CN101389423A - Method for manufacturing a three dimensional frame structure for use as a core structure in a sandwich construction and frame structure manufactured thereby - Google Patents

Method for manufacturing a three dimensional frame structure for use as a core structure in a sandwich construction and frame structure manufactured thereby Download PDF

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Publication number
CN101389423A
CN101389423A CNA2007800062970A CN200780006297A CN101389423A CN 101389423 A CN101389423 A CN 101389423A CN A2007800062970 A CNA2007800062970 A CN A2007800062970A CN 200780006297 A CN200780006297 A CN 200780006297A CN 101389423 A CN101389423 A CN 101389423A
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finished product
heat
semi
frame structure
network
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CN101389423B (en
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汉斯-于尔根·韦伯
格列戈尔·克里斯蒂安·恩德雷斯
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Airbus Operations GmbH
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Airbus Operations GmbH
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Priority claimed from PCT/EP2007/001549 external-priority patent/WO2007096172A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00Making rigid structural elements or units, e.g. honeycomb structures
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/005Making gratings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/04Making rigid structural elements or units, e.g. honeycomb structures composite sheet metal profiles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F27/00Making wire network, i.e. wire nets
    • B21F27/12Making special types or portions of network by methods or means specially adapted therefor
    • B21F27/128Making special types or portions of network by methods or means specially adapted therefor of three-dimensional form by connecting wire networks, e.g. by projecting wires through an insulating layer
    • 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
    • B29C53/02Bending or folding
    • 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
    • B29D24/00Producing articles with hollow walls
    • B29D24/002Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • 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 form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products 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 comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64DEQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENTS OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D1/00Dropping, ejecting, releasing, or receiving articles, liquids, or the like, in flight
    • B64D1/02Dropping, ejecting, or releasing articles
    • B64D1/08Dropping, ejecting, or releasing articles the articles being load-carrying devices
    • 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
    • E04C2/34Building 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 two or more spaced sheet-like parts
    • 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
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • 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
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06Rod-shaped
    • 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
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • 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
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • 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
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • 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
    • B29C53/02Bending or folding
    • B29C53/04Bending or folding of plates or sheets
    • B29C53/06Forming folding lines by pressing or scoring
    • B29C53/063Forming folding lines by pressing or scoring combined with folding
    • 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
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
    • B32B37/203One or more of the layers being plastic
    • B32B37/206Laminating a continuous layer between two continuous plastic layers
    • 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
    • E04C2/34Building 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 two or more spaced sheet-like parts
    • E04C2002/3488Building 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 two or more spaced sheet-like parts spaced apart by frame like structures
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/40Weight reduction

Abstract

The present invention relates to a method for manufacturing a three dimensional frame structure that can be used as a core structure in a sandwich construction. Furthermore, the invention relates to a frame structure for a sandwich construction, which frame structure has been manufactured in accordance with the method according to the invention. In the method, a two dimensional lattice structure (1) is made from bar-shaped linear semifinished products (2, 3), in which structure (1) the semifinished products (2, 3) intersect at defined points of intersection (4); the bar- shaped linear semifinished products (2, 3) are connected at the points of intersection (4) and are softened by locally applying heat to the lattice structure (1) in each case along three non-intersecting (imaginary) straight lines (5, 6).; In order to impart a three dimensional shape to the lattice structure (1) a force (F) is introduced into the lattice structure (1) along the middle one of the (imaginary) straight lines (5, 6) to which heat has been applied, wherein, as a result of deformation of the lattice structure, the introduced force F is deflected into pairs of tensile forces acting in the semifinished products, as a result of which the lattice structure (1) is pulled into a third dimension, along the middle (imaginary) straight line (5, 6) to which heat has been applied.

Description

Be used for making as the method for the three-dimensional frame structure of the cored structure of sandwich structure and the frame structure of making thus
The reference of related application
The U.S. Provisional Patent Application No.60/776 that the application requires to submit on February 24th, 2006 German patent application No.10 submitted on February 24th, 2,006 008728.3 and 2006,524 priority, this mode with reference that is disclosed in of above-mentioned application is included this paper in.
