CN101678599A - 用于从夹层结构制造具有增强拐角的物体的方法以及这类物体 - Google Patents

用于从夹层结构制造具有增强拐角的物体的方法以及这类物体 Download PDF

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CN101678599A
CN101678599A CN200880017175A CN200880017175A CN101678599A CN 101678599 A CN101678599 A CN 101678599A CN 200880017175 A CN200880017175 A CN 200880017175A CN 200880017175 A CN200880017175 A CN 200880017175A CN 101678599 A CN101678599 A CN 101678599A
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sandwich
layer
fibre
thermoplastic
cover layers
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CN101678599B (zh
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M·T·德格路特
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Fits Holding BV
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Fits Holding BV
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • B29C53/06—Forming folding lines by pressing or scoring
    • B29C53/063—Forming folding lines by pressing or scoring combined with folding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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    • B29C66/43421—Joining substantially flat articles for forming corner connections, e.g. for making V-shaped pieces with a right angle, e.g. for making L-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种用于在由夹层结构制成的物体中制造并且增强拐角的方法，该夹层结构包括一个热塑性芯层(18)，该芯层被安排在两个覆盖层(16)之间，这两个覆盖层中的至少一个是塑性覆盖层，该方法包括以下步骤：生产一个物体，该物体在两个物体部分之间包括一个拐角；在该拐角中安置一个热塑性芯部件(24)以及一个附加的纤维增强热塑性层(26)，该热塑性芯部件具有与该拐角相适配的形状，其方式为使附加的纤维增强热塑性层(26)基本上覆盖芯部件(24)的暴露表面；并且将该夹层结构的一个覆盖层(16)连接到附加的纤维增强热塑性层(26)。

Description

用于从夹层结构制造具有增强拐角的物体的方法以及这类物体
技术领域
根据一个第一方面，本发明涉及一种用于在由夹层结构制成的物体中制造并且增强拐角的方法，该夹层结构包括一个芯层(core layer)，该芯层被安排在两个覆盖层之间，这两个覆盖层中的至少一个是塑性(plastic)覆盖层。
背景技术
在本领域中已知一种用于从热塑性夹层结构制造包括成角的物体部分的物体的方法。例如，欧洲专利431,669披露了一种用于从热塑性夹层材料制造物体的方法，其中至少两个表面或物体部分的法线彼此成一个角。这种已知的方法包括至少以下步骤：借助一个压模(die)使热塑性夹层材料的表面之一的一部分在一段距离上软化，该距离至少对应于这两个表面之间的拐角的一个假想的折线的长度，其中该压模至少部分地被压入热塑性夹层材料的顶层之中，并沿着(about)该折线折叠热塑性材料的这两个表面，其方式为使已经软化的表面因此而位于该拐角的内侧上。
