CA2002568A1 - Light-weight construction material as well as a process and installation for manufacturing honeycomb structures from light-weight construction material - Google Patents

Light-weight construction material as well as a process and installation for manufacturing honeycomb structures from light-weight construction material

Info

Publication number
CA2002568A1
CA2002568A1 CA 2002568 CA2002568A CA2002568A1 CA 2002568 A1 CA2002568 A1 CA 2002568A1 CA 2002568 CA2002568 CA 2002568 CA 2002568 A CA2002568 A CA 2002568A CA 2002568 A1 CA2002568 A1 CA 2002568A1
Authority
CA
Canada
Prior art keywords
foil
strip
thermoplastic
fibrous
light
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA 2002568
Other languages
French (fr)
Inventor
Peter Krass
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schutz Werke GmbH and Co KG
Original Assignee
Schutz Werke GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schutz Werke GmbH and Co KG filed Critical Schutz Werke GmbH and Co KG
Publication of CA2002568A1 publication Critical patent/CA2002568A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00Subject matter not provided for in other groups of this subclass
    • B29D99/0089Producing honeycomb structures
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/22Corrugating
    • B29C53/24Corrugating of plates or sheets
    • B29C53/28Corrugating of plates or sheets transverse to direction of feed
    • B29C53/285Corrugating of plates or sheets transverse to direction of feed using rolls or endless bands

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

Abstract Plates of honeycomb structure, that are made, for example, from polyamide paper, are used as core material for sand-wich boards with covering layers of carbon or glass fibre rein-forced plastics or of aluminium. The new light-weight construction material is to be used for manufacturing honeycomb structures which, in comparison to the known honeycomb structures, are characterized by higher strength and stiffness, improved energy absorption and improved behavior in fire. The light-weight construction material consists of a fibrous thermoplastic compo-site foil which contains carbon, silicon carbide, whisker or the like fibres in the form of woven fabric, or mats, the fibres being embedded in a matrix of a high temperature thermoplastic such as polyether ether ketone, polyether sulfone or polysulfone.
The sandwich boards with honeycomb cores are used in the field of aeronautics and space travel, mechanical engineering, and in the construction of rail vehicles and watercraft as well as of sport and recreational equipment.

