CN103209827B - 夹层式构件及其制造方法 - Google Patents
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Abstract
本发明提供了一种具有湿气屏障的夹层式构件及其制造方法。该夹层式构件包括至少一个覆盖层(2)和一蜂窝状芯部。所述覆盖层(2)包括由具有热塑性基体的增强纤维制成的覆盖子层(2a),并且所述蜂窝状芯部由纤维素基材料构成并且具有多个连接片(1),其中,所述连接片的末端边缘位于一平面中,所述覆盖层(2)抵靠在该平面上。在此,所述覆盖层(2)在所述覆盖子层(2a)与所述蜂窝状芯部的连接片(1)之间包括隔离子层(2c),该隔离子层由热塑性材料制成,该隔离子层的热塑性材料的熔化特性与所述覆盖子层(2a)的热塑性基体材料所具有的熔化特性相对应。此外,在所述覆盖子层(2a)与所述隔离子层(2c)之间形成有中间子层(2b),该中间子层具有来自所述覆盖子层(2a)的增强纤维和所述隔离子层(2c)的热塑性材料,其中,该中间子层(2b)的增强纤维渗透有所述覆盖子层(2a)的热塑性基体材料的一部分以及所述隔离子层(2c)的热塑性材料的一部分。
Description
技术领域
本发明涉及一种夹层式构件,该构件包括纤维素基蜂窝状芯部以及至少一个覆盖层。本发明还涉及该构件的制造方法。
背景技术
在机动车构造的轻质构造策略中,为了降低燃料消耗并由此降低成本,还为了降低二氧化碳排放,越来越多地使用了具有夹层结构的构件,由于形成芯部的材料的密度较小,这些构件相对于传统构件具有显著降低的重量并且通过选择合适的覆盖层材料还能提供足够的强度值。此类夹层结构的其它优点在于其热学特性和声学特性。
从DE 10 2004 015 472 B4已知一种多层模制件及其制造方法,其中,用于这种模制件的材料应当是非常轻的、便宜的并且可毫无问题地循环的,并且在特珠场合下对湿气应当是不敏感的。模制件的覆盖层设置在蜂窝层的蜂窝室的开放侧上,并在与该蜂窝室热塑性连接之前由无定向织物类的、仅单侧针织的纺织材料组成,该纺织材料包含热塑性塑料纤维,其中,该纺织材料的另一棉状侧在热变形和固化之后插入到蜂窝室中。
发明内容
为了能够在其它构件中利用此类夹层结构的轻质构造潜能,希望在不损失强度特性的情况下降低覆盖层的单位面积质量(Masse)。不利的是,具有更小单位面积质量的覆盖层迄今为止还不具有足够的湿气屏障作用。因此,从现有技术提出以下的目的,即,提供一种具有覆盖层的夹层结构,该夹层结构应具有降低的单位面积质量而不损害机械强度,并且应当是不可透过湿气的,以便保护蜂窝状芯部。
这个目的是通过具有这种特征的夹层式构件来实现的:该夹层式构件包括至少一个覆盖层以及一蜂窝状芯部,所述覆盖层包括由具有热塑性基体的增强纤维制成的覆盖子层,所述蜂窝状芯部由纤维素基材料构成并且具有多个连接片,其中,所述连接片的末端边缘位于一平面中,所述覆盖层抵靠在该平面上,所述覆盖层在所述覆盖子层与所述蜂窝状芯部的连接片之间包括隔离子层,该隔离子层由不带有增强纤维的热塑性材料制成,该隔离子层的热塑性材料的熔化特性与所述覆盖子层的热塑性基体材料所具有的熔化特性相对应,在所述覆盖子层与所述隔离子层之间形成有中间子层,该中间子层具有来自所述覆盖子层的增强纤维和所述隔离子层的热塑性材料,其中,该中间子层的增强纤维渗透有所述覆盖子层的热塑性基体材料的一部分以及所述隔离子层的热塑性材料的一部分,所述隔离子层和所述中间子层的厚度之和在0.2mm到0.4mm的范围内,其特征在于,所述蜂窝状芯部的连接片的末端边缘被所述热塑性隔离子层包边并且由此与所述覆盖层相连接。
