

DETAILED DESCRIPTION

[0031] The present disclosure will now be described in detail with reference to the specific examples. It should be understood that examples described herein are only for explaining the present disclosure, and not intended to limit the present disclosure.

Example 1

[0032] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are carbon fiber-reinforced phenolic resin-based composite sheets. The core material layer consists of 60 parts by mass of silicon dioxide aerogel, 35 parts by mass of a polyethylene resin, and 4 parts by mass of an expandable microsphere foaming agent, i.e., EM406 (with average diameter of 20 .Math.m, which is commercially available from NOF CORPORATION).

[0033] The method for preparing the above sandwich composite board includes the following steps of: [0034] (1) adding polyethylene resin powder in a container and heating at 120° C. to allow it to melt and obtain slurry A, then cooling the slurry A to 40° C. by standing; [0035] (2) adding silicon dioxide aerogel and the expandable microsphere foaming agent, i.e., EM406, to the slurry A obtained in step (1), and mixing uniformly to obtain slurry B; [0036] (3) flatly placing the lower panel layer, i.e., one carbon fiber-reinforced phenolic resin-based composite sheet, spreading the slurry B obtained in step (2) uniformly on the lower panel layer, and then placing the upper panel layer, i.e., the other carbon fiber-reinforced phenolic resin-based composite sheet, on the slurry B to obtain a sandwich composite layer; and [0037] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 150° C. and the pressure of 4 MPa for 1 hour, to obtain the sandwich composite board.

Example 2

[0038] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are tempered glass panels. The core material layer consists of 50 parts by mass of aluminum oxide aerogel, 25 parts by mass of a phenolic resin and 4 parts by mass of an expandable microsphere foaming agent, i.e., EHM401 (with average diameter of 60 .Math.m, which is commercially available from NOF CORPORATION).

[0039] The method for preparing the above sandwich composite board includes the following steps of: [0040] (1) adding phenolic resin powder in a container and heating at 130° C. to allow it to melt and obtain slurry A, then cooling the slurry A to 30° C. by standing; [0041] (2) adding aluminum oxide aerogel and the expandable microsphere foaming agent, i.e., EHM401, to the slurry A obtained in step (1), and mixing uniformly to obtain slurry B; [0042] (3) flatly placing the lower panel layer, i.e., one tempered glass panel, spreading the slurry B obtained in step (2) uniformly on the lower panel layer, and then placing the upper panel layer, i.e., the other tempered glass panel, on the slurry B to obtain a sandwich composite layer: and [0043] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 130° C. and the pressure of 3 MPa for 50 minutes, to obtain the sandwich composite board.

Example 3

[0044] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are coated glass panels. The core material layer consists of 65 parts by mass of titanium dioxide aerogel. 35 parts by mass of an epoxy resin, and 4 parts by mass of an expandable microsphere foaming agent, i.e., TEP-160 (with average diameter of 80 .Math.m, which is commercially available from NOF CORPORATION).

[0045] The method for preparing the above sandwich composite board includes the following steps of: [0046] (1) adding epoxy resin powder in a container and heating at 150° C. to allow it to melt and obtain slurry A, then cooling the slurry A to 50° C. by standing; [0047] (2) adding titanium dioxide aerogel and the expandable microsphere foaming agent, i.e., TEP-160, to the slurry A obtained in step (1), and mixing uniformly to obtain slurry B; [0048] (3) flatly placing the lower panel layer, i.e., one coated glass panel, spreading the slurry B obtained in step (2) uniformly on the lower panel layer, and then placing the upper panel layer, i.e., the other coated glass panel, on the slurry B to obtain a sandwich composite layer: and [0049] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 160° C. and the pressure of 5 MPa for 40 minutes, to obtain the sandwich composite board.

Example 4

[0050] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are glass fiber-reinforced epoxy resin-based composite sheets. The core material layer consists of 40 parts by mass of zirconium dioxide aerogel. 20 parts by mass of a polyamide resin, and 2 parts by mass of an expandable microsphere foaming agent, i.e.. EM406 (with average diameter of 20 .Math.m, which is commercially available from NOF CORPORATION).