Description

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The i~vention relates to light-weight construction material and to a process for manufacturing honeycomb structures from such light-weight construction material.
Plates of honeycomb structure, that are preferably manufactured from a high-strength polyamide paper and coated with a phenolic resin unaffected by high changes of temperature, are used as core material fox sandwich boards with covering layers of carbon or glass fibre reinforced plastics or of aluminium. Such sandwich boards are structural members with a very high strength 1~ and stiffness, a high specific energy absorption cap~city and good elasticity at the lowest weight. Sandwich boards with honeycomb cores are used in the fields of aeronautics and space travel, mechanical engineering and in -the construction of rail vehicles and watercraft as well as of sports and recreational equipment.
Light-weight building boards with a honeycomb structure are manufactured according to the "expansion process" or the "pro-filing process".
During the expansion process strip material, for ex-ample polyamide paper drawn from a reel is severed into sheets, an adhesive is dotted onto the sheets in straight lines running in the direction of travel of the strip, the sheets are stacked and the lines of adhesive are hardened. Finally the layers of paper stacked on top of one another are pulled or spread apart into honeycomb blocks Erom which plates with the desired thickness can be cut. Furthermore, it is possible ko cut discs of the desired thickness from the stack of sheets and to then spread : . : .
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~O~S6~3 these discs apart into plates o~ honeycomb structure.
The profiling process is used to manufacture honeycomb structures having greater strength. In this process the strip material, for example o~ aluminium, running off a reel, is rolled by means of profile reels into, for e~ample, a trapezoidal profile strip, the profiled strip is severed into trapezoidal profile plates, an adhesive is applied to the raised parts of the trape-zoidal profile plates and the plates are stacked on top of one another and glued together to form a honeycomb block from which paneling of desired thickness is cut.
It is the object of the present invention to develop a light-weight construction material as well as a process and in-..:
stallation for manufacturing honeycomb structures from this mate-- rial which, in comparison to the known honeycomb structures, areI characterized by a higher strength and stiffness, improved energyj absorption as well as improved behaviour in fire.
The light-weight construction material according to the present invention which meets these objectives consists of a fibrous thermoplastic composite foil which contains carbon, sili-con carbide, whisker or the like fibres in the form of woven fabric, nests or mats, the ibres being embedded in a matrix of a high temperature thermoplastic such as polyether ether ketone, polyether sulfone or polysulfone.
Three processes are proposed in accordance with the present invention for manufacturing honeycomb structures from fibrous thermoplastic composite foil described above, these ",' ' : ~
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'',,',: . . ~: "` ' ' '` ' processes using -the known "profiling pxocess" and being distin-yuished by the production of fibrous thermoplastic composite foil as the base material for the honeycomb structures.
In the first process an upper and a lower heated thermo-plastic foil strip and a fibrous material guided between the two foil strips are joined together by rolling.
The second process is characterized in that the thermo-plastic foil strip is extruded and subsequently joined to a fi-brous material by rolling.
The third process is characterized therein that thermoplastic granules are melted and in the melted state rolled with a fibrous material to a fibrous thermoplastic composite foil.
The latter process avoids the disadvantages occurring in the first two processes of poor fibre wetting and fibre damage caused by the high viscosi~y of the thermoplastic composite foil used.
In all three processes the fibrous thermoplastic com-posite ~oil is compressed following rolling by subsequently heat-ing and rolling it once or several times and is brought to the desired thickness.
Three installations operating according to the processes described abo~e are explained herebelow on the basis of the accom-panying schematic drawings, which show in Figure 1: a side view of a complete installation for manufacturing honeycomb structures, Figures 2 and 3: side ~iews of two modified parts I

