CN102056735A - 槽格状结构制造方法、槽格状结构和相应设备 - Google Patents

槽格状结构制造方法、槽格状结构和相应设备 Download PDF

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CN102056735A
CN102056735A CN2009801212809A CN200980121280A CN102056735A CN 102056735 A CN102056735 A CN 102056735A CN 2009801212809 A CN2009801212809 A CN 2009801212809A CN 200980121280 A CN200980121280 A CN 200980121280A CN 102056735 A CN102056735 A CN 102056735A
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sheet material
sheet
convex
concave
block
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CN102056735B (zh
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马克·勒·莫尼埃
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered 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
    • B32B3/10—Layered 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
    • B32B3/12—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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    • B23K26/26—Seam welding of rectilinear seams
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • 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
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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    • B29L2031/00—Other particular articles
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
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Abstract

一种制造槽格状蜂窝结构的方法，该槽格状蜂窝结构由彼此附接的多个热塑片材(101)形成，其中凸凹区域(2a、3a)设置在每个片材内，并且每个自由片材(101b)与由预先附接在其中的不同片材形成的中间块体(21)的相邻片材(101a)通过利用激光源，在该自由片材和该相邻片材的至少一些接触的平坦区域(3a、2b)处、沿着平行于所述凸凹的轴线的连续线(L)的焊接而附接。

Description

槽格状结构制造方法、槽格状结构和相应设备
本发明涉及一种用于以塑料材料制造槽格状蜂窝类型结构的方法。本发明还涉及由此得到的结构以及一种允许应用这种方法的设备。
基于热熔材料的蜂窝类型的槽格状结构已经工业化生产了大约二十年。由于聚丙烯(PP)具有重量轻、成本低、便于应用、出色的耐湿性和耐大多数化学品的能力，大多数所使用的聚合物为聚丙烯(PP)。并且其容易回收。聚碳酸酯(PC)和聚醚酰亚胺(PEI)的蜂窝体占据了特定市场，并且目前存在以聚氯乙烯(PVC)、聚对苯二甲酸乙二醇酯(PET)、三乙酸纤维素(CTA)制造的边际产品。