另一个目的在于,提供一种用于此类夹层式构件的简单且廉价的制造方法。
这个目的是通过具有这种特征的方法来实现的:夹层式构件的覆盖层至少形成在蜂窝状芯部的下侧面或上侧面之一处,并且所述蜂窝状芯部的连接片的末端边缘位于一平面中,所述覆盖层抵靠在该平面上,该方法包括以下步骤:
-在所述蜂窝状芯部上设置热塑性塑料薄膜,
-在该塑料薄膜上设置半成品件,其中,该半成品件由具有热塑性塑料基体的增强纤维构成,
-在压制模中加热并压制由所述蜂窝状芯部、所述塑料薄膜和所述半成品件构成的组件,使得由热塑性材料制成的、具有彼此对应的熔化特性的热塑性塑料基体和塑料薄膜至少部分地熔接,
-由所述热塑性塑料薄膜的材料形成隔离子层,
-通过在所述覆盖层的远离所述塑料薄膜的位置处固化具有热塑性塑料基体的增强纤维,形成覆盖子层,以及
-通过在靠近所述塑料薄膜的位置处固化所述覆盖子层的增强纤维,与所述覆盖子层的热塑性基体材料的一部分以及与所述隔离子层的热塑性材料的一部分一起形成所述中间子层。
该构件和方法的改进方案在下面的描述中体现。
根据本发明的夹层式构件由至少一个覆盖层和一个蜂窝状芯部组成。覆盖层(Decklage)通过由具有热塑性基体(Matrix)的增强纤维制成的覆盖子层(Deckschicht)形成,而蜂窝状芯部由纤维素基材料构成并且具有多个连接片,所述连接片的末端边缘位于一平面中,所述覆盖层抵靠在该平面上。
在本发明的夹层式构件的第一个示例实施方式中,覆盖层在该覆盖子层与该蜂窝状芯部的连接片之间包括由热塑性材料制成的隔离子层。隔离子层的热塑性材料的熔化特性与覆盖子层的热塑性基体材料的熔化特性相对应,由此在覆盖子层和隔离子层之间可以形成中间子层,该中间子层具有来自覆盖子层的增强纤维以及隔离子层的热塑性材料。相对应的熔化特性尤其是指熔点、玻璃化转变温度和熔融粘度,它们彼此之间没有实质性的偏差。中间子层的基体因此由聚合物混合物或者聚合物共混物形成,其包括隔离子层的热塑性塑料和覆盖子层的热塑性塑料。除了痕迹(Spuren)以外,隔离子层不包含增强纤维。增强纤维的痕迹是指从中间子层伸入到隔离子层中的纤维。
中间子层的增强纤维在此渗透有覆盖子层的热塑性材料的一部分以及隔离子层的热塑性材料的一部分。热塑性隔离子层(借助它该中间子层材料配合地与覆盖子层相连接)一方面防止了来自的覆盖子层的增强纤维渗透到这些连接片之间的蜂窝内部空间中并且由此减少覆盖子层中形成强度的纤维比例,而且另一方面形成了整体的湿气屏障,该湿气屏障保护纤维素基蜂窝状芯部以免钻入湿气。蜂窝内部空间因此是几乎不含自由放置的或未通过热塑性塑料结合的增强纤维。除了痕迹以外,蜂窝内部因此没有增强纤维。增强纤维的痕迹是指从中间子层伸入到隔离子层中并延伸通过隔离子层的个别纤维。
也就是说,通过隔离子层可以使覆盖子层在单位面积重量方面得以降低,因为可以使用所有存在的增强纤维,而没有由于蜂窝空心空间中的纤维而导致的覆盖子层损失。用更大的热塑性塑料比例大幅度加强的中间子层附加地有助于该覆盖层的强度。
在一个有利的实施方式中,隔离子层的热塑性材料可以是与覆盖子层的热塑性基体材料相同的热塑性材料。为此,尤其可以考虑如聚酰胺、丙烯腈-丁二烯-苯乙烯、聚丙烯和/或其它聚烯烃的热塑性塑料。
根据本发明的夹层式构件的覆盖子层可以具有在0.4mm到0.8mm范围内的厚度,该厚度优选为约0.6mm,而隔离子层和中间子层的厚度之和在0.2mm到0.4mm的范围内并且尤其为约0.3mm。隔离子层和中间子层的子层厚度之和在此对应地比用于形成这些子层的薄膜的厚度略大。为了制造隔离子层,优选使用厚度为0.1mm到0.4mm的热塑性薄膜。