这种方法产生了具有彼此成角的两个表面的物体，其中夹层材料变软的顶层的盈余材料存在于该拐角的内侧上，并且融入折叠位置中的芯的泡沫(foam)之中。这避免了盈余材料向外突出，并且因此确保能够获得一个令人满意的折痕或拐角。
本领域已知的这种物体的一个缺点是由于折叠的纤维增强顶层而产生的它在拐角位置的低强度。尤其是，拐角外侧的装紧强度(impact strength)以及拐角的刚度(stiffness)和/或强度(strength)有待改进。
一般地，对基于带有热固性覆盖层的热固性芯层的夹层结构——如蜂窝板(honeycomb panel)，在有待形成拐角的位置处的覆盖层以及，如果希望的话，蜂窝状结构被除去，该蜂窝状结构填充有灌注复合物(potting compound)，并且在弯折操作之后留存的灌注复合物被除去，此后使该构件硬化。这种填充操作不但导致了重量的显著增加(虽然这种夹层结构实际上是要用于轻重量应用)，而且仅是略微地增加了(局部的)刚度和强度。
此外，当使夹层结构彼此接合(join)时，经常使用铝挤压部件并且/或者从该夹层板局部地铣削掉(mill off)一些条带(strip)，在其中放入有待与该夹层板连接的夹层板的首端(head end)。上述接合导致了重量的显著增加或强度和刚度的相当大的局部降低。
发明内容
本发明的一个目的是减少上述的缺点和/或提供一种替代性方法。
为此，根据本发明的用于在由夹层结构——该夹层结构包括一个芯层，该芯层被安排在两个覆盖层之间，这两个覆盖层中的至少一个是由塑性材料(plastic)制成的覆盖层——制成的物体中制造并且增强拐角的方法包括以下步骤：
●产生一个物体，该物体包括在两个物体部分之间的一个拐角；
●在该拐角中放置一个热塑性芯部件以及一个附加的纤维增强热塑性层，该热塑性芯部件具有与该拐角相适配的形状，其方式为使该附加的纤维增强热塑性层基本上覆盖该芯部件的暴露表面；并且
●将该夹层结构的一个覆盖层连接到该附加的纤维增强热塑性层。
通过根据本发明的方法，首先由夹层结构形成一个在其两个物体部分之间具有拐角的物体。该夹层结构包括一个芯层，该芯层在两个主表面都具有一个覆盖层。优选地，该芯层是由热塑性材料制成的，更优选地是由热塑性泡沫制成的。这些覆盖层之一是塑性覆盖层，优选地是纤维增强覆盖层，极优选地是纤维增强热塑性覆盖层。更优选地，两个覆盖层都是纤维增强热塑性覆盖层。这些物体部分可以是两个分立的部件，这两个部件彼此毗邻(abut)并且围成一个角。这些物体部分还可以彼此连接，例如根据欧洲专利431,669的成角板(angled panel)的情况。根据本发明，通过在该拐角中放置一个具有与该拐角相适配的形状的热塑性芯部件来增强该拐角。“与拐角相适配的形状”这种表述旨在说明该芯部件的对应表面部分基本上抵靠(bear against)这些物体部分的对应表面部分。
该芯部件的暴露侧(不与这些物体部分接触的表面，或以另一种方式表述，远离这些物体部分的覆盖层的表面)可以具有任何适当的形状并且配备有一个附加的纤维增强热塑性层。可以分立地施用该附加的纤维增强热塑性层。优选地，这个层被连接到芯部件。连接有作为覆盖层的纤维增强热塑性层的芯部件在下文中也被称为增强元件。随后该附加的纤维增强热塑性层被连接到这些物体部分的对应覆盖层。有利的是，该附加的纤维增强热塑性层在一定的距离上重叠在该覆盖层上。该附加的纤维增强热塑性层的存在，以及其与这些围成角的物体部分的覆盖层的连接，增强了该拐角。尤其是，该拐角的强度以及刚度得到增加。有利的是，该附加的纤维增强热塑性层被连接到这些物体部分的塑性覆盖层上。在热塑性覆盖层的情况下，该附加的热塑性层借助热和压力，例如通过压制或焊接，或借助粘合剂，可以很容易地被连接。材料的加入，尤其是该附加的纤维增强热塑性层的加入，以及这些层的彼此连接，导致了拐角的增强，同时保持了该夹层结构的有利的重量特性。
有利的是，这些物体部分的塑性覆盖层、更优选的是纤维增强覆盖层、极优选的是纤维增强热塑性覆盖层，界定了该拐角的内侧，并且该附加的纤维增强热塑性层被连接到这个覆盖层。如果该覆盖层也包括热塑性材料，那么通过简单地将这些热塑性物质融合在一起就可以实现这种连接。