这些产品的主要商业用途是夹层板，这些产品构成了夹层板的芯体。夹层的上下表层是薄而致密的材料，其弹性拉伸模量通常很高。具有蜂窝类型的槽格状芯体(即槽格轴线垂直于片材平面，并且以此方式设计，即使槽格截面不总是六边形)的夹层结构提供了硬度/重量比和抗压强度/重量比，而不用任何配对元件。这是为何建筑、车辆、家具、航天、铁路运输工业以及造船工业越来越多地采用这种技术。
在民用工程和环境美化的领域，具有非常大的槽格(大到50mm)的聚丙烯蜂窝结构也可裸露使用，或者在其表面上热粘接有非织造物，从而防止槽格被填补：减小回填、雨水管理。
蜂窝芯体通常由具有六边形槽格的挤管(WO 94/25258)或带有矩形截面的元件(WO 87/00119)制成。管通过共挤接收具有较低熔点的用作粘合剂的聚合物的外部覆层。这些管或这些梁被切成所需长度，并且叠置以形成块体。在管的示例下，通过使其在长的热风炉中经过，可以融化粘合剂并且在冷却之后，得到固化的块体，该块体容易被带锯切割从而得到具有所需长度的板。这些梁通过热刀片彼此贴靠焊接在一起(镜像焊接)。
这些方法具有多个显著缺陷：使用具有低熔点的热熔粘合剂限制了槽格结构的热机械强度，以至于该热机械强度的水平明显地比所述结构的基本聚合物的热机械强度低。另外，为了经受将其运输通过炉子的钳施加在其侧面上的压力，即使热空气使其软化，管状蜂窝块体应当具有极小密度。在用于夹层板应用的小尺寸槽格(通常截面为8mm)的情况下，对于聚丙烯来说，该密度是80kg/m3。现在，对于大多数应用来说，很少需要55kg/m3以上。这种技术问题因此阻碍了最终产品的重量和成本的优化。
另一种结果是用热线将块体切成片，与通过带锯切割相比更有美感，但是其只可在10cm/min的最大速度下实现，并且在当具有80kg/m3密度的聚丙烯块体的情况下具有热降解的风险，由此而不能使用。在较轻的蜂窝的情况下，其变得有利：因此可以得到30cm/min的速度以及具有50kg/m3密度的聚苯乙烯块体。另一方面，通过使用叠置的容器和钳，不能获得具有大于3米长度的块体，该块体使得大尺寸的面板的制造变得复杂并且在某些情况下不能制造具有大尺寸的面板。设计用于给定类型的聚合物(防止制造商使用非常不同材料的蜂窝)的挤压螺杆也存在有问题。最后，不能运输紧凑的半成品，并且不能使用对大量使用者来说易获得的轻量工业装置来组装该半成品为蜂窝体。由于传统的拖车很难取走60m3以上的蜂窝体，运输成本很快变成制约因素。
还存在有将槽格结构连续和直接地制造成所需厚度的方法。文献WO-A-9841388描述了通过具有多个细槽的模具以热熔材料对平行片材的挤压，以及片材之间的隔腔的生产。通过在两个隔腔的一个隔腔内轮流地减压和流体填充，由此制成槽格结构。对于大的板的厚度来说，这种方法比前面的方法更加经济。现在，后者由于该技术的复杂性而限于大约三十毫米。另外，所得产品的密度更高。
文献WO-A-0032382描述一种通过真空转动热成型制成的蜂窝结构。两个热成型区域均形成半槽格，并由平坦区域分开，其中该平坦区域用作沿着片材的宽度的折叠线。类似于手风琴来实施折叠从而将半槽格更加靠近在一起，一旦它们并置便形成蜂窝结构。槽格的端部被平坦区域覆盖。为了保持该结构的形状，此蜂窝芯体的制造步骤需要紧随着用于粘接形成面板的外表面的表层的步骤之后。
换言之，虽然在文献WO-A-0032382考虑到了半槽格的壁的连接，但此方法需要面板完整制成，而不仅是蜂窝芯体。另外，不能进行厚度的调整(由于在圆筒上的热成型，而调整始终非常受限)。
本发明旨在提供一种早些讨论的技术问题的解决方案。
为此，其目的在于提供一种制造槽格状蜂窝结构的方法，该蜂窝结构由热塑材料的多个片材彼此组装而形成，以及一种在每个片材制造设有凸凹的区域的方法，并且每个自由片材与由预先组装在一起的不同片材形成的中间块体的相邻片材通过利用激光源，在该自由片材和该相邻片材的至少一些平坦接触区域处、沿着平行于所述凸凹的轴线的连续线的焊接而组装。
