CA2075579A1 - Lightweight panelling and a method of manufacturing same - Google Patents

Lightweight panelling and a method of manufacturing same

Info

Publication number
CA2075579A1
CA2075579A1 CA002075579A CA2075579A CA2075579A1 CA 2075579 A1 CA2075579 A1 CA 2075579A1 CA 002075579 A CA002075579 A CA 002075579A CA 2075579 A CA2075579 A CA 2075579A CA 2075579 A1 CA2075579 A1 CA 2075579A1
Authority
CA
Canada
Prior art keywords
layer
panelling
core layer
covering
slits
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
CA002075579A
Other languages
French (fr)
Inventor
Leonardo Meinei
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.)
Euro Composites SA
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of CA2075579A1 publication Critical patent/CA2075579A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/06Interconnection of layers permitting easy separation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/40Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels
    • E04C2/405Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels composed of two or more hingedly connected parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02Composition of the impregnated, bonded or embedded layer
    • B32B2260/021Fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/02Cellular or porous
    • B32B2305/024Honeycomb

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Abstract of the DISCLOSURE

In lightweight panelling, at least one core layer (10) is provided, to the outer surfaces (11,12) of which thin outer layers (15, 16) are attached. A plurality of parallel slits (17) of predetermined width are provided which extend from one intact outer layer (16) through a substantial part of the thickness of the core layer (10), in order to make the panelling easily deformable in one direction.

Description

2~75~7~

LIG~T~EIGHT PANELLING AND A METHOD OF MANUFACTURING SAME

The present invention relates to panelling of lightweight construction and .to a ~ethod of manufacturing such panelling.

Known lightweight panelling is usually of sandwich construction and compri~es a core layer of foamed artificial resin, balsa wood or honeycomb material, plus outer layers to ~tiffen it. Preferably, the panelling is constructed with a core layer of honeycomb structure, su~h as is described in, for example, International Patent Application W0 ~9/10258.

In many applications, for example in the ~anufacture of a sliding door, it is advantageous for the panelling to be highly resilient or flexible in a first bending direction and simultaneously extremely rigid in a ~econd direction perpendicular to the first. The known panelling mentioned above cannot fulfill this requirement.

The object of the present invention iq to provide lightweight panelling with ~ predetermined degree of flexi~ility in one direction, which differ3 ~ubstantially from the degree of flexibility in a 3econd perpendicular direction.

According to a first a~pect of the present invent;on there is provided panelling o~ lightweight con~truction comprising a lightweight core layer and two relatively 2~75~7~

thinner outer layers joined respectively to two outer surface~ defined by the core layer, and wherein the core layer defines a plurality of parallel slits, each of a predetermined width and extending from an intact said outer layer through at least a substantial part of the thickness of said core layer.

According to a second aspect of the present invention there iq provided a method of manufacturing lightweight panelling having a lightweight core layer and comprising the steps of (a) applying first and second covering layers to first and second opposite surfaces of said core layer respectively;
(b) forming a plurality of slits, earh of a predetermined width, completely through said first covering layer and through a substantial part of the thickness of said core layer (10); and (c) finishing the panelling on at least the side of said first covering layer by the application thereto of a first outer layer.

lt will be appreciated that the first outer layer coverQ the outer openings of the ~lits and, on the one hand, endows the remaining core ~aterial with the required stiffness, while on the other hand, can be compressed in the places where it covers the slits to allow the panelling to flex toward said outer layer. On the ~pposite surface, however, the outer layer and the remaining core material attached to it are incomprecsible and provide a ~mooth surface that is merely bent.

Preferably, covering layers are attached to ~aid outer surfaces of the core layer between the core layer and the outer layer~. , 207~7~

Fig~. 1 to 5 show ~chematically various stage in the manufacture of one embodiment of lightweight panelling in accordance with the invention.

In the embodiment of the invention shown in the drawings, a core layer 10 comprising a honeycomb material with the cell axis of the honeycombs perpendicular to Raid outer surfaces 11, 12 is made from, for example, Nomex and paper. First and second covering layers 13, 14, which preferably comprise a web material preimpregnated with phenol, epoxy or thermoplastic material, are laid onto the outer Rurfaces 11 and 12 of the core layer 10. Onto the first covering layer 13 a tear-off web 18 iQ also laid and to the lower covering layer 14 is attached, ~y adhesive between the two layers, a superficial or outer layer 15 such as an adhesive sheet. This adhe~ive sheet 15 constitutes the outer surface of the finished structure and hence is preferably decorated or ornamented (colored, textured etc.) as the user desires.