特别重要的是,连接片的末端边缘容纳在覆盖层的热塑性隔离子层中。连接片的末端边缘在此完全由隔离子层的热塑性塑料包围。这些连接片在与覆盖子层的连接区域中侧向地通过隔离子层或隔离子层的热塑性塑料来支撑。由此一方面实现了覆盖层与蜂窝状芯部的连接片的相对牢固的连接,另一方面实现了蜂窝状芯部与外部的良好密封。连接片在该边缘处在一定程度上是通过该热塑性塑料密封的。仅通过连接片边缘的包边或根据方法的环绕(Umflieβen),就可以实现非常良好的密封。因为隔离子层的热塑性塑料不是纤维增强的,所以实现了非常致密的且无缺陷的包边。由此非常有效地保护连接片材料和蜂窝内部空间以免湿气进入。当蜂窝状芯部由纸或纸板构成时,这种密封是特别有利的,因为纸或纸板是多孔材料,湿气可以正好经由未受保护的边缘吸收。
末端边缘的穿过隔离子层的热塑性塑料的包边的深度起到显著作用。包边的深度尤其取决于连接片的宽度(连接片宽度)和隔离子层厚度之间的关系。在此隔离子层的厚度是指在蜂窝连接片之间的区域中的厚度,因为隔离子层的厚度在包边区域中自然较小。特别优选的是,隔离子层的厚度为连接片宽度的30%以上且150%以下,尤其是30%到50%。远大于连接片宽度的隔离子层厚度一般不带来更多的优点。
连接片的宽度优选在200μm到600μm的范围内。特别优选的是,使用由纸制成的蜂窝状芯部,其中,连接片宽度在200μm到400μm的范围内。
包边的深度或者蜂窝状芯部的连接片的末端边缘向隔离子层中插入的长度优选为连接片宽度的至少80%。优选为连接片宽度的100%至200%。包边的深度在此可以朝向连接片的两侧或者在连接片的侧向延伸上变化。大于连接片宽度两倍的包边深度一般不带来更多的优点。
通过连接片末端边缘的侧向包边或者连接片相对较深地插入覆盖层中,确保了特别牢固的连接,因为能够良好地吸收剪切力。
用于形成覆盖子层的、具有热塑性基体的增强纤维能够通过纤维毡(例如无纺布)或者混合纺织物、混合编织物或针织物等来形成。
覆盖子层的热塑性基体还可以以未加强的(nicht-konsolidierter)热塑性塑料纤维的形式插入。除了增强纤维之外,它们还存在于纺织物等中。这些纤维(热塑性塑料纤维以及增强纤维)都可以按成束的形式作为纤维粗纱(Rovings)存在。还可设想的变形方案是,增强纤维单独地或成束地被热塑性基体子层包围。作为此类混合结构的替代,具有热塑性基体的增强纤维还可以通过带有嵌入的增强纤维纺织物的预加强的热塑性塑料板来制备。在加工过程期间,将热塑性塑料纤维熔化并且相应地形成热塑性基体。
增强纤维可以是天然纤维、玻璃纤维、碳纤维、聚合物纤维(尤其是芳香族聚酰胺纤维)或者它们的组合。
一种用于制造此类夹层式构件的方法总体上包括形成该夹层式构件的覆盖层,该覆盖层至少设置在该蜂窝状芯部的侧面(下侧面或上侧面)上,使得该覆盖层抵靠在该蜂窝状芯部上。为了形成覆盖层,首先在蜂窝状芯部的连接片末端边缘所处的平面上,将热塑性塑料薄膜放置到纤维素基蜂窝状芯部上。并不需要涂覆粘合剂。此外,在其上方设置由增强纤维和热塑性塑料基体构成的半成品件。