通过在竖向位置的片材对片材的焊接，形成块体，其长度可以是没有限定的，并且密度非常低。另外，与热塑粘合剂粘接相比，焊接的方式在机械和温度上具有更大耐受性。
根据本发明的有利但非强制的方面，该方法可结合一个或多个以下特征：
热塑材料是热成型材料，并且通过每个片材的真空热成型，特别是通过转动圆筒状模具来制造设有凸凹的区域。
每个片材的真空热成型通过转动圆筒状模具(而不是平面模具)来实现，从而能够形成热成型片材的多变的长度。
圆筒的整个表面在规则的空间间隔处被分成凹入的键槽，该键槽平行于圆筒的轴线并几乎从圆筒宽度的一端延伸到另一端。这些键槽在垂直于圆筒轴线的平面内的截面是规则的半六边形。
实施条带的真空热成型，接着此条带被切割从而形成不同的自由片材。为此，在热成型线的输出处，带键槽的塑料条带通过轧刀切成所选长度，并且得到的薄片例如彼此堆叠位于容器中。
通过在片材的第一面和相对面上交替地紧压地标记线，并接着通过在这些折叠线的两侧上施加压力从而导致片材的折叠，设有凸凹的区域被制成。作为示例，平行于片材的宽度并彼此等间距的线可以被紧压地标记，并且在这些折叠线的两侧在相反方向上施加压力，从而使得片材根据半六边形的型式在纵向上折叠。
在前面段落中描述的实施例是真空热成型的变型。作为用来描述此变型实施例的非限制性示例，特别是根据文献FR1532509的教导，通过通过圆筒的压力在其表面上标记平行于片材宽度并彼此等距的线，可以在冷条件下折叠片材。位于片材上方的设有薄直边凸凹的圆筒将在片材的上表面上紧压地标记两条连贯的线，并且位于片材之下的相同的圆筒接着随后标记这两条线，即片材下表面上的两条新线。并且不停地重复该循环。放置在片材上方和下方的一组致动器(压缩空气喷嘴、带键槽的辊子)使得平坦片材通过沿着事先在所述片材表面上刻出的线折叠而采取具有半六边形纵向型式的三维形状。不同于真空热成型，折叠不会导致材料拉伸。因此在冷却之后没有收缩问题，并且片材的任何地方具有相同的厚度。同时不同于真空热成型，其不要求片材的基本材料是气密的。
设有凸凹的每个自由片材在其焊接到中间块体的相邻片材之前被加热。为此，在焊接位置，操纵机器人的臂将例如抓住容器内的样品，并使其一个表面暴露于红外辐射加热器的面板。
由此预加热的片材被竖向引入焊接机器，其中片材在两个竖向平面之间通过重力滑动，其中一个平面由与片材的凹入凸凹的形状配合的固定金属导件构成，并且另一个平面由正在形成的蜂窝块体的壁构成。通过机械装置，块体在侧部进行小的平移运动，使得块体和片材上的凸凹反相，并且这些凸凹的平坦部分优选地彼此面对。
块体发生位移从而在压力的作用下将刚刚引入的片材贴靠金属导件。块体和片材的彼此相对的凸凹的平坦部分现在彼此压靠。
在位于金属导件的另一侧的空间内设有水平板，水平板上附接有光纤的组件，每个光纤输送在将两个连贯的金属导件分开的空间中间处对中的激光束。新的片材将因此通过一组平行焊接线被附接到块体上，该焊接线通过且只通过块体和片材的所有接触凸凹。对于不要求非常高机械性能的某些应用，可以只焊接某些线。
例如使用激光源，该激光源发射从可见光到中红外的范围放射，即具有对应于可见光的低限值的最小波长(即大约380纳米)以及具有大约25微米的最大波长。有利地，一组激光二极管用作激光源，放射包含在800和1200纳米之间的波长。有利地，来自激光源的电磁辐射经由光纤传播。
实际上，例如价格适中的光束宽度、高产量、不错的耐用性以及低负载使得激光二极管成为产生具有2-4mm宽度的焊接线的理想工具。焊接的原理基于通过电磁辐射的材料加热。通过压力彼此保持贴靠的两个塑料片材的焊接可以如下实现：
1.通过透明，采用包括两层的塑料片材，一层是“透明的”，而另一层吸收近红外。大多数热塑聚合物不吸收或者仅少量吸收激光二极管的波长间隔内的电磁辐射。为了使其具有强的吸收能力，充分条件是添加例如炭黑(1％的质量就足够)的填充物。射线经过透明层，并且其电磁能量被转化为吸收层内的热量。后者熔化，并且通过热传导还使得其所在的其它双分子层片材的表面熔化。在冷却之后，获得良好质量的焊接。这种技术是公知的，但是在制造蜂窝的范围内具有两个缺陷，即非常难以：在寻求轻重量时，对于每种聚合物来说，为双分子层片材提供小于250微米的厚度。另外，透明材料通常是不合杂质的和非回收的材料。