Technical field
The present invention relates to the technical field of composite.Particularly, the present invention relates to a kind of method that is used for making as the three-dimensional frame structure of the cored structure of sandwich structure.In addition, the present invention relates to a kind of frame structure that is used for sandwich structure, described frame structure is according to made according to the method for the present invention, and relates to a kind of aircraft that comprises the structure member of sandwich structure form, and the cored structure of described sandwich structure utilizes the method according to this invention to make.
Background technology
Because the rigidity of composite or desirable rate, the especially sandwich structure of intensity and density, composite is with a wide range of applications in the aircraft construction field.In general, the honey comb like cored structure of for example being made up of the unit of vertically extending hexagonal cross-section between top cover layer and bottom cladding layer forms by top cover layer and bottom cladding layer and in order to strengthen rigidity in sandwich structure.
As a kind of alternative of the design that comprises honeycomb structure, can use the rigidity porous material.But, when comparing, comprise that the sandwich structure of rigidity porous material core has defective to a certain extent with sandwich structure with honeycomb cored structure and similar density, promptly their mechanical performance is relatively poor.In order to remedy this shortcoming, the semi-finished product framework of fiber, filament or pultrusion can be combined in the rigidity porous material with the angle of qualification and the density of qualification.Under the situation of binding fiber or filament and resin impregnating process subsequently, fiber just helps the mechanical strength of porous material.In this case, porous material not only serves as carrier and is used for and will keeps in position with the spicule that resin reinforced fiber or filament form occur, and also is used for firm spicule to prevent or to postpone at least when described spicule and be in any warpage or fracture under the load.
But, determined because the load ability to bear of the rigidity porous material of this enhancing mainly is the semi-finished product framework by spicule of being introduced or the pultrusion introduced, so existing porous core tends to cause the increase of the density of cored structure in the mode of not expecting.In addition normally, the porous material structure of gaining in strength only is included in the very little zone of rubber-like under the load, and common like this tending to caused damage plasticity and permanent to composite.At last, the sandwich structure with the porous material that increases rigidity can't be ventilated and draining, because the space between the cover layer is filled up by the rigidity porous material fully.
For example from WO 2004/022869 A2 and WO 03/101721 A1, become known for making the method for three dimensional network structure, in described method, at first generate the metal grill structure, by means of bed die and corresponding mold with the metal grill structure to third dimension bending, thereby produce three-dimensional network.During this bending, the horizontal boundary of metal grill aperture plate does not remain on original position, because this will stop any bending that enters the third dimension.But this to utilize the bending of bed die and corresponding mold be quite inflexible, because the height that changes the angle of network and change network need be changed bed die and corresponding mold.
US 3,884, and 646 have also described a kind of manufacture method of the three dimensional network structure that uses as cored structure in sandwich structure.In the method, at first form the network on plane from metallic plate, next crooked described network once more by a forming step, makes described planar meshes lattice structure have 3D shape by means of bed die and corresponding mold.
But the three dimensional network structure of making according to above-mentioned printed publication and above-mentioned porous material strengthen the shortcoming of cored structure and uncorrelated, and the described manufacture method that is used for making three dimensional network structure is owing to having used bed die with mold and relative dumb.
Summary of the invention
Wherein, it may be noted that and a kind ofly do not using the method for making three-dimensional frame structure under the situation of the carrier material of rigidity porous material for example, wherein said frame structure about produce various grid geometry aspect have more flexibility than the manufacturing process of described use bed die and mold.
If use term " the linear semi-finished product of bar shaped " in the context of the present invention, it refers to the strip geometry that limits cross section that has of pultrusion, extrusion modling or drawing moulding, and described cross section can for example be circle, triangle, rectangle, hexagon, tubulose or some similar geometries.Semi-finished product can be made under the situation that is with or without the fortifying fibre that is used to strengthen.Semi-finished product can for example comprise: the thermoplastic of extrusion modling; (partial cross-linked) condensate, especially thermoset plastic material of pultrusion or duromer (duromer); The metal of extrusion modling or pottery, especially precursor ceramic, wherein thermoplasticity and thermoset plastic material (duromer) can comprise fortifying fibre extraly.