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of an installation for manufac-turing the fibrous thermoplastic composite foil, Figure 4: part of a longitudinal section of a profiled plate for manufacturing a honeycomb structure, and Figure 5: a modification of part II of an installation for manufacturing a honeycomb structure from the fibrous thermo-plastic composite foil.
The installation according to Figure 1 comprises a part I for manufacturing the fibrous thermoplastic composite foil 1 in the form of strips and a part II for further processing the com-; posite foil to a block 2 of honeycomb structure, from which honey-comb plates are cut, these plates being used as core material for sandwich boards with covering layers of carbon or glass fibre reinforced plastics or of aluminium.
Part I of the installation includes a two-hi~h rolling stand with a pair of calender rollers 3, 4, an upper and a lower strip guide 5, 6 for two thermoplastic foil strips 7, 8 running ; off reels (not illustrated), heating devices 9 in the area of the strip guides 5, 6 and a centre guide 10 for a fibrous material 11 drawn off a reel (not illustrated).
Part II of the installation comprises three heating devices 9 and two additional two-high rolling stands with pairs of calender rollers 12, 13 arranged alternately in succession, a profiling device 14 with two profile rollers 15, 16 with which the fibrous thermoplastic composite foil strip 1 is rolled to a trape-zoidal profile 17 with a pitch X, a device 1~ with a roller 19 for ., : , .. . .
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, . ~ . .
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:~- ~ . , 3ZS6~3 applying an adhesive to the raised parts 20 of the trapezoidal profile 17, a cutting device 21 Eor cutting profiled plates 22 from the fibrous thermoplastic composite foil and a press 23 for gluing together the plates 22 stacked on top oE one another to form a honeycomb block 2.
Instead of gluing, the profiled plates 22 can also be join~d together by fusion welding or ultrasonic welding in that by means of a welding head 24 two profiled plates 22 are respectively held by a welding mandrel 25.
In part I of the installation the two thermoplastic foil strips 7, 8 are heated by means o heating devices 9 in the area of the upper 5 and the lower 6 strip guide and are rolled with ~ ;
; the fibrous material 11 (that runs in the centre guide 10 between the two foil strips 7, 8) in the two-high rolling stand with the pair of calender rollers 3, 4 to the fibrous thermoplastic com-posite foil 1.
After being first heat~d by the heating devices 9, the fibrous thermoplastic composite foil 1 is compressed in part II of ~.
the installation by two additional roll passes in two-high rolling stands with pairs of calender rollers 12, 13 arranged after one another and is rolled to the desired thickness. After being heat-ed again in final heating device 9, the strip-like fibrous :~
thermoplastic composite foil 1 is rolled by the profiling device 14 into a foil strip with a trapezoidal pro.file 17 and the raised parts 20 of the trapezoidal profile strip are subse~uently coated .
with an adhesive in the applicator 18. Plates 22 are continually :,,: , , ~ .
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20~2~ 26636-28 cu-t from the profiled strip in the following cutting device 21, the plate length L amounting to a rnultiple plus half of the pitch X of the trapezoidal profile 17. Finally, the trapezoidal profile ; plates 22 are stacked and are gluecl together under pressure (and possibly under renewed heating) in a press 23 to form a honeycomb block 2 from which plates of desired measurements are cut follow-ing hardening o~ the adhesive.
Part I of the installation illuistrated in Figure 2 for manufacturing the fibrous thermoplastic composite foil l is char-acterized by an extruder 26 with a slit nozzle 27, followed by a foil strip mill 28 designed as a three-high mill with a centre strip guide 29 for the foil strip 30 emerging from the extruder 26 as well as an upper guide 31 for a fibrous material ll.
Part I of the installation I according to Figure 3 for manufacturing the fibrous thermoplastic composite foil l is equip-ped with a horizontal lower conveyor belt 32 and arranged at a distance above it a parallel, upper conveyor belt 33 which extends over the rear area of the lower belt 32 and with it forms a longi-tudinal gap 34. Heating devices 9 are installed in the area of the longitudinal gap 34 between the carrying run and the empty return ru~ of the two belts 32, 33. Two feed stations 35, 36, designed as hoppers for a thermoplastic granule 37, are arranged at different heights above the forward area of the lower conveyor belt 32 and in front of the upper conveyor belt 33. A feed with a deflection pulley 38 is provided between the two feed stations 35, 36 for introducing a fibrous material 11 below the second ~:. : . ; , .
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2~ 5~3 feed station 36 throuyh into the longitudinal gap 34 between the two conveyor belts 32, 33, whereby the plane of travel of the fibrous material 11 through the longitudinal gap 34 lies in the area of the centre plane of the gap5 A specific rolling force is transferred to the two conveyor belts 32, 33 by the deflection pulleys 32a, 32b and 33a, 33b and the plastic melt located in the longitudinal gap 34 is thereby rolled with khe fibrous material 11 to the fibrous thermoplastic composite oil 1.

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Claims (11)