在压制模中加热并压制由所述蜂窝状芯部、所述塑料薄膜和所述半成品件构成的组件,使得由热塑性材料制成的、具有彼此对应的熔化特性的热塑性塑料基体和塑料薄膜至少部分地熔接。通过热塑性塑料薄膜的熔接的材料,隔离子层直接与蜂窝状芯部邻接地形成,而通过在该覆盖层的远离塑料薄膜或隔离子层的位置处固化具有热塑性塑料基体的增强纤维,形成了该覆盖子层。在该覆盖子层和该隔离子层之间,通过在靠近塑料薄膜或隔离子层的位置处固化覆盖子层的增强纤维,与该覆盖子层的热塑性基体材料的一部分以及隔离子层的热塑性材料的一部分形成了中间子层。于是在中间子层中产生了由增强纤维和更高比例的热塑性塑料组成的、大幅度加强的材料,该热塑性塑料由基体材料和塑料薄膜材料组合而成。
此外,通过将热塑性塑料基体与塑料薄膜至少部分地熔接,实现了蜂窝状芯部与覆盖层之间的良好结合,其中,连接片的末端边缘至少接纳在覆盖层的热塑性隔离子层中。连接片的末端边缘在塑料薄膜的部分熔接过程中从被该薄膜围绕,使得形成了由热塑性塑料产生的末端边缘的包边。在此尤其重要的是,隔离子层不是纤维增强的。由此该热塑性塑料可以不受阻碍地流动,并且形成非常致密且无缺陷的包边。末端边缘由此在侧面和在顶部完全由致密的热塑性塑料封闭。通过连接片的末端边缘的侧向包边或者将连接片相对较深地插入覆盖层中,也能够良好地吸收剪切力。
对于给定的热塑性塑料,连接片末端边缘的包边深度或者蜂窝状芯部在热塑性薄膜中的下沉可以例如通过压制模的压力来控制。
压制模中的加热在此通过在热塑性塑料的熔化温度的范围内施加温度而实行。塑料基体和塑料薄膜的温度优选处于玻璃化转变温度到对应塑料的熔化温度的范围内。压制模的加热温度在此至少为该熔化温度。
为了获得模制的夹层式构件,蜂窝状芯部可以在覆盖层形成前成型,其方式为首先用水通过喷洒或蒸发来将其润湿。润湿的蜂窝状芯部然后可以设置在带有凸模和凹模的压制模中,所述凸模和凹模具有预先确定的夹层式构件形状。然后在凸模和凹模之间在40℃到200℃范围内的温度下通过施加压力使润湿的蜂窝状芯部再成型。
随后是根据本发明来布置该塑料薄膜和半成品件,它们的同时熔接或熔化以及固化是通过在具有相应形状的压制模中压制而进行的。
因此,根据本发明提供了一种夹层式构件,其中,通过隔离子层防止了纤维插入到蜂窝室中,在蜂窝室中,它们不再具有增强效果,而是有利地使在覆盖层中存在的所有增强纤维都有助于进行增强。于是可以减小覆盖子层的厚度,其中,防止插入蜂窝内部空间的隔离子层同时起湿气屏障的作用并且保护纤维素基蜂窝状芯部以免钻入湿气。
附图说明
这些和其它的优点将通过参考附图的以下说明来展现。在说明书中对附图的参考用于支持说明书,并且使其主题更易理解。这些附图仅是本发明实施方式的示意性图示。
图1是在覆盖层处的蜂窝连接片的连接区域的示意性侧剖视图,
图2是没有隔离子层的连接区域的显微对比照片,
图3是连接区域的显微对比照片,其中,使用了0.08mm厚的薄膜,该薄膜没有形成隔离子层,
图4是根据本发明的夹层式构件的连接区域的显微照片,其中,使用了0.3mm厚的薄膜,以便形成隔离子层。
具体实施方式
本发明的夹层式构件使得能够降低覆盖层的单位面积质量或者单位面积重量,以便在不同类型的构件中能够释放出该夹层结构的轻质构件潜力,该夹层式构件具有如在图1中示意性示出的覆盖层2。
安置在蜂窝状芯部的连接片1的末端边缘上的覆盖层2具有作为最上的——也就是说,最远离连接片1放置的——子层的覆盖子层2a,该覆盖子层2a由具有热塑性基体的增强纤维制成。
术语“蜂窝”应当不限于是指蜂窝状芯部的结构,而是指由多个连接片构成的、具有较小密度和较高刚度的结构。合适的蜂窝状芯部结构包括典型的六角形“蜜蜂窝结构”,如波纹形、圆形、菱形或矩形的折叠结构,还有不规则形式的仿“有机”结构。
特别地,可以考虑纸和卡纸作为用于蜂窝状芯部的纤维素基材料。