According to a first aspect of the invention, purpose of the present invention can realize by a kind of method that is used to make three-dimensional frame structure, in described method, in first step, makes the two-dimensional grid structure of being made by the linear semi-finished product of bar shaped.In the method, linear semi-finished product can be used as continuous material provides.In this process, arrange linear semi-finished product to form the two-dimensional grid structure, make them intersect at the place, crosspoint that is limited.For example, can arrange the linear semi-finished product of ground floor when initial, in this layer, the linear semi-finished product of each bar shaped extend in groups in mode parallel to each other.Next, to be positioned on the ground floor with the linear semi-finished product of the second layer that mode parallel to each other is extended in groups, wherein should the linearity semi-finished product arrange with different angles, make that the linear semi-finished product in two-layer intersect at the place, crosspoint that is being limited with respect to the linear semi-finished product in the ground floor.Can do not comprised uniform pattern when initial, but this is not essential by the formed network of the linear semi-finished product of bar shaped connected to one another.In further operation, the linear semi-finished product of bar shaped are interconnected at the place, crosspoint.This connection can be for example realize by the contact of the point in cross-point region heating, thereby semi-finished product are softened and bonding a little each other.In the ensuing further step relevant with this method, make the linear semi-finished product of bar shaped softening then, some is clamminess or has viscosity thereby it is become.This softening can for example the realization by the network part being applied heat along three imaginary non-cross linears.For example can be and correspondingly carry out the two-dimensional grid structure is applied heat along second group of (imaginary) non-cross linear along first group of (imaginary) non-cross linear, wherein first group of straight line and second group of straight line alternately extend each other; In other words, in all cases, second group straight line is between two straight lines of first group, and first group straight line is between two straight lines of second group.
In order next to make network have the three-dimensional structure of expectation, the middle straight line in the imaginary line that it is applied heat is introduced network with power, thereby makes network break away from its two dimensional surface distortion.Because this distortion of network, the power of being introduced is deflected into the paired tension force that acts on the semi-finished product, therefore along the intermediate hypothesis straight line that it is applied heat described network is drawn in the third dimension.The similar deep draw program of this step, not elongation of half-finished material in this program.On the contrary, thus since network distortion enter the third dimension and in the plane, shorten.At random depart from for fear of network when power is introduced, can keep the straight line of the border or the middle straight line both sides of network by mobile bearing, guarantee that like this power introduced can change or resolve into tension force in the semi-finished product according to the mode of target.
Power is being introduced in the step of network, also alternately formed the peak by adjoining land and make two-dimensional grid malformation become the three dimensional fold structure with trough.In this layout, the peak is positioned on first group the straight line, and the deepest point of trough is positioned on second group the straight line.In this article, any term that relates to peak and trough relates to the viewgraph of cross-section of the three dimensional fold structure that is produced, and wherein the peak of foldable structure and trough are tangible.In stereogram, when looking with respect to the network surface, peak and trough are elongated to " mountain range " or ridge and microscler " mountain valley " between them.In this layout, peak and trough are to produce as follows: promptly in the linearity region of two groups of straight lines, alternately power is introduced network on the direction that will produce spikes/low-points.By on the direction of the spikes/low-points that will produce, power being introduced, make the two-dimensional grid structure from plane deformation, so the straight line in two groups of straight lines produce the above-mentioned mountain range that has the mountain valley therebetween.Owing to be applied to the power on the semi-finished product of network, the two-dimensional grid structure from plane deformation, therefore produces peak and trough according to desired mode along the straight line of two straight line groups.Should be pointed out that any relating to " along " straight line introduces network with power and means that all the mode with approximate vertical is applied to network with power, described power distributes along straight line.
In order aspect required time, to implement this method in optimized mode, can carry out in continuous continuous productive process and connect the linear semi-finished product of bar shaped, the linear semi-finished product of softening bar shaped at crosspoint place and power is introduced, wherein above-mentioned steps is repeating, is implementing in the continuous program that producer upwards carries out.Especially, if it will be favourable carrying out the linear half-finished connection of bar shaped when described product is softened, because since this softening these products are become some is clamminess, promptly have viscosity a little, thereby make semi-finished product stacked on top of each other be easy to be bonded to each other together.Certainly, linear half-finished softening must the occurring in the zone of tie point of bar shaped, thus the linear semi-finished product of bar shaped are connected to each other in these zones.The production routine of this continuous repetition be characterised in that producer to, in continuous program, heat is applied to another imaginary line of network, and applies power along these straight lines in order to make the network distortion.
In order further to optimize fabrication schedule, when when three non-cross linears apply heat to network, carrying out applying of power.Because applying of this heat can make network along above-mentioned straight line generation plastic deformation according to the mode of target owing to the introducing of power.