2.或者通过传导，这是本发明特别有利的方面。由此，可以采用含有炭黑的100％回收材料的单层片材。由于片材厚度小，以米/分钟的单位表示的焊接率将总是较高的。该方法非常适用于200微米和更小的厚度。其原理在于小心地升高塑料片材的温度，直到其赋予大分子充分的可动性，使其活化(在结晶聚合物的情况下，这通过材料的纯融化来表示)，因此通过传导入其它片材内来扩散卡路里。如早些所述，压力应该施加在两个片材上，使其大分子从一个片材到另一片材相互渗透。来自光纤的激光束的直接应用用来将所有能量集中在直径为2-4mm的斑点上。这造成暴露而与空气接触的吸收片材氧化，即聚合物的不可逆的降解。因此有利的是在较长时间内逐渐施加此能量，而不减小焊接率。这可将该斑点“延伸”成具有相同宽度并具有几厘米长的区段，该区段沿着待焊接的线移动。在它于片材的给定点上移动的过程中，温度将逐渐升高直到其超过聚合物的软化点。这种温度的逐渐升高被赋予下面的片材，并且足以在焊接线上快速施加强压，并接着使其冷却。
实际上，例如从激光源，产生激光束，激光束转化为激光分段，其宽度基本上接近激光束的直径，其长度远大于该直径，并且这种激光分段沿着所述连续的线移动。有利地，激光束朝着设有多面并进行旋转运动的柱面镜指向，从而产生所述分段。
接收激光束的每个小通过使其由此覆盖线分段来将其投射到塑料片材上。镜的转动足够快速，使得“能量线”从该斑点产生。激光在3-4mm宽和长约15厘米的分段内的能量分布的较大均匀性使得塑料片材的温度升高，直到与由激光束直接形成的斑点在片材表面所作相比使得大分子以更加逐渐和更好控制的方式运动。对于例如聚丙烯和聚苯乙烯的普通用途的聚合物来说，每焊接线100W的额定功率足以确保高的生产率。当然，对于这种装置，还可以通过透明来焊接双分子层片材，而不需要为设备提供无关紧要的调整。
通过该板的竖向运动，这组能量分段将片材焊接在块体上，同时在接触的平坦表面内产生焊接线。为了使得材料相互渗透，在激光焊接步骤的过程中并紧接着在此步骤之后，沿着所述连续线，每个自由片材被压靠相邻片材。
由此通过一个片材增大的块体在此制造方向上移动，并接着在横向上发生小的位移，同时从顶部引入新的片材。
再次开始前述的循环。
本发明的目的还在于通过热成型材料的多个片材组装在一起形成的槽格状蜂窝结构，每个片材设有凸凹区域，与两个相邻片材的至少一些接触的平坦区域通过平行于凸凹轴线的连续焊接线而汇集。
根据有利的特征，槽格状结构具有小于80kg/m3的密度，特别小于60kg/m3，对于槽格来说，其最大横向尺寸小于12mm。
最后本发明的目的在于用于实施所述方法的设备，其包括：
用于在每个片材内形成凸凹的装置；
用于将每个自由片材在中间块体的相邻片材附近设定就位的装置；
用于将此自由片材与相邻片材焊接的装置；
用于向每个自由片材连同相邻片材施加压力的装置。
根据其它特征：
焊接装置包括能够产生激光束的激光源和用于将激光束转化为激光分段的装置，分段的长度远大于激光束的直径。
压力装置包括能够使得中间块体与自由片材接触的第一压力构件以及能够伸入到所述中间块体的槽格内并增加自由片材和相邻片材之间的沿着所述连续线的压力的附加压力构件。
在阅读随后的根据本发明的方法和实施该方法的设备的描述(仅作为示例)示例并参照附图后，将更加清楚本发明及其其它优点，附图中：
图1是带有转动圆筒的热成型设备的纵向剖视的局部示意图，该转动圆筒使得塑料片材再生产出半六边形形状的皱褶。
图2描述了圆筒的热成型槽格。
图3是片材部分的简化示意图，后者在图1设备中热成型。
图4是用于通过热成型塑料片材的激光焊接制造蜂窝的机器的示意图。
图5、6、7、8、9和10是焊接器内的沿水平平面的剖视图，表示片材的进入、与块体的压靠以及通过激光射线的焊接。
图11说明能量分段是如何产生的以及通过能量分段的产生强压是如何施加在熔焊线上的。
图12是支承光学焊接装置的板的俯视图；
图13是根据本发明的槽格状结构的三维立体图。