[0051] The method for preparing the above sandwich composite board includes the following steps of: [0052] (1) adding polyamide resin powder in a container and heating at 140° C. to allow it to melt and obtain slurry A, then cooling the slurry A to 45° C. by standing; [0053] (2) adding zirconium dioxide aerogel and the expandable microsphere foaming agent, i.e., EM406 to the slurry A obtained in step (1), and mixing uniformly to obtain slurry B; [0054] (3) flatly placing the lower panel layer, i.e., one glass fiber-reinforced epoxy resin-based composite sheet, spreading the slurry B obtained in step (2) uniformly on the lower panel layer, and then placing the upper panel layer, i.e., the other glass fiber-reinforced epoxy resin-based composite sheet, on the slurry B to obtain a sandwich composite layer; and [0055] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 140° C. and the pressure of 3 MPa for 40 minutes, to obtain the sandwich composite board.

Example 5

[0056] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are glass fiber-reinforced polycarbonate resin-based composite sheets. The core material layer consists of 30 parts by mass of silicon dioxide aerogel, 20 parts by mass of a phenolic resin, and 3 parts by mass of an expandable microsphere foaming agent, i.e., EM406 (with average diameter of 20 .Math.m, which is commercially available from NOF CORPORATION).

[0057] The method for preparing the above sandwich composite board includes the following steps of: [0058] (1) adding silicon dioxide aerogel, phenolic resin powder, and the expandable microsphere foaming agent EM406 in a container, and mixing uniformly to obtain a mixture A; [0059] (2) placing the mixture A obtained in step (1) into a nonwoven bag and sealing the bag to obtain a core material B; [0060] (3) flatly placing the lower panel layer, i.e., one glass fiber-reinforced polycarbonate resin-based composite sheet, and spreading the core material B obtained in step (2) on the lower panel layer, and then placing the upper panel layer, i.e., the other glass fiber-reinforced polycarbonate resin-based composite sheet, on the core material B to obtain a sandwich composite layer; [0061] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 150° C. and the pressure of 4 MPa for 1 hour, to obtain the sandwich composite board.

Example 6

[0062] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are aramid fiber-reinforced polyamide resin-based composite sheets. The core material layer consists of 50 parts by mass of aluminum oxide aerogel, 35 parts by mass of a polystyrene resin, and 4 parts by mass of an expandable microsphere foaming agent, i.e., EM406 (with average diameter of 20 .Math.m, which is commercially available from NOF CORPORATION).

[0063] The method for preparing the above sandwich composite board includes the following steps of: [0064] (1) adding aluminum oxide aerogel, polystyrene resin powder, and the expandable microsphere foaming agent EM406 in a container, and mixing uniformly to obtain a mixture A; [0065] (2) placing the mixture A obtained in step (1) into a nonwoven bag and sealing the bag to obtain a core material B; [0066] (3) flatly placing the lower panel layer, i.e., one aramid fiber-reinforced polyamide resin-based composite sheet, and spreading the core material B obtained in step (2) on the lower panel layer, and then placing the upper panel layer, i.e., the other aramid fiber-reinforced polyamide resin-based composite sheet, on the core material B to obtain a sandwich composite layer: [0067] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 130° C. and the pressure of 3 MPa for 50 minutes, to obtain the sandwich composite board.

Example 7

[0068] A sandwich composite board includes an upper panel layer, a core material layer and a lower panel layer in sequence from top to bottom. The upper panel layer and the core material layer are integrally formed, and the lower panel layer and the core material layer are integrally formed. The upper panel layer and the lower panel layer are tempered glass. The core material layer consists of 45 parts by mass of titanium dioxide aerogel, 25 parts by mass of an epoxy resin, and 4 parts by mass of an expandable microsphere foaming agent, i.e., EHM401 (with average diameter of 60 .Math.m, which is commercially available from NOF CORPORATION).

[0069] The method for preparing the above sandwich composite board includes the following steps of: [0070] (1) adding titanium dioxide aerogel, epoxy resin powder, and the expandable microsphere foaming agent EHM401 in a container and mixing uniformly to obtain a mixture A; [0071] (2) placing the mixture A obtained in step (1) into a nonwoven bag and sealing the bag to obtain a core material B; [0072] (3) flatly placing the lower panel layer, i.e., one tempered glass panel, and spreading the core material B obtained in step (2) on the lower panel layer, and then placing the upper panel layer, i.e., the other tempered glass panel, on the core material B to obtain a sandwich composite layer; [0073] (4) hot-press molding the sandwich composite layer obtained in step (3) at the temperature of 160° C. and the pressure of 3 MPa for 40 minutes, to obtain the sandwich composite board.