Because relate to the reason of statics and structure, if the crosspoint of the linear semi-finished product of bar shaped on the third dimension forms the external boundary of the three-dimensional frame structure that will produce, then the hope that applies of heat is carried out in such a way: promptly heat always is applied to simultaneously and is positioned at about the crosspoint of producer on vertical direction.These are positioned at about the crosspoint of producer on vertical direction is the crosspoints of the different linear semi-finished product of network in the vicinity of this place's intersection.Because always along on network, its middle straight line that applies in three straight lines of heat being introduced power in the network, because the introducing of power and owing to the distortion of network is exerted all one's strength and is deflected into the paired tension force that acts on the semi-finished product, therefore the crosspoint that has been applied in heat is drawn into the third dimension of expectation, so utilize described crosspoint to form the external boundary of three-dimensional frame structure in the third dimension.
As mentioned above, heat is applied to simultaneously be positioned at perpendicular to producer to direction on the crosspoint during, can connect the linear semi-finished product of bar shaped at crosspoint place.Be favourable like this, especially be heat to be applied to simultaneously be positioned at about producer under the situation in the crosspoint on the vertical direction applying of heat, because the linear semi-finished product deliquescing in the zone in crosspoint in this mode in each layer, and because their contact---and if applicable because the applying of corresponding power (for example gravity)---and be connected to each other.
According to special aspects of the present invention, can produce the three dimensional fold structure as follows: promptly in program continuous and that repeat, next, along every second imaginary line that it is applied heat power is introduced network, described power is drawn in semi-finished product the degree of depth of the expectation of the third dimension.In this program, the plane of network deforms, and makes to its two straight lines of middle straight line both sides that apply heat planar close to each otherly, so produces foldable structure, and described foldable structure has the concertina shape when from cross-sectional view.Certainly also may on the positive direction of the third dimension, make network stressed along every second straight line that it is applied heat, and also stressed on the negative direction of the third dimension to its each the first, the 3rd, the 5th isoline that applies heat, the zigzag foldable structure of wherein same generation.
When comparing with the known method of the forming tool that uses bed die and mold, the method according to this invention is very flexibly, owing to along the straight line that it is applied heat power is introduced, can be produced the three-dimensional frame structure of any desired special thickness or intensity.For example, power and heat can be applied to semi-finished product, wherein, depend on that seamed edge enters into the degree of depth of the third dimension, can produce the frame structure of different-thickness by means of the removable seamed edge that enters the third dimension and can heat.Therefore, for example the thickness of three-dimensional frame structure can constantly change, and is moved in the third dimension in various degree as long as will be in the seamed edge at the diverse location place of network in order to make network distortion.
In order to guarantee of the reliable connection of the linear semi-finished product of bar shaped at the place, crosspoint, along be positioned at about producer to the crosspoint on the vertical direction apply be used for the linear half-finished heat of softening bar shaped during power can be introduced, thereby in the zone in crosspoint, the pressurized material that occurs small size on linear semi-finished product, this can be so that improve half-finished foldability in these positions as positive effect.
In the superincumbent paragraph, described a kind of method that is used to make three-dimensional frame structure, wherein in general, the two-dimensional grid structure is along it and folding straight line does not intersect.But, can certainly apply heat to network along parallel (imaginary) straight line, and power be introduced network at above-mentioned straight line place in order to produce the three dimensional network structure of rule as far as possible.
In order to make the two-dimensional grid structure, in further step,, on the direction of the shaping that produces on subsequently will direction the preform pit is impressed in the semi-finished product in the third dimension along the straight line that it is applied heat easily to third dimension distortion.The impression of preform pit can carry out in the independent step fully by means of the prismatic coining tool that is provided for this purpose specially; As a kind of of this substituted, the preform pit also can be stamped in the semi-finished product by means of removable and heatable seamed edge.Because the linear semi-finished product of the bar shaped in each layer intersect at the place, crosspoint, thereby the material thickness in these positions is similar to and doubles, by impression preform pit in cross-point region, these thickenings can be reduced or under the half-finished situation of thermoplasticity even can be eliminated fully.Especially, under the half-finished situation of thermoplasticity, also can use the welding method that is used to connect.