The tear-off web 18 and the first outer layer 15 are each covered with a separating sheet 19, so that the stack 80 produced can be pressed between surfaces 20, 20~ of a heatable press, as shown in Fig. 1. During ~ompression and simultaneous heating in the pre~s, the covering layers 13 and 14 bond to the underlying core layer 10 a~d the fir~t outer layer 1~ bonds to the second covering layer 14.

After the bonds between the layers have hardened, the resulting laminated structure is laid on a support plate 21 with the ~irst outer ,la~er 15 face down, as shown in Fig.
2. This facilit~tes manipulation of the "blank". First, 2~75S79 the tear-off web 18 is removed, leaving a roughened surface on the first covering layer 13.

Next, a saw or an end mill is used to make a series of parallel slits 17 in the ~lank in such a way that a residual part of the thickness of the core layer 10 is retained, as shown in Fig. 3. In principle, it is also possible to extend the slits 17 all the way to the second covering layer 14 but care must be taken that the remaining material is sufficiently rigid to resist forces applied in a direction parallel to the surface whilst still being capable of bending elastically. Preferably, the depth of the slits is in the range corresponding to 80% to 95% of the thickness of the core layer and the slits are e~uidistant from one another, After the slits 17 have been made, the resulting structure, together with the support plate 21, is again placed between the compression surfaces 20, 20' of the heatable press, as shown in Fig. 4. The support plate 21 is prevented from sticking to the surface 20' by the interposition of a separating sheet 19 therebetween.

Prior to compression of the structure by the surface 20, an adhesive layer 22 is applied to the roughened surface of the first covering layer 13. On the adhesive layer is laid a second ~uperficial or outer layer 16, which in turn is separated from the associated compression surface 20 by a second separation ~heet 19. During the subsequent compression and heating process the ~econd outer layer 16 bonds to the underlying first covering layer 13.
The panelling so produced is now removed fro~ the support plate 21 and has a structure, in cross-section, as shown in Fig. 5.

It should be note~ at this juncture that, for clarity, the relative thickne~ses of the layerR 13-16 are greatly exaggerated in the drawings.

Claims (17)

1. Panelling of lightweight construction comprising a lightweight core layer and two relatively thinner outer layers joined respectively to two outer surfaces defined by the core layer, and wherein the core layer defines a plurality of parallel slits, each of a predetermined width and extending from an intact said outer layer through at least a substantial part of the thickness of said core layer.
2. Panelling as claimed in Claim 1, wherein said core layer comprises a honeycomb material with the cell axis of the honeycombs perpendicular to said outer surfaces.
3. Panelling as claimed in Claim 2, wherein said core layer comprises Nomex and paper.
4. Panelling as claimed in Claim 1, wherein covering layers are attached to said outer surfaces of the core layer between the core layer and the outer layers.
5. Panelling as claimed in Claim 4, wherein said covering layers comprising preimpregnated web material.
6. Panelling as claimed in Claim 1, wherein the depth of the slits is in the range corresponding to 80% to 95% of the thickness of the core layer.
7. Panelling as claimed in Claim 1, wherein the slits are equidistant from one another.
8. A method of manufacturing lightweight panelling having a lightweight core layer and comprising the steps of (a) applying first and second covering layers to first and second opposite surfaces of said core layer respectively;
(b) forming a plurality of slits, each of a predetermined width, completely through said first covering layer and through a substantial part of the thickness of said core layer (10); and (c) finishing the panelling on at least the side of said first covering layer by the application thereto of a first outer layer.
9. A method as claimed in Claim 8, comprising the further step of (d) applying a second outer layer to said second covering layer.
10. A method as claimed in Claim 8, wherein said first and second covering layers are bonded to the core layer in a press under the action of heat.
11. A method as claimed in Claim 8, wherein said first and second covering layers comprise preimprednated web material.
12. A method as claimed in Claim 8, wherein said outer layer is attached to said underlying covering layer by an adhesive.
13. A method as claimed in Claim 8, wherein said slits are formed by machining.
14. A method as claimed in Claim 13, wherein said slits are formed by sawing or milling.
15. A method as claimed in Claim 8, wherein in step (a) a tear-off web is applied to the first covering layer and immediately prior to step (c) said tear-off web is removed to leave the surface defined by the first covering layer in a suitable condition for attachment by adhesive of said first outer layer.
16. A method as claimed in Claim 8, wherein the blank formed in step (a) is fixed to a manipulable support plate for the duration of the subsequent steps of the method.
17. A method as claimed in Claim 9, wherein the steps (a) and (d) are carried out simultaneously.
CA002075579A 1991-08-13 1992-08-07 Lightweight panelling and a method of manufacturing same Abandoned CA2075579A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DEP4126781.8 1991-08-13
DE4126781A DE4126781C2 (en) 1991-08-13 1991-08-13 Lightweight surface element and method for producing the same