图14-16表示可以根据本发明获得的蜂窝槽格的几个示例。
图1所示的设备在此附图的左侧包括从卷筒2输送的片状材料的条带1。这种气密的片状材料由在真空中热成型的热塑材料制成，其厚度在0.1和1mm之间(这些数值没有限制含义)。这种热成型材料例如选自聚烯烃(聚丙烯、聚乙烯)、聚酯、聚苯乙烯、聚碳酸酯、丙烯腈-丁二烯-苯乙烯、聚醚酰亚胺、聚醚醚酮。其可以利用玻璃、碳纤维或聚芳基酰胺纤维来加强，由此来加强最终产品的热机械性能。
条带在两个红外辐射面板3之间的竖向位置上展开，红外辐射面板3将条带的温度增加到低于其熔点的度数。通过重力，热的条带置于缓慢转动的热成型圆筒4的表面。确保圆筒表面和条带之间的密封的装置未示出。圆筒包括厚度为大约30mm的铝套筒，其通过水循环来冷却。该表面被加工从而刻出凹入的直边键槽，键槽都是相同的并平行于圆筒的轴线。牢固地附接到固定轴线6的一组翼片5a和5b使得圆筒的内部被分成两个密封箱体。下部箱体7连接到永久操作的真空泵。因此在其转动运动过程中，在圆筒热条带1带至箱体7处时，包含在圆筒和片材之间的空气经由排气口8被突然抽吸，并且后者在键槽9的槽底处变平(图2)。其接着出色地再生产出圆筒状模具的表面，它将只在运动经过箱体7的另一端充分冷却之后离开。
因此得到可以在图3的纵向剖视图中看到的带键槽的条带1a，该条带1a设有峰2a和谷3a。凸凹区域2a和3a是平坦的。换言之，热成型条带1a看上去如同褶皱的金属片材。它经过积聚器11并接着到带键槽的变针圆筒12的前部。后者控制轧刀14，在用一对切割盘13切割边缘之后轧刀生产出具有所需长度的条带1a。在切割条带1a之后，因此得到多种带相同键槽的片材(附图标记为101)，该片材通过未示出的装置被放置在容器15内。
重要的是注意到如果这种热成型线允许快速地从塑料材料切换成另一种，则特别地加工圆筒应适用于给定的聚合物，从一种聚合物到另一种聚合物片材的收缩率不同。通过圆筒的快速更换，保证所获得的样本具有相同的尺寸特性。
容器15通过对中装置定位在激光焊接机器的前部的地上，如图4所示。在端部处设有抓握板17的操作臂16接连地拾取叠摞顶部的每个片材，从而将其提供给红外辐射面板18。其目的在于将热成型片材的温度尽可能地带至最高值，并同时避免其变形。在焊接机器内部，用于加热空气的装置(未示出)使得温度得到保持。其目的在于通过在温度上升曲线的最高点开始来减少激光焊接所需的时间。
接着，臂将热片材转移到一组转动辊子19，辊子19将其承载到焊接机器内部。片材通过重力在钢引导件20和中间蜂窝块体21的竖向壁之间向下运动，直到它邻靠在平滑的不锈钢水平板22上。这种中间块体21通过事先组装的不同片材101形成。两个竖向定位的带式输送器23在块体的侧面施加永久压力，并且赋予其前后运动。这两个输送器被牢固附接到托台24，托台24本身使它们横向运动并交替地从左运动到右，从而得到相当于六边形槽格的3/4的长度的移位，使得块体和片材发生反相。
图5是表示中间块体的水平平面内的截面的放大视图，设有峰2a和谷3a的最后片材101a将添加到该中间块体上。图6表示在侧部输送器23作用下朝着中间块体21运动以及在托台的作用下该块体侧向平移3/4的槽格长度的同步动作，并接着插入附加片材(所谓的自由片材101b)。
图7表示块体21的向后运动，使得分别属于块体21的最后片材101a和自由片材101b的凸凹3a和2b的平坦区域接触。接着，通过气动致动器驱动的耙25的钢或挤拉碳型材被引入块体21的最后一排的槽格，如图8所示。一旦它经过块体21的整个高度，耙紧贴引导件20从而准确地将压力施加在凸凹3a和2b的平坦区域(图9)。激光束29将接着熔化片材101a和101b之间的这些接触表面。其通过之后马上就是转动隆起32或33，该隆起将点式强压施加到这些软化部分上，从而导致两个片材之间的材料的相互渗透，同时耙25确保均衡压力(图10)。