For the power that increases the three-dimensional frame structure of producing is by this way refused resistance, make described frame structure aspect flexural deformation, be difficult for reacting, in further relevant step, cover layer can be attached at least one side of the space frame structure that---for example being glued at---produced, make the distal-most end adjacency that is drawn into the third dimension of respective side of cover layer and frame structure with this method.Therefore, these cover layers absorb owing to apply compression stress and the tension force that bending force is refused to produce, thereby when being subjected to bending force and refusing, three-dimensional frame structure itself can not be out of shape, or is slight deformation.In order to make these cover layers be difficult for being affected for shear-type load or for the relevant detrusion of three-dimensional frame structure, and especially in order to increase the shear-type load that to be transmitted, except above-mentioned attached, cover layer can be sewn onto the distal-most end of the respective side of frame structure by the stitching program, wherein can use a latasuture to close method especially.Substitute as a kind of, cover layer also can be fixed to frame structure by the following method: promptly the tooth of location comb passes frame structure and is pressed in the cover layer along its distal-most end, wherein finally is fixed in the cover layer owing to resin solidification makes described tooth.
As shown in superincumbent paragraph, utilization is according to the method that is used to make three-dimensional frame structure of the present invention, when when utilizing the rigidity porous material to compare as the design of cored structure, because not needing in the method according to the invention provides this rigidity porous material, so can realize reducing of cored structure density.In addition, utilize the method according to this invention can produce cancelled structure, it is characterized in that described structure helps discharging, promptly can easily ventilate and draining.In addition, because the design of the exposed throughout type of structure undoubtedly can utilize artificial passage to place cable and can not cause any problem that jeopardizes described construction machine integrality by this structure.
When comparing with the cored structure of using the rigidity porous material, utilize the three-dimensional frame structure of the method according to this invention manufacturing further to have the characteristics that to carry out strain in a big way, do not damage thereby do not exist plastic deformation to damage or only stay very little plastic deformation.But when being subjected to excessive load, single of folding linear semi-finished product form can flexiblely sink, and can realize improved anti-damageability thus.
Because in the method according to the invention, can use the geometry of the qualification cross section (triangle, quadrangle, hexagon, hollow, tubulose, circle) of pultrusion, extrusion modling or continuous drawing moulding, so structural engineer or designer can further select to change single warpage performance of three-dimensional frame structure, thereby by the selection that target is arranged to the frame geometry that limits, the characteristic of cored structure can be improved according to the mode of target.
Owing to can in continuous continuous productive process, implement this method,, and, can realize the formation on inclined-plane, the density of three-dimensional frame structure and the difference of thickness by changing the angle in network by the speed that changes extruding or pull out.
Because make the two-dimensional grid structure when the third dimension is folding, not have bed die and the mold device that uses as known in the art, so can improve the flexibility of program, this is because when using bed die and mold, for essential bed die and the mold changed of the height that changes folding angle and structure.Utilize the method according to this invention, the change of this folding angle and structure height can utilize heatable seamed edge to realize, described seamed edge can be moved toward the third dimension and described seamed edge can be moved to the different degree of depth in the third dimension.
Description of drawings
Below, explain the present invention with reference to the accompanying drawings in further detail.What should emphasize is that the accompanying drawing that is provided only is the purpose that is used for the illustrated example embodiment, and should not be construed as any type of restriction to protection domain.Illustrate below:
Fig. 1 shows the two-dimensional grid structure of being made by the linear semi-finished product of bar shaped;
Fig. 2 has explained the preform pit has been impressed in the semi-finished product;
Fig. 3 has illustrated that thereby power is introduced network draws in the third dimension with network;
Fig. 4 shows the final products of three-dimensional support frame structure; And
Fig. 5 has explained cover layer has been placed on the three-dimensional frame structure.
Run through institute's drawings attached, identical Reference numeral is used for same or corresponding elements.
The specific embodiment
Fig. 1 shows two-dimensional grid structure 1, and in the illustrative embodiments shown in the diagram, it is made by two groups of linear semi-finished product 2, wherein, at first arranges first group 2, makes described semi-finished product extend in parallel in ground floor and is spaced apart from each other.Next the linear semi-finished product 3 of second group 3 bar shaped are arranged on the ground floor, make and extend in mode parallel to each other and that be spaced apart from each other in second group the second layer of the linear semi-finished product 3 of each bar shaped on ground floor 2.Owing to the linear half-finished this arrangements of first group 2 and second groups 3 bar shapeds generate two-dimensional grid structure 1, the linear semi-finished product of each bar shaped in wherein two-layer intersect at 4 places, crosspoint that limit.