本发明使用夹层结构作为起始材料，该夹层结构包括一个芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层。有利的是，该夹层结构包括一个非致密的(non-solid)热塑性芯层。优选地，为了重量、强度以及可变形能力起见，该芯层是热塑性泡沫芯层。这也适用于所述芯部件。如以上已经提到的，该芯层极优选地是处于两个纤维增强热塑性覆盖层之间。该夹层结构可以有利地是板的形状，换言之，表面尺寸(长度和宽度)相对于厚度而言是大的。该夹层结构还可以是条带形状，通过本发明，该条带变成杆形结构元件形式的、增强的角形部件。
优选地，在本发明中所使用的这些夹层结构以及增强元件是通过原位发泡(in-situ foaming)生产的，例如从EP-A1-0 636 463中得知的。这种板形式的夹层结构是由被两个覆盖层所覆盖的一个发泡式芯层构成的，至少一个覆盖层包括一种或多种(纤维增强)热塑性材料。该原位发泡过程由不同的步骤构成。第一个步骤是一个组装步骤，其中，一个芯板(core web)，其包括至少一个由热塑性材料——该材料包含一定量的适当的发泡剂——制成的薄膜，被置于例如两个(纤维增强)覆盖层之间，这些覆盖层通常由与该芯板相同的热塑性材料制成。随后，由芯板和覆盖层构成的构件(unit)被安排在加压机(press)中的两个压板(press plate)之间。在此位置，进行一个发泡步骤，其中热量和压力经由该加压机施加于该构件，这样该芯板开始发泡，并且同时被连接到该覆盖层或多个覆盖层。在这个发泡步骤中，当温度已经变得足够高时，加压机被慢慢地打开，其结果是这两个压板之间的距离增加。这允许发泡剂(blowing agent)(溶胀剂(swelling agent)、溶剂(solvent)、惰性气体或其组合物)膨胀，其结果是芯板的材料开始发泡。这种膨胀通常在受控的条件下进行。以此方式，该芯板发泡，并且在单个生产步骤中实现了该芯板与该覆盖层或多个覆盖层之间的连接，而无需分立的或附加的粘合剂。如果该发泡芯板已经达到了预定厚度，那么允许该构件在一个冷却步骤中冷却下来。以此方式获得的产品包括被两个覆盖层所覆盖并且被连接到其上的发泡芯板。此外，通常进行一个干燥步骤。
用于包括热塑性泡沫的芯层的溶胀剂的实例包括：丙酮、甲基乙基酮、乙酸甲酯、丙酸甲酯、硝基乙烷、环己烷、醚、乙醇、甲醇和戊烷，以及混合物如乙醇/丙酮以及甲醇/乙酸甲酯。丙酮是一种优选的溶胀剂。适合于该芯层以及该纤维增强覆盖层基体(matrix)的热塑性物质的实例包括：聚醚酰亚胺(PEI)、聚醚砜(PES)、聚砜(PSU)、聚苯砜(PPSU)、聚酮如聚醚醚酮(PEEK)、液晶聚合物、聚碳酸酯(PC)、丙烯(PP)、聚氯乙烯(PVC)、聚乙烯(PE)等，以及其组合物。聚醚酰亚胺是一种优选的热塑性物质，从通用电气(General Electric)可获得商品名Ultem下不同等级的该物质。玻璃纤维是优选的增强手段。也可以以相同的方式使用其他无机纤维如金属纤维、炭纤维，以及有机纤维如芳纶和聚丙烯纤维，条件是它们可以被变形到足够的程度并且可以承受变形所需要的温度。除以上的合成纤维以外，还有可能使用天然纤维。这些纤维可以以毡片(mat)、织物(fabric)、短切纤维(choppedfibre)以及类似物的形式来使用。还可以有利地使用纤维方向已经被适配为适合于预期用途的方向纤维，尤其是单向纤维。如果希望的话，可以用上述类型的纤维或用纳米颗粒来增强该芯层以及该芯部件的材料，优选地是泡沫芯。优选地，该芯层和/或该芯部件的热塑性材料与覆盖层中的热塑性材料相同。然而，也可以使用不同的热塑性物质的组合。其适当的实例包括但不限于：被由PPSU、PS、PEEK或PC制成的覆盖层所覆盖的PEI泡沫、被由PSU(聚砜)或PC制成的覆盖层所覆盖的PES或PPSU泡沫、以及被由聚酰胺如尼龙制成的覆盖层所覆盖的PP泡沫。
以上的实例类似地适用于可以存在的任何附加的增强层。这些附加的增强层可以用作加固层或用作预浸料(prepreg)，所述加固层或预浸料本身可以由彼此叠放的几个层(层片(ply))构成。
如果希望的话，该芯层还可以由可以被中间层分隔的几个层组成，该中间层例如是可选地纤维增强的(热塑性)层、陶瓷层或金属层。