1. A light-weight construction material for manufacturing honeycomb structures, wherein this material consists of a fibrous thermoplastic composite foil which contains carbon, silicon carbide, whisker or the like fibres in the form of woven fabric, or mats, the fibres being embedded in a matrix of a high temperature thermoplastic such as polyether ether ketone, poly-ether sulfone or polysulfone.
2. A process for manufacturing honeycomb structures from light-weight construction material according to claim 1 in which the strip-like foil is profiled and severed into plates that are bonded together into a honeycomb structure by adhesives or by fusion or ultrasonic welding, wherein heated thermoplastic foil strip and fibrous material are joined together by means of rolling.
3. A process according to claim 2, wherein an upper and a lower heated thermoplastic foil strip and a fibrous material guided between the foil strips are joined together by rolling.
4. A process according to claim 2, wherein the thermo-plastic foil strip is extruded and subsequently joined to a fibrous material by rolling.
5. A process for manufacturing honeycomb structures from light-weight construction material according to claim 1, wherein thermoplastic granular material is melted and in the melted state is rolled with a fibrous material to a fibrous thermoplastic composite foil.
6. A process according to any one of claims 2 to 5, where-in after rolling the fibrous thermoplastic composite foil is compressed by subsequently heating and rolling it one or more times and is brought to the desired thickness.
7. A process according to any one of claims 2 to 5, wherein the profiled, strip-like foil is severed into plates with a length (L) that amounts to a multiple plus half a dimension of the pitch (X) of the strip profile.
8. An installation for carrying out the process according to claims 2 to 7 comprising a profiling device for the foil strip, a device for applying the adhesive or a welding device, a cutting device for dividing the foil strip and a press for gluing or weld-ing together the profiled foil plates, comprising a two-high roll-ing stand with a pair of calender rollers arranged in front of the profiling device, an upper and a lower strip guide for two thermoplastic foil strips equipped with heating devices and a centre guide for the fibrous material at the strip inlet.
9. An installation for carrying out the process of claims 2 to 7, comprising an extruder with a slit nozzle for manufactur-ing a thermoplastic foil strip, followed by a foil strip mill installed in front of the profiling device in particular a three-high mill with a centre strip guide for the foil strip emerging from the extruder as well as an upper guide for a fibrous material at the strip inlet.
10. An installation for carrying out the process of claims 2 to 7, comprising a horizontal lower conveyor belt arranged in front of the profiling device and arranged at a distance above said conveyor belt a parallel, upper conveyor belt which extends over the rear area of the lower belt and with it forms a longi-tudinal gap, heating devices being installed between the carrying run and the return run of the two belts in the area of the longi-tudinal gap, two feed stations, for a thermoplastic granule being arranged at different heights above the foward area of the lower conveyor belt and in front of the upper conveyor belt as well as a feed with a deflection pulley located between the feed stations for introducing a fibrous material below the second feed station through into the longitudinal gap between the two conveyor belts, whereby the plane of travel of the fibrous material through the longitudinal gap lies in the area of the centre plane of the gap.
11. An installation according to any one of claims 8 to 10, comprising at least one rolling stand with a pair of calender rollers as well as at least one heating device between the part of the installation for manufacturing the fibrous thermoplastic composite foil and the profiling device.
CA 2002568 1988-11-10 1989-11-09 Light-weight construction material as well as a process and installation for manufacturing honeycomb structures from light-weight construction material Abandoned CA2002568A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19883838153 DE3838153A1 (en) 1988-11-10 1988-11-10 LIGHTWEIGHT MATERIAL AND METHOD AND SYSTEM FOR PRODUCING HONEYCOMB STRUCTURES FROM THE LIGHTWEIGHT MATERIAL
DEP3838153.2 1988-11-10

Publications (1)

Publication Number Publication Date
CA2002568A1 true CA2002568A1 (en) 1990-05-10

Family

ID=6366898

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2002568 Abandoned CA2002568A1 (en) 1988-11-10 1989-11-09 Light-weight construction material as well as a process and installation for manufacturing honeycomb structures from light-weight construction material

Country Status (6)

Country Link
EP (1) EP0368238A3 (en)
JP (1) JPH02269131A (en)
CA (1) CA2002568A1 (en)
CS (1) CS277061B6 (en)
DE (1) DE3838153A1 (en)
HU (1) HUT58602A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6506276B1 (en) 2000-06-12 2003-01-14 Newcourt, Inc. Method for forming a cellular core member
US20150136013A1 (en) * 2012-05-24 2015-05-21 Global Ip Holdings, Llc Deep-drawn marine hull having a sandwich structure with a cellulose-based core and watercraft utilizing same
US10661838B2 (en) 2017-05-31 2020-05-26 Honda Motor Co., Ltd. Multi-material vehicle roof stiffener