Linear semi-finished product can for example comprise: the thermoplastic of pultrusion (partial cross-linked) thermoset plastic material, extrusion modling, the metal or the pottery of continuous drawing moulding---precursor ceramic especially, wherein can use different cross-sectional geometry.
Shape for fixing network of producing by this way, so that for ensuing forming step, 4 places interconnect the linear semi-finished product of two-layer 2,3 bar shaped in the crosspoint, for example, by applying heat and carrying out above-mentioned connection by applying corresponding power if applicable along straight line 5,6 shown in dotted lines in Figure 1.In this layout, this be connected producer on 7 can be link up with orderly.In this program, make progress at producer, make consistently in the crosspoint 4 of extending on 7 vertical straight lines 5,6 about producer basically and heated simultaneously.Owing to applied heat, linear semi-finished product are heated at 4 places a little in the crosspoint, are clamminess a little thereby they are become, and promptly have viscosity, and therefore interconnect.
In further relevant step with this method, next can make linear semi-finished product 2,3 deliquescing of the bar shaped along three non-cross linears 5,6 in the group, also can for example, network 1 part realize by being applied heat.Because connect the linear half-finished program of bar shaped at 4 places, crosspoint has been to apply under the situation of heat to carry out, so in a step, be favourable in conjunction with connection and the linear semi-finished product of softening bar shaped simultaneously, thereby correspondingly make network 1 softening along three straight lines shown in dotted lines in Figure 1, described straight line is interconnected on about producer to 7 vertical upwardly extending crosspoints 4, side.
In order in the deforming step of back, to be convenient to the shaping of network 1 in the third dimension, as shown in Figure 2, in intermediate steps, can in semi-finished product 2,3, impress the preform pit.Shown in the diagram among Fig. 2, in network 1, impress small rut, the direction that its pits 9 is extended is the direction that network 1 subsequently is drawn in the three-dimensional to be entered.In this layout, pit 9 is arranged on the aforesaid straight line 5,6 equably, thereby along described straight line 5,6 heat is applied to network 1 the linear semi-finished product 2,3 of bar shaped is softened.Because the softening of the linear semi-finished product 2,3 of bar shaped preferably carries out in such a way: be about to the zone that heat is applied to the crosspoint 4 of these semi-finished product 2,3, because the above-mentioned preform pit 9 of impression can obtain following situation: promptly can reduce the thickening of the material in the zone in crosspoint 4, perhaps can eliminate the thickening of the material in the zone in crosspoint 4 fully under the half-finished situation of thermoplasticity.
As shown in Figure 3, in the relevant step of further this method, network 1 is introduced with power F in one of centre in three imaginary lines that it applied heat, wherein the power F of Yin Ruing causes network 1 to be out of shape in third dimension degree, cause the power F of this introducing to be deflected to paired power like this, as as shown in the intermediateness of Fig. 3, promptly act on tension force F ' and F on the semi-finished product ".In independent parallelogram of forces shown in Figure 3, this force resolution or this deflection have been explained with the mode of chart.In this mode, so tension force is introduced semi-finished product, along the middle straight line that it is applied heat, described tension force is drawn in the third dimension with network.
As among Fig. 3 further shown in, along expectation straight line 5,6---it will represent the distal-most end of three-dimensional frame structure subsequently, network is sandwiched between pair stringers 10, two stringers 10 can be realized three kinds of functions simultaneously.So, make these pairs stringer 10 can be fit to be heated and be fit to be moved in the third dimension.In this mode, the linear semi-finished product 2,3 of the bar shaped of each layer of network 1 can utilize two stringers 10 and interconnect, and the described pair of stringer 10 that provides acts on network 1 along adjacent crosspoint 4.By heating two stringers 10, then heat is put on network 1 or crosspoint 4, so linear semi-finished product of bar shaped 2,3 are softened and interconnect in these positions.In the crosspoint 4 places connect the effect of the linear semi-finished product 2,3 of bar shaped can be supported extraly because two stringer 10 is against being pressed together each other, therefore in a kind of favourable mode, can reduce 4 places in the crosspoint material do not wish the part that thickens.In addition, by two stringers 10 are forced together, on the direction of the shaping that can produce on subsequently will direction preform pit 9 is stamped in the semi-finished product, can be convenient to like this because power is introduced the shaping of being carried out in the network 1 in the third dimension.In order finally network to be drawn in the third dimension, along power being introduced network by means of seamed edge 8, two stringer 10 to its one of centre that applies in three straight lines 5,6 of heat, thereby as shown in Figure 3, because above-mentioned force resolution makes network 1 distortion enter the third dimension.In order in the process of force resolution, can on half-finished direction, in fact to produce tension force F ' and the F that is limited ", two stringers 10 are clamped network firmly along two straight lines 5.But indicated as the arrow among Fig. 3 in this layout, two stringers 10 can be moved in the plane of network 1, thereby owing to apply power F, make two stringers 10 move towards the direction of middle straight line 6, perhaps are pulled on described direction.In this program, the reaction force that two stringers 10 produce for displacement, thereby can generate tension force F ' and F according to the mode of target ".