Publications (1)

Publication Number Publication Date
CA2075579A1 true CA2075579A1 (en) 1993-02-14

Family

ID=6438225

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002075579A Abandoned CA2075579A1 (en) 1991-08-13 1992-08-07 Lightweight panelling and a method of manufacturing same

Country Status (3)

Country Link
EP (1) EP0527484A1 (en)
CA (1) CA2075579A1 (en)
DE (1) DE4126781C2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7997384B2 (en) 2007-05-15 2011-08-16 Airbus Operations Gmbh Multilayer board for reducing solid-borne sound

Families Citing this family (10)

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Publication number Priority date Publication date Assignee Title
DE19527081C1 (en) * 1995-07-25 1996-09-19 Buderus Sell Flat light construction element
DE19801045A1 (en) * 1998-01-14 1999-07-22 Kaldewei Franz Gmbh & Co Laminar material surface
DE10034990B4 (en) * 2000-07-19 2005-02-10 Airbus Deutschland Gmbh Multi-layer panel for reducing the sound radiation
DE10037317A1 (en) * 2000-07-29 2002-02-14 Airbus Gmbh Technical honeycomb has coating system on end sides, adhesive system, tear-off tissue, openings, and walls.
DE10231791C1 (en) * 2002-07-15 2003-12-18 Airbus Gmbh Multi-layer panel for reducing sound radiation e.g. for aircraft cabin, having core layer provided with curved vertical and horizontal slits
JP4657634B2 (en) 2004-06-10 2011-03-23 日東電工株式会社 Steel sheet reinforcement sheet
DE102008063923A1 (en) 2008-12-19 2010-06-24 Airbus Deutschland Gmbh Multi-layer panel for sound insulation
FR2979211A1 (en) * 2011-08-22 2013-03-01 Teddy Jean Alain Robert Deckchair, has flexible base tensioned by system of flexible and removable structures, where parallelepipeds are attached on straps of structures, and female and male parts are used as junction between base and structures
EP2740588A1 (en) * 2012-12-04 2014-06-11 Magna Steyr Fahrzeugtechnik AG & Co KG Sandwich component, bodywork section of a motor vehicle and method for producing a sandwich component
US11557937B2 (en) 2018-11-15 2023-01-17 Cummins Power Generation Ip, Inc. Genset enclosures with low acoustic noise

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US2768924A (en) * 1956-06-14 1956-10-30 Cable Makers Australia Proprie Cushioning element
GB1096982A (en) * 1963-11-21 1967-12-29 Benbow & Co Modern Shopfitters Laminated panel
FR1582581A (en) * 1968-07-30 1969-10-03
CA966967A (en) * 1972-04-18 1975-05-06 Chemacryl Plastics Limited Flexible core material for laminated structures and method of producing the same
US4121008A (en) * 1975-02-07 1978-10-17 Unitex Limited Foam sandwich constructions
GB1603085A (en) * 1977-06-03 1981-11-18 Ciba Geigy Uk Ltd Fire protection means
FR2562837B1 (en) * 1984-04-16 1987-06-26 Mcintosh Jonathan COMPOSITE CONSTRUCTION ELEMENTS AND METHOD FOR THE PRODUCTION OF MULTI-DIRECTIONAL STRUCTURES BY FORMING AND / OR ASSEMBLY OF SUCH ELEMENTS
DE8624880U1 (en) * 1986-09-17 1987-08-27 Euro-Composites S.A., Echternach, Lu
GB8710812D0 (en) * 1987-05-07 1987-06-10 Bpb United Kingdom Ltd Profiled insulation material
EP0412118A4 (en) * 1988-04-29 1991-09-25 Barry M. Fell Reinforced thermoplastic honeycomb structure
EP0424312A1 (en) * 1989-10-13 1991-04-24 Alusuisse-Lonza Services Ag Flexible laminate

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7997384B2 (en) 2007-05-15 2011-08-16 Airbus Operations Gmbh Multilayer board for reducing solid-borne sound

Also Published As

Publication number Publication date
DE4126781A1 (en) 1993-02-18
DE4126781C2 (en) 1997-02-20
EP0527484A1 (en) 1993-02-17

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