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0512433B1 (en) * 1991-05-04 1997-07-30 Hoechst Aktiengesellschaft Porous honeycomb material, process for its manufacture and its use
US5324465A (en) * 1991-11-25 1994-06-28 E. I. Du Pont De Nemours And Company Apparatus and process for cutting a honeycomb half-cell structure into sheets
CA2123899A1 (en) * 1991-11-25 1993-06-10 Paul James Arnold Apparatus and processes for forming a hexagonal-cell honeycomb core, and the core formed thereby
US5340429A (en) * 1991-11-25 1994-08-23 E. I. Du Pont De Nemours And Company Apparatus and process for stacking sheets of half-cell structure to make a honeycomb core
US5288537A (en) * 1992-03-19 1994-02-22 Hexcel Corporation High thermal conductivity non-metallic honeycomb
DE4301396C2 (en) * 1993-01-20 1995-07-27 Hartmut Dr Greulich Process for the production of porous fiber components
DE4304845A1 (en) * 1993-02-17 1994-09-08 Euro Composites Shipping container
US5498462A (en) * 1994-04-01 1996-03-12 Hexcel Corporation High thermal conductivity non-metallic honeycomb
US6199342B1 (en) * 1998-02-17 2001-03-13 Newcourt, Inc. Method for forming structure suitable for use as a core member
EP2295216B1 (en) 2009-09-15 2016-01-06 INVENT Innovative Verbundwerkstoffe Realisation und Vermarktung neuer Technologien GmbH Method for producing a honeycomb structure from a semi-finished fibre product
DE102010030233A1 (en) 2010-06-17 2011-12-22 Evonik Degussa Gmbh Semi-finished product for the production of fiber composite components based on storage-stable polyurethane compositions
WO2012072149A1 (en) * 2010-12-03 2012-06-07 The Swisscore Ag Device and method for producing a honeycomb structure and a honeycomb structure
RU2641125C1 (en) * 2016-12-14 2018-01-16 Российская Федерация, от имени которой выступает Министерство промышленности и торговли Российской Федерации (Минпромторг России) Texstolite of multifunctional purpose

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FR874092A (en) * 1940-09-16 1942-07-28 Manufacturing process of flat gaskets for gaskets
US3356555A (en) * 1964-10-29 1967-12-05 Hexcel Corp Method and apparatus for the manufacture of honeycomb product
AT264275B (en) * 1966-04-15 1968-08-26 Pimex Anstalt Device for the production of core honeycombs
DE1729016A1 (en) * 1967-12-16 1971-06-03 Siempelkamp Gmbh & Co Plant for the production of conveyor belts
US4496415A (en) * 1982-04-08 1985-01-29 Westinghouse Electric Corp. Method for impregnating resin powder directly into a laminate lay up
IT1181389B (en) * 1984-02-10 1987-09-23 Marangoni Meccanica MACHINE FOR THE CONFORMATION OF A PRE-EXTRUDED RUBBER PROFILE NOT GEOMETRICALLY DEFINED AND FOR THE INSERTION INTO IT OF METALLIC WIRES OR ANY TEXTILE TEXTILES
GB2188866B (en) * 1985-04-14 1990-03-14 H R Smith Lightweight high temperature thermoplastics material structures
JPS61287732A (en) * 1985-06-16 1986-12-18 有限会社 宮田技研 Joining body of member

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6506276B1 (en) 2000-06-12 2003-01-14 Newcourt, Inc. Method for forming a cellular core member
US20150136013A1 (en) * 2012-05-24 2015-05-21 Global Ip Holdings, Llc Deep-drawn marine hull having a sandwich structure with a cellulose-based core and watercraft utilizing same
US9567037B2 (en) * 2012-05-24 2017-02-14 Global Ip Holdings, Llc Deep-drawn marine hull having a sandwich structure with a cellulose-based core and watercraft utilizing same
US10661838B2 (en) 2017-05-31 2020-05-26 Honda Motor Co., Ltd. Multi-material vehicle roof stiffener
US11634179B2 (en) 2017-05-31 2023-04-25 Honda Motor Co., Ltd. Multi-material vehicle roof stiffener

Also Published As

Publication number Publication date
HUT58602A (en) 1992-03-30
JPH02269131A (en) 1990-11-02
EP0368238A3 (en) 1991-08-21
CS277061B6 (en) 1992-11-18
DE3838153A1 (en) 1990-05-31
DE3838153C2 (en) 1991-03-21
EP0368238A2 (en) 1990-05-16
HU895846D0 (en) 1990-02-28
CS636089A3 (en) 1992-04-15

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