As what set forth in the top explanation, utilize removable and heatable pair of stringer arrangement 10 can in common step, be implemented in 4 places, crosspoint and be connected linear semi-finished product, the linear semi-finished product 2,3 of softening bar shaped and introducing power, when along producer when 7 observe, wherein above-mentioned step can be carried out consistently and in the program that repeats continuously.
The method according to this invention, wherein network is introduced with power F in one of the centre in three straight lines 5,6 that it applied heat, and its feature is that especially it has flexibility with respect to the deformation program of using bed die and mold.Therefore, utilize the method according to this invention, can make the three-dimensional frame structure that changes density and thickness because two stringers can be arranged 10 or seamed edge 8 move to different depth in the third dimension because described program makes the thickness that can have influence on three-dimensional frame structure.Therefore no longer need intricately replacing bed die and mold device so that make the three-dimensional frame structure of different depth.
Fig. 4 shows and utilizes three-dimensional frame structure made according to the method for the present invention.By the distortion of two-dimensional grid structure 1 shown in Figure 1, can generate the stereoscopic grid structure of the periodicity repetition that comprises a plurality of rectangular pyramids.In this layout, the top of pyramid is formed by the former crosspoint 4 that is used as in the two-dimensional grid structure 1, owing to applying heat along adjacent crosspoint 4 and power being introduced, so form the distal-most end that defines three-dimensional frame structure on the side direction after deformation procedure.For illustrative purposes, Fig. 4 shows three straight lines 5,6 once more, along described straight line, original two-dimentional frame structure 1 applies temperature by the part and 4 places are softened in the crosspoint, so that power is introduced under the effect of network in one of centre in the straight line that it is applied heat, two-dimensional grid structure 1 is drawn in the third dimension.
At last, Fig. 5 has described the optional step relevant with this method, wherein applies cover layer 11 in two sides of the three-dimensional frame structure that is produced, thereby cover layer 11 is supported by the point that the pyramid top is produced.For cover layer 11 is attached to three-dimensional frame structure, cover layer can be glued to the top of pyramid.But, because the gluing of surfaces on pyramid top is very little, shown in the suture of pointing out by summary among Fig. 5 12, can extraly cover layer 11 be sewn on the distal-most end of three-dimensional frame structure of pyramid top form, wherein preferably use a latasuture to close method.
In addition, should be pointed out that " comprising " do not get rid of other element or step, and " one " or " in one " does not get rid of a plurality of situations.In addition, should be pointed out that with reference to described feature in the top illustrative embodiments or step and also can be used in combination with further feature or the step in above-mentioned other illustrative embodiments.Reference numeral in the claim should not be interpreted as playing the effect of restriction.
Reference numerals list
1 network (two dimension)
The linear semi-finished product (first group, ground floor) of 2 bar shapeds
The linear semi-finished product (second group, the second layer) of 3 bar shapeds
4 crosspoints
5 straight lines (first group)
6 straight lines (second group)
7 producers to
8 seamed edges (removable, as can to heat)
9 preform pits
10 pairs of stringers
11 cover layers
12 sutures

Claims (15)

1. a method that is used to make three-dimensional frame structure comprises the steps:
-produce two-dimensional grid structure (1) by the linear semi-finished product of bar shaped (2,3), locate to intersect in the crosspoint (4) that limits at semi-finished product (2,3) described in the described network (1);
-locate to connect the linear semi-finished product (2,3) of described bar shaped in described crosspoint (4);
-by along three non-cross linears (5,6) described network part being applied heat in all cases, make the linear semi-finished product of described bar shaped (2,3) softening;
Described network (1) is introduced with power (F) in-one of centre in the described straight line (5,6) that it is applied heat,
Wherein because the distortion of described network (1), the power of described introducing (F) be deflected into the paired tension force that acts on the described semi-finished product (2,3) (F ', F "); therefore straight line (5,6) is drawn in the third dimension with described network (1) in the middle of it is applied heat described.