用于制造包括一个芯层以及至少一个纤维增强热塑性覆盖层的构件的其他方法包括但不限于：将热塑性泡沫挤到一个纤维增强热塑性覆盖层上，优选地挤到两个这样的覆盖层之间，以及将(热塑性)泡沫粘到一个纤维增强热塑性覆盖层上。所使用的粘合剂应该能够承受变形所需要的温度。
根据本发明的一个特别优选的实施方案，该方法包括以下步骤：
a)在一个夹层结构的两个部分之间产生一个拐角，该夹层结构包括一个芯层，优选地是热塑性芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层、优选地是纤维增强覆盖层、更优选地是纤维增强热塑性覆盖层，其方式为使该拐角位置处的夹层结构中形成一个凹陷，该凹陷具有预定形状；
b)用一个增强元件填充该凹陷，该增强元件包括一个热塑性芯部件以及至少一个纤维增强热塑性覆盖层，该芯部件具有一个具有与该凹陷的预定形状互补的形状的侧面；并且
c)将该增强元件的纤维增强热塑性覆盖层连接到该夹层结构的一个覆盖层、优选地是纤维增强覆盖层、尤其是纤维增强热塑性覆盖层。
通过根据本发明的方法的这个优选实施方案，在一个夹层板中产生了一个拐角，并且同时在该拐角位置产生了一个凹陷。为此目的，在热塑性覆盖层的情况下可以使用例如一个热压模(hot die)，该热压模使对应的覆盖层变形，并且局部地压缩该芯层的材料以形成一个更紧密的层。如果必要的话，可以例如通过切削(cutting)、铣削(milling)或锯切(sawing)来预先断开对应的覆盖层。有利的是，该凹陷延伸至该纤维增强热塑性覆盖层。随后，用一个增强元件来填充以此方式形成的凹陷。该增强元件的一个侧面(即表面部分)安装在该凹陷之中。为了进一步增强该拐角，可以在这个侧面与界定了该凹陷的夹层结构的底部和壁之间(如果希望的话，首端除外)提供一个另外的附加的纤维增强热塑性层。然后，使用上述连接技术之一种或多种，如压制、(感应)焊接或粘合，将这个另外的附加的纤维增强热塑性层连接到该夹层结构的一个覆盖层、极优选的是纤维增强热塑性覆盖层。该增强元件的附加的纤维增强热塑性层还连接到界定了该凹陷的覆盖层。该凹陷可以被提供在有待形成的拐角的外侧和内侧上。有利的是，成品中的该附加的纤维增强热塑性覆盖层从该夹层结构的一个表面上的(纤维增强热塑性)覆盖层延伸到相对的(opposite)表面处的另一个覆盖层。这改进了(弯折)刚度。在一个增强元件中，该附加的纤维增强热塑性层被预先施用到其芯部件的对应侧上。应当理解，也有可能使用分立的热塑性芯部件以及分立的附加的纤维增强热塑性层。
该增强元件的一个优选实施方案具有狭长的形状(elongate shape)，该形状的纵向侧面包括一个纤维增强热塑性覆盖层。如果希望的话，首端可以配备有一个可选地纤维增强的塑性覆盖层，优选地是热塑性覆盖层。通过这个实施方案，将该附加的和该另外的附加的纤维增强热塑性覆盖层两者连接到该热塑性芯部件。
一个优选的方法、尤其是步骤a)，包括以下子步骤：
1)提供一个夹层结构，该夹层结构包括一个热塑性芯层，该芯层处于两个热塑性覆盖层之间，这两个覆盖层中的至少一个是纤维增强热塑性覆盖层；
2)在有待产生拐角的位置的夹层结构的一个覆盖层中提供一个间断；
3)折叠与该热塑性覆盖层中的间断相邻的覆盖层的边缘，其方式为使该夹层结构中产生一个凹陷；
4)弯折与所形成的凹陷相邻的夹层结构片段(section)，以便形成一个在拐角位置中具有所述凹陷的夹层结构，该凹陷具有预定形状。
通过这个优选实施方案，在该(可选地纤维增强的)热塑性覆盖层中提供一个间断，如具有与(假想的)折线对应的长度的切口(incision)，该间断处于该夹层结构的该至少一个纤维增强热塑性覆盖层的对面，有利的是处于或接近有待形成拐角的位置。此后，通过施用压力和热量，例如使用一个热压模，使切口的边缘变形。在这种情况下，界定了间断的覆盖层的边缘弯向另一个纤维增强热塑性覆盖层，并且同时该芯层被压缩。如果希望的话，一个附加的纤维增强热塑性增强层可以在该变形步骤之前被放置在该切口上，并且同时被变形。因此，形成一个凹陷，其壁至少部分地被该覆盖层的变形的边缘界定。优选地，该凹陷延伸至该纤维增强热塑性覆盖层，因此该纤维增强热塑性覆盖层形成了该凹陷的底部。此后或同时，该凹陷的侧面上的物体部分被沿着该(假想的)折线弯折以形成一个所希望的拐角。可以用以下方式完成所述弯折操作——即该凹陷的这些壁朝向彼此移动，还可以用以下方式——即该凹陷的这些壁背离彼此移动。