图11表示由致动器驱动的板26，该致动器以匀速从块体底部向上运动的以达到其顶部。在下一个循环过程中，它将执行反向运动。在该板上安装有光纤27，该光纤27输送由激光二极管源28产生的电磁辐射。光纤将激光束29发送到反射镜30，反射镜将其传递到多面旋转镜31。后者在由块体21和耙25施加的压力而抵靠在钢引导件20上的片材101b的表面上，产生具有等于斑点的直径(即2-4mm)的宽度和可以在10和15cm之间变化的长度的能量分段S。
转动隆起32和33具有相当于从该分段选择的宽度。在发现逐渐变得不好的情况下，它们设有橡胶凸缘或平滑特氟龙冠体。对于每个焊接线都有一个隆起，并且每个线大致对应于由凸凹2b和3a限定的平坦接触区域的中央。在板26向上运动时，一组气动致动器34使得隆起32压靠凸凹2b和3a处的片材，而铸件33保持退后设置。相反，在板向下运动时，隆起33是在致动器35的压力下在焊接线上滚动的部件，而铸件32退后设置。
图12是表示光纤27、激光射线29、反射镜30、旋转镜31的定位的板的俯视(局部)图。为了更好地理解，隆起32、33和致动器34、35没有绘示。一旦板26来到行程端部，侧部输送器23向前移动块体21，并且新的自由片材(即尚未组装的)从机器顶部引入。循环再次开始。
图13表示根据上述方法制得的根据本发明的槽格状蜂窝结构。这种结构由组装在一起的多个片材形成，最后两个相邻片材带有附图标记101m和101n。另外，附图13表示平行于凸凹轴线并标识为L的连续焊接线，使得这两个相邻片材在其平坦接触区域处组装。
每个线L大致在整个这些平坦接触区域上延伸，换言之，在结构的整个高度上延伸。如上所述，某些平坦接触区域可以不焊接，特别是在不需要非常高的机械强度的情况下。
采用本发明范围内使用的设备，能够提供热成型圆筒4和相应的钢引导件20加工的蜂窝结构的槽格，该槽格的截面不是规则的六边形。图14-16给出可以在本发明范围内使用的槽格形状的几个示例，最后两个示例允许蜂窝板在至少一个给定方向上变形。
通过以上描述的方法得到的蜂窝块体将通过一组热线有利地切割成多个板。熔化使得表面上略微的材料积聚，增加了与夹层结构表层接触的表面面积，并因此增加了后者的黏合。表层在制造家具和分隔件的情况下是装饰性的(层压件、木制品)，尤其是用于游船的内部。它们在车辆和铁路部件的情况下是结构性的(复合物、钢片材)。它们在制造用于卡车拖车、野营车、风力涡轮机机舱的壁的情况下是既有结构性又有装饰性的(涂漆铝、涂有凝胶涂层的复合物)。但是蜂窝板还可用作复合结构的中空芯体。在这种情况下，它被涂覆密封膜和非织造物以粘接通过接触或注入施加的树脂，树脂本身通过放置在蜂窝板的表面上的一个或多个玻璃垫层加强。
另外，由防腐聚合物制成并具有六边形大网格的块体将有利地被建筑工业应用以保持雨水。
无论何种工业应用，激光焊接的塑料蜂窝对于压缩、弯折和剪切提供显著的抵抗能力，同时减轻了现有结构。通过该制造方法，可以使用大多数热塑聚合物，并由此获得重量轻和耐用的块体，这是以前所不能实现的。同样还可以将非常长的长度的部件制成一体。
最后，由于焊接设备和热线材切割机的体积小和重量轻，对于大量使用者来说可以尽可能容易地安装这些装置。因此，只有位于特定容器的凹入叠置的设有凸凹的片材被运送，显著地减小了运送成本。换言之，在第一位置，可以执行刻键槽和切割操作。另一方面，可以在不同位置(可以在远离所述第一位置)进行特别是焊接不同片材的后续操作。
在参照附图描述和绘示的实施例中，采用气密热塑材料的真空热成型，该材料因此使其能够经受热成型操作。但是，作为没有绘示的变型，能够使用非气密热塑材料，例如非织造纤维、格栅或穿孔片材。在这种情况下，如上所述，设置凸凹的区域可以在每个片材内通过不同于真空热成型的方法制成。这种变型方法可以是根据文献FR1532509的教导的非限制性的方法。

Claims (17)

1.一种用于制造槽格状蜂窝结构的方法，该槽格状蜂窝结构由热塑材料的多个片材(101)组装在一起而形成，在方法中，在每个片材中都制成有设有凸凹(2a、3a)的区域，并且每个自由片材(101b)与由预先组装在一起的不同片材形成的中间块体(21)的相邻片材(101a)通过利用激光源，在该自由片材和该相邻片材的至少一些接触的平坦区域(3a、2b)处、沿着平行于所述凸凹的轴线的连续线(L)的焊接而被组装。