2. the method for claim 1, wherein can in continuous continuous productive process, carry out in described crosspoint (4) and locate to connect the linear semi-finished product (2 of described bar shaped, 3), the linear semi-finished product (2 of softening described bar shaped, 3) and with power introduce, above-mentioned steps is to implement in the program of the continuous repetition that producer carries out on (7) in continuous continuous productive process.
3. method as claimed in claim 1 or 2 is wherein when described network (1) being carried out the introducing of power when applying heat along described three non-cross linears (5,6).
4. each described method in the claim is as described above wherein carried out applying of heat, makes heat be applied to simultaneously to be positioned at about the described crosspoint (4) of described producer on (7) vertical direction.
5. method as claimed in claim 4, wherein in that being applied to simultaneously, heat is positioned at perpendicular to described producer during the described crosspoint (4) on the direction of (7) and owing to heat is applied to simultaneously is positioned at perpendicular to the described crosspoint (4) of described producer on the direction of (7), carry out locating to connect the linear semi-finished product (2,3) of described bar shaped in described crosspoint (4).
6. each described method in the claim as described above, wherein in the program that repeats continuously, next along every second straight line (5 that it is applied heat, 6) power is introduced described network (1), described power is drawn in desired depth in the described third dimension with described semi-finished product, therefore generates the three dimensional fold structure.
7. each described method in the claim as described above wherein is applied to described semi-finished product (2,3) by means of the seamed edge that can move into the described third dimension and can heat (8) with power and heat.
8. method as claimed in claim 7, wherein with described edge (8) thus move to the different-thickness that different depth in the described third dimension generates described frame structure.
9. as each described method in the claim 4 to 8, wherein be used for softening the linear semi-finished product (2 of described bar shaped applying heat along being positioned at about the described crosspoint (4) of described producer on (7) vertical direction, 3) during power is introduced, therefore carry out locating to connect the linear semi-finished product (2,3) of described bar shaped in described crosspoint (4).
10. each described method in the claim as described above wherein carries out the heat of described network (1) is applied along parallel lines (5,6).
11. each described method in the claim as described above comprises further step:
-along the described straight line (5,6) that it is applied heat, on the direction of the shaping that produces on subsequently will direction preform pit (9) is impressed in the described semi-finished product (2,3) in the third dimension.
12. each described method in the claim as described above comprises further step:
-cover layer (11) is attached at least one side of the three-dimensional frame structure of being produced, make the distal-most end adjacency that is drawn into the described third dimension of respective side of described cover layer (11) and described frame structure.
13. the method for claim 1 is wherein closed the distal-most end that method (12) is attached to cover layer the respective side of described frame structure by a latasuture.
14. a support frame structure that is used for sandwich structure, wherein said support frame structure is made according to a described method in the claim 1 to 13.
15. an aircraft that comprises the structure member of sandwich structure form, the cored structure of described sandwich structure utilize in the claim 1 to 13 each described method to make.
CN2007800062970A 2006-02-24 2007-02-22 Method for manufacturing a three dimensional frame structure for use as a core structure in a sandwich construction and frame structure manufactured thereby Expired - Fee Related CN101389423B (en)

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US77652406P 2006-02-24 2006-02-24
US60/776,524 2006-02-24
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DE102006008728A DE102006008728B3 (en) 2006-02-24 2006-02-24 Producing a three-dimensional framework useful for making structural components of aircraft comprises applying heat and force to a two-dimensional lattice of rods
PCT/EP2007/001549 WO2007096172A1 (en) 2006-02-24 2007-02-22 Method for manufacturing a three dimensional frame structure for use as a core structure in a sandwich construction and frame structure manufactured thereby

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DE102006008728B3 (en) 2007-07-19
JP2009527379A (en) 2009-07-30

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