在第一种情况下，产生了一个成角夹层板，其中该凹陷位于该拐角的内侧上。在第二种情况下，该凹陷位于该拐角的外侧上。随后，在该拐角位置处的凹陷中放置一个热塑芯部件以及至少一个纤维增强热塑性层，它们作为分立的多个部分或者作为一个一体的增强元件。后一实施方案是优选的。这样，该增强元件即安装在该凹陷之中。该增强元件例如通过焊接或粘合而被连接到夹层结构。以此方式，通过附加材料、尤其是纤维增强热塑性覆盖层，增加了该拐角的刚度/强度以及装紧强度。因此，以此方式产生的成角夹层板具有高的装紧强度以及良好的力的传递(transmission of force)，而只增加了非常小的重量。这对于飞机的手推车(trolley)、厨房(galley)以及行李箱(luggage bin)是特别重要的。
当两个分立的物体部分——每个部分在一个边缘具有一个局部的凹陷或凹口(例如，通过热变形压模而产生)——彼此成角地并且使凹陷或凹口(recess)对准地放置时，借助于被放置在这些对准的凹陷或凹口中并且被连接到这些物体部分的增强元件，可以同时实现该拐角的连接和增强。
如果希望的话，一个附加的增强轮廓(profile)——如一个纤维增强热塑性层——可以被放置在拐角的外侧上，尤其是该轮廓与该拐角作为两个分立的物体部分。这种轮廓还可以与物体部分的变形的边缘形成一个整体部分。
该芯部件的厚度(与有待被提供在其上或已经被提供在其上的纤维增强热塑性层的表面成直角测量)优选地大于最薄的物体部分的厚度，更优选地大于这两个物体部分之每一个的厚度。
在一个优选实施方案中，该增强元件具有固定边缘(securing edge)，这些固定边缘在被放置在该凹陷中之后抵靠(rest against)与该凹陷相邻的物体部分的覆盖层。有利的是，这些固定边缘是与所述纤维增强热塑性覆盖层一体的。这些边缘还可以被压制、焊接或粘合在对应的覆盖层上。有利的是，当从具有夹层结构——该夹层结构包括之间具有一个热塑性芯部件的两个纤维增强热塑性层——的一条材料来产生该增强元件时，通过将顶部以及底部纤维增强热塑性层压制和融合而形成这种固定边缘。
在两个或更多不平行的增强元件会聚的位置处，例如在一个矩形体的拐角处，可以局部地放置一个填充体，该填充体优选地由一个热塑性芯和一个纤维增强热塑性覆盖层构成，其中该热塑性覆盖层处于该芯体的暴露部分上。
例如，可以通过将一个热塑性覆盖层——例如用金属线或碳纤维增强的——压制在该增强元件的侧面上而完成焊接，所述侧面因此而抵靠(lieagainst)该凹陷的壁。例如，通过电阻焊接或感应焊接，可以在该增强元件的这个纤维增强热塑性覆盖层，和，由(纤维增强的)覆盖层材料制成的界定了凹陷的壁之间，产生一个连接。
根据另一个有利的实施方案，该方法还包括根据以下步骤制造增强元件：
a)提供一个夹层结构，该夹层结构包括一个热塑性芯部件，该芯部件处于两个覆盖层之间，这两个覆盖层中的至少一个是纤维增强热塑性覆盖层；
b)使该夹层结构的、与该纤维增强热塑性覆盖层相对的侧面变形，以形成具有至少一个周边部分(peripheral part)的一个增强元件，该周边部分具有与该凹陷的预定形状互补的形状，并配备有优选地也是纤维增强的热塑性覆盖层。
以上描述的增强元件的实施方案和细节也适用于这种情况。
本发明还涉及由夹层结构制成的、具有增强拐角的物体，该物体包括两个部分，这两个部分彼此成一个角，并且由夹层结构制成，该夹层结构包括一个芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层，其中该物体在该拐角处、在夹层结构中包括一个具有预定形状的凹陷，在该凹陷中存在一个包括热塑性芯部件的增强元件，该芯部件至少在其周边部分上具有与该凹陷的预定形状互补的形状，并且其中该暴露的表面部分配备有一个纤维增强热塑性层，并且其中该增强元件的纤维增强热塑性层被连接到该夹层结构的一个覆盖层。该物体可以是，例如，用于飞机或其他(空中)运输工具的手推车、厨房或行李箱(的一部分)。上述实施方案和细节也适用于本发明的这个方面。
本发明的一个另外的方面是，当将塑性元件——如板、尤其是热塑性板、优选地是纤维增强塑性板、极优选地是纤维增强热塑性板——彼此接合时，上述的、包括在纵向方向上的所有侧面上覆盖有纤维增强热塑性覆盖层的热塑性芯的增强元件的应用。本发明的这个方面涉及，当将多个塑性板和/或元件彼此接合时，包括在纵向表面上(以及，如果希望的话，在首端上)覆盖有纤维增强塑性覆盖层的芯部件的增强元件用于连接多个塑性板或元件并且增强该连接。