2.根据权利要求1所述的方法，其特征在于，使用放射从可见光到中红外的激光源。
3.如权利要求1或2所述的方法，其特征在于，使用一组波长介于800至1200纳米之间的发射器(28)作为激光源。
4.如上述权利要求中任一项所述的方法，其特征在于，来自所述激光源的电磁辐射通过光纤(27)传输。
5.如权利要求1-4中任一项所述的方法，其特征在于，所述激光源(28)产生激光束(29)，该激光束被转化为激光分段(S)，该激光分段(S)的宽度基本接近于所述激光束的直径，该激光分段(S)的长度远大于该直径，并且该激光分段(S)沿着所述连续线(L)移动。
6.如权利要求5所述的方法，其特征在于，所述激光束朝着设有多个面并进行旋转运动的镜(31)指向，从而产生所述分段。
7.如上述权利要求中任一项所述的方法，其特征在于，所述热塑材料是可热成型材料，并且由每个片材(101)的真空热成型而设有凸凹的区域尤其是通过旋转的圆筒形模具而制成。
8.如权利要求7所述的方法，其特征在于，执行条带(1)的真空热成型，并且此条带接着被切割从而形成不同的片材(101)。
9.如权利要求1-6中任一项所述的方法，其特征在于，通过交替地在片材的第一表面和相对表面上紧压地标记线，并接着通过在这些折叠线的两侧施加压力从而使该片材折叠，从而来制成设有凸凹的区域。
10.如权利要求9所述的方法，其特征在于，平行于片材的宽度方向并彼此等距的线被紧压地标记，并且接着在这些折叠线的两侧在相反方向上施加压力，从而使得片材在纵向上根据半六边形型式折叠，并接着该条带被切割从而形成不同的片材(101)。
11.如上述权利要求中任一项所述的方法，其特征在于，每个自由片材(101b)在将其焊接到中间块体(21)的相邻片材(101a)之前被加热。
12.如上述权利要求中任一项上述的方法，其特征在于，在激光焊接步骤过程中，每个自由片材压靠相邻片材，并且在紧接着该步骤之后，每个自由片材沿着所述连续线压靠相邻片材。
13.一种由热塑材料的多个片材(101)组装在一起形成的槽格状蜂窝结构，每个片材设有凸凹(2a、3a)的区域，两个相邻片材(101a、101b)的至少一些接触的平坦区域通过平行于凸凹的轴线的连续焊接线(L)而组装。
14.如权利要求13所述的槽格状结构，其特征在于，所述槽格状结构具有小于80kg/m3的密度，特别是小于60kg/m3，所述槽格状结构的槽格的最大横向尺寸小于12mm。
15.一种用于执行根据权利要求1-12中任一项所述方法的设备，包括：
用于在每个片材中形成凸凹的装置；
用于将每个自由片材设置在中间块体的相邻片材附近就位的装置；
用于将此自由片材与相邻片材焊接的装置；
用于向每个自由片材连同相邻片材施加压力的装置。
16.如权利要求15所述的设备，其特征在于，焊接装置包括能够产生激光束的激光源、以及用于将该激光束转化为激光分段的装置，所述分段的长度远大于激光束的直径。
17.如权利要求15或16所述的设备，其特征在于，压力装置包括能够使得中间块体与自由片材接触的第一压力构件、以及能够伸入到所述中间块体的槽格内并增加自由片材和相邻片材之间的沿着所述连续线的压力的附加压力构件。
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CN102056735B (zh) 2014-08-20
JP5646453B2 (ja) 2014-12-24
US20110098170A1 (en) 2011-04-28
WO2009130419A3 (fr) 2010-02-25
US20130112344A1 (en) 2013-05-09
JP2011519752A (ja) 2011-07-14
US9586378B2 (en) 2017-03-07
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FR2929549B1 (fr) 2012-04-20
CA2719896A1 (fr) 2009-10-29

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