附图说明
以下将参考附图说明本发明，在附图中：
图1示出了根据本发明的方法的一个第一实施方案；
图2示出了根据本发明的方法的一个第二实施方案；
图3示出了根据本发明的方法的一个第三实施方案；
图4示出了根据本发明的方法的一个第四实施方案；
图5示出了根据本发明的方法的一个子步骤的一个实施方案；并且
图6示出了根据本发明的方法的一个子步骤的一个第二实施方案；
图7示出了本发明的另一方面；
图8示出了本发明的一个另外的方面；
图9示出了带有致密层(solid layer)的构造元件的连接的一个实施方案。
具体实施方式
图1示出了根据本发明的方法的一个第一实施方案。两个夹层板10和12彼此连接。每个板10、12具有一个夹层结构14，在这种情况下，该夹层结构包括两个纤维增强热塑性覆盖层16，在这两个覆盖层之间存在一个热塑性泡沫层18。这种板是有利地通过如以上已经描述的原位发泡方法生产的。板10的一个首端20被放置在板12的覆盖层16上，这样板10和12围成一个90度的角。在这种情况下，在两个拐角中提供了一个增强元件22。在这个实施方案中，增强元件22包括一个热塑性芯部件24，该芯部件有利地由泡沫制成，并在所有侧面上配备有一个纤维增强热塑性覆盖层26。在截面中所见，增强元件22是直角三角形的形状。因此，与其直角相邻的侧面28分别平行于板10和12的对应表面(覆盖层16)。例如，通过焊接或粘合，增强元件22的纤维增强热塑性覆盖层被连接到板10和12的纤维增强热塑性覆盖层16。在这个图中，右手边的增强元件22的锐角拐角配备有固定边缘29，这些固定边缘29平行于板10和12的表面(覆盖层16)，并且通过例如(热)焊接或粘合而附接在其上。
在以下要讨论的这些图中，与图1中的那些部件相同的部件由相同的参考数字表示。
图2示出了例如根据EP-A-431,669中所描述的方法产生的带有拐角的夹层结构14，其中一部分纤维增强热塑性覆盖层16在软化之后被折叠在该拐角中。根据本发明，用一个增强元件22来增强这个拐角。这个增强元件22本质上(essentially)被构造为如在图1中已经描述的。
图3示出了根据本发明的方法的一个优选实施方案。一个夹层板14包括两个纤维增强热塑性覆盖层16以及一个热塑性泡沫芯18。在其一个覆盖层16中，在有待形成的拐角(折线)的长度上制成一个切口。使用一个热压模(未展示)，该切口的任一侧面上的覆盖层16的边缘40被变形并且被压向另一个纤维增强热塑性覆盖层16。在所展示的这个情形中，变形的边缘部分40延伸至另一个覆盖层16。因此，形成了一个凹陷42，在截面中，该凹陷的底部由部分地与边缘部分40重叠的纤维增强热塑性覆盖层16形成。由变形的边缘部分40形成了倾斜的壁46(从凹陷42的底部44来看，分开很宽)。在凹陷42中放置了一个增强元件22，该增强元件具有与凹陷42的内侧周边同样的一个周边部分50(在截面中所见)。增强元件22包括由热塑性泡沫制成的一个芯部件24，该芯部件在平坦底侧上覆盖有一个纤维增强覆盖层26。在这种情况下，所述周边部分50也覆盖有一个纤维增强覆盖层26。增强元件22被粘合或焊接在凹陷42中，这样在该拐角的内侧上的纤维增强覆盖层16与增强元件22的纤维增强层26之间存在至少一个连接。增强元件22配备有固定边缘29，优选地是纤维增强热塑性覆盖层26的“延伸部分”。这些边缘29导致了附着表面的扩大，这就更容易实现连接操作，如压制或焊接。
图4示出了另一个实施方案，其中凹陷42被提供在该拐角的外侧上，该拐角被一个增强元件22增强。
图5和图6示出了一种用于制造增强元件22的方法。首先使用一个热压模(未展示)使包括一个热塑性泡沫24(其具有比物体本身的夹层材料更大的厚度)——在其两侧上覆盖有纤维增强热塑性覆盖层26——的一条夹层材料60在第一覆盖层26的一个边缘62处变形，以使这个边缘62覆盖泡沫24的自由侧面。随后，以相同的方式处理第二覆盖层26，以使原本自由的侧面被两个覆盖层边缘62覆盖。以相似的方式，使用一个具有适当形状(例如，头部的截面是三角形)的热压模，使条带60的另一个侧面上的第二覆盖层26变形，在这之后将第一覆盖层26的凸起边缘62折叠在变形的第二覆盖层26上。如果凸起边缘62没有被折叠在上面，则这个凸起边缘62还可以用作一个固定边缘29，在这种情况下，覆盖层26的一部分有利地被同时压制以形成固定边缘29的一部分。如果希望的话，在变形步骤之前，一个或更多附加的纤维增强热塑性层可以被施加到该覆盖层，或者泡沫可以被去除。
图6示出了一种用于使用用于图3所述方法的热压模70来制造增强元件22的另一个实施方案的方法。有利的是，一个更大尺寸的附加的纤维增强热塑性覆盖层80可以被放置在顶部覆盖层26上，与覆盖层26同时被变形并且与变形的覆盖层26相结合。如果附加层的边缘延伸超出覆盖有覆盖层26的元件的本体，则该边缘可以用作固定边缘或唇缘。
以上的增强元件还可以由一条热塑性泡沫材料或在一侧或两侧上具有一个或多个另外的热塑性纤维增强层的完成的夹层结构制成，在这之后该组合物在一个或多个步骤中被压制以形成一个增强元件，其中该另外的层的边缘有利地延伸超出被覆盖的元件的本体从而可以用作固定边缘或唇缘。
通过增加一个芯部件以及一个附加的纤维增强热塑性层，夹层结构还可以被局部地增强和加强，这改进了将力引入的可能性。
本发明的另一方面涉及一种用于在夹层结构中制造局部强化物的方法，该夹层结构包括一个芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是纤维增强热塑性覆盖层，该方法包括以下步骤：
在该至少一个纤维增强热塑性覆盖层上放置一个热塑性芯部件，在该芯部件上放置一个附加的纤维增强热塑性覆盖层，并通过融合将该附加的纤维增强热塑性覆盖层连接到该纤维增强热塑性覆盖层。在该连接步骤之前，如果希望的话，可以例如使用黏着(adhesive)或融合而将该芯部件附接在该夹层结构上。优选地，所述附接或连接发生在该连接步骤本身中，有利地使用一个热压模。根据这种压模的形状，该附加的纤维增强热塑性层以及该芯部件可以在该连接步骤中被变形，在这种情况下该芯部件可以被压缩。如果希望的话，该夹层结构的纤维增强热塑性覆盖层可以被局部地断开和/或去除，例如通过切削、锯切或铣削，并且如果希望的话，该芯部件还可以在这个过程中被附接。如以上已经解释的，该芯部件以及该附加的纤维增强热塑性层可以被连接以形成一个增强元件而不是分立的组件。这种增强元件可以具有任何适当的、包括一个或多个突出的固定边缘的形状。
以上给出的对于该夹层结构、芯部件以及附加的纤维增强热塑性层的材料和结构的选择的解释也适用于本发明的这个方面。
参考图7进一步解释这个方面。图7示出了一个夹层板10，在这种情况下，该夹层板包括两个纤维增强热塑性覆盖层16，在这两个覆盖层之间存在一个热塑性泡沫芯层18。由热塑性泡沫制成的一个芯部件24被放置在覆盖层16的顶部上，并且一个附加的纤维增强热塑性层26被放置在芯部件24的顶部上，所述层26延伸超出芯部件24的边缘。使用具有一个预定的模具腔(mouldcavity)100的一个热压模70使层26以及芯部件24变形，并且使层26的突出的边缘与顶部覆盖层16融合。
图8示出了本发明的又一方面，即两个夹层板10与12之间的接合的一个实施方案。放置一个拐角增强元件22以产生连接42。增强元件22包括由热塑性泡沫制成、并且在所有侧面上覆盖有纤维增强热塑性覆盖层26的一个芯部件24。增强元件22被粘合或焊接到夹层板10和12，这样在该拐角的内侧上的纤维增强覆盖层16与增强元件22的纤维增强层26之间存在至少一个连接。增强元件22配备有附接边缘(attatchment edge)29，优选地是纤维增强热塑性覆盖层26的“延伸部分”。夹层板10还优选地配备有一个固定边缘29。这些边缘29导致了该附接表面的扩大，这就更容易实现连接操作，如压制和焊接。增强元件22本身可以由一个夹层板制成，该夹层板包括两个纤维增强热塑性覆盖层以及在它们之间的一个热塑性泡沫芯层。
图9示出了根据本发明的致密塑性板50之间的接合的另一个实施方案。一个拐角增强元件22被用于连接42。上述由一条夹层材料制成的增强元件22包括由热塑性泡沫制成的一个芯部件24，该芯部件在纵向方向上的所有侧面上覆盖有纤维增强热塑性覆盖层26。增强元件22被粘合或焊接到致密层50，这样在该拐角的内侧上的致密层与增强元件22的纤维增强层26之间存在至少一个连接。增强元件22优选地配备有附接边缘29，优选地是纤维增强热塑性覆盖层26的“延伸部分”。这些边缘29导致了该附接表面的扩大，这就更容易实现连接操作，如压制和焊接。

Claims (15)

1.用于制造并且增强由夹层结构制成的物体中的拐角的方法，该夹层结构包括一个芯层，该芯层被安排在两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层，该方法包括以下步骤：
·产生一个物体，该物体包括在两个物体部分之间的一个拐角；
·在该拐角中放置一个热塑性芯部件以及一个附加的纤维增强热塑性层，该热塑性芯部件具有与该拐角相适配的形状，其方式为使该附加的纤维增强热塑性层基本上覆盖该芯部件的暴露表面；并且
·将该夹层结构的一个覆盖层连接到该附加的纤维增强热塑性层。
2.根据权利要求1所述的方法，其中该夹层结构的该至少一个塑性覆盖层是纤维增强覆盖层，优选地是纤维增强热塑性覆盖层。
3.根据权利要求1或2所述的方法，其中该塑性覆盖层界定了该拐角的内侧，并且该附加的纤维增强热塑性层被连接到该塑性覆盖层。
4.根据以上权利要求之一所述的方法，该方法包括以下步骤：
a)在一个夹层结构的两个部分之间产生一个拐角，该夹层结构包括一个芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层，其方式为使在该拐角位置的夹层结构中形成一个凹陷，该凹陷具有预定形状；
b)用一个增强元件填充该凹陷，该增强元件包括一个热塑性芯部件以及至少一个纤维增强热塑性覆盖层，该芯部件具有一个具有与该凹陷的预定形状互补的形状的侧面；并且
c)将该增强元件的纤维增强热塑性覆盖层连接到该夹层结构的一个覆盖层。
5.根据以上权利要求之一所述的方法，其中该夹层结构的芯层包括热塑性材料。
6.根据以上权利要求之一所述的方法，其中该夹层结构的芯层和/或该热塑性芯部件包括热塑性泡沫层。
7.根据以上权利要求之一所述的方法，其中该夹层结构包括两个纤维增强热塑性覆盖层。
8.根据权利要求4-7之一所述的方法，其中该增强元件具有狭长的形状，该增强元件的纵向侧面包括纤维增强热塑性覆盖层。
9.根据权利要求4-8之一所述的方法，其中该增强元件配备有一个或多个固定边缘，这些固定边缘平行于该夹层结构的覆盖层之一。
10.根据权利要求9所述的方法，其中所述固定边缘与该增强元件的纤维增强热塑性覆盖层是一体的。
11.根据以上权利要求之一所述的方法，其中该方法，尤其是权利要求4的步骤a)，包括以下的子步骤：
1)提供一个夹层结构，该夹层结构包括一个热塑性芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是纤维增强热塑性覆盖层；
2)在有待产生拐角的位置的夹层结构的一个覆盖层中提供一个间断；
3)折叠与该热塑性覆盖层中的间断相邻的覆盖层的边缘，其方式为使该夹层结构中产生一个凹陷；
4)弯折与所形成的凹陷相邻的夹层结构片段，以形成在拐角位置中具有所述凹陷的夹层结构，该凹陷具有预定形状。
12.根据以上权利要求之一所述的方法，其中该方法还包括制造一个增强元件，该方法包括以下步骤：
a)提供一个夹层结构，该夹层结构包括一个热塑性芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是纤维增强热塑性覆盖层；
b)使该夹层结构的、与该纤维增强热塑性覆盖层相对的侧面变形，以形成具有至少一个周边部分的一个增强元件，该周边部分具有与该凹陷的预定形状互补的覆盖层的形状。
13.根据以上权利要求之一所述的方法，其中该热塑性芯部件的厚度大于该夹层结构的芯层的厚度。
14.由夹层结构制成的、具有增强拐角的物体，该物体包括两个彼此成角的部分，并且由夹层结构制成，该夹层结构包括一个芯层，该芯层处于两个覆盖层之间，这两个覆盖层中的至少一个是塑性覆盖层，其中该物体在拐角位置的夹层结构中包括一个具有预定形状的凹陷，一个增强元件位于该凹陷之中，该增强元件包括一个热塑性芯部件，该芯部件至少在其周边部分上具有与该凹陷的预定形状互补的形状，并且其中该暴露的表面部分配备有一个纤维增强热塑性层，并且其中该增强元件的纤维增强热塑性层被连接到该夹层结构的一个覆盖层。
15.一种增强元件用于接合塑性元件——如板，该增强元件包括一个热塑性芯，该芯在纵向方向上的所有侧面上覆盖有纤维增强热塑性覆盖层。
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