用于形成覆盖子层的增强纤维可以以无纺布、无定向织物或具有定向纤维的纤维毡、纺织物、针织物、结织物(Gelegen)的形式以单向或多向方式存在。在此还可以设想使用混合纱线,从而使用含有形成基体的热塑性纤维的纤维半成品以及增强纤维。增强纤维可以是天然纤维、玻璃纤维、碳纤维、聚合物纤维(尤其是芳香族聚酰胺纤维),但也可以使用不同纤维的组合。
根据本发明,覆盖层2在覆盖子层2a与连接片1之间具有隔离子层2c,隔离子层2c由与热塑性基体材料相似的热塑性材料组成。然而,根据本发明,至少覆盖子层和隔离子层的热塑性材料的熔化特性必须彼此相对应。优选地,热塑性基体材料和隔离子层的热塑性材料为相同的热塑性塑料材料,例如可以是聚酰胺、丙烯腈-丁二烯-苯乙烯、聚丙烯或者其它聚烯烃。
隔离子层2c一方面防止了覆盖子层2a上的增强纤维插入由连接片1限定的蜂窝内部空间中,这样使得全部增强纤维保留在覆盖层2的内部并且促进增强效果。因为由此不再产生增强纤维的“损失”,所以可以减小覆盖层2的单位面积重量。此外,隔离子层2c作为纯热塑性子层提供了如下优点:其起湿气屏障的作用并因此为纸蜂窝状芯部提供了足够的保护以防湿气,甚至在单位面积重量减小时。在此,在隔离子层2c与覆盖子层2a之间形成有中间子层2b,该中间子层通过由来自覆盖子层2a的增强纤维形成的大幅度加强的材料不仅与来自覆盖子层2a的基体材料而且与来自隔离子层2c的热塑性材料固化为纤维-基体复合材料,该复合材料的特征在于提高的热塑性材料比例。
覆盖层2的这种三子层构造可以借助于本发明的方法以简单的方式进行生产,其中,将热塑性塑料薄膜设置在蜂窝状芯部上以及具有热塑性塑料基体的纤维半成品件的塑料薄膜上,将它们一起在压制模中加热并且压制,由此将增强纤维固化在基体熔体中。为了获得热塑性塑料薄膜与半成品件的热塑性塑料基体的同时熔接和熔化,使用了相似的热塑性塑料,优选使用相同的热塑性材料。用于形成隔离子层2c的薄膜在此必须是较厚的,以便形成对来自覆盖子层2a的增强纤维的反压力。在压制时,薄膜在无纺布上施加反压力,并且于是使无纺布固化并保持在一起。
图3展示了在连接片1上的覆盖层2,其中,此处在蜂窝状芯部与覆盖子层之间仅设置0.08mm厚的薄膜。这个薄膜的厚度不足以将来自覆盖子层的增强纤维固化,它没有形成隔离子层,因此增强纤维3仍然能够插入蜂窝中的空间中。蜂窝连接片部分地被覆盖层包边。这种包边(Umrandung)在此部分地由含纤维且多孔的材料构成,并部分地由薄膜的热塑性塑料形成。薄膜的厚度在此不足以保证连接片的边缘的密封包边。
这从图2中也能非常清楚地看到,为了对比的目的,图2示出了没有隔离子层的夹层式构件的连接区域,其中,没有使用薄膜。在此可以清楚地看到插入蜂窝内部中的增强纤维3,这些增强纤维因此不能再促进覆盖层2的加强效果。连接片在一定程度上不接纳在覆盖层中,或者在一定程度上连接片未包边。向上以及朝连接片边缘的侧面也不存在密封的封闭。而是这些连接片边缘靠在多孔的、渗入有纤维的材料上。
另外,如在图4中可以看出的,本发明的夹层式构件:在此没有增强纤维插入蜂窝内部空间中,而是在覆盖层2中存在的所有增强纤维都促进了增强效果。覆盖子层2a在此具有大约0.6mm的厚度,同时这两个子层——中间子层2b和隔离子层2c——形成大约0.3mm的总厚度,如可以通过0.3mm厚的薄膜来实现。于是,在没有增强特性损失的情况下,降低了覆盖层2的单位面积重量,同时隔离子层2c是有效的湿气屏障。
使用了连接片宽度约为300μm的纸作为蜂窝状芯部的材料。在显微图示中出现的650μm的宽度是由于在制备时倾斜地切割连接片而造成的。具有热塑性塑料的包边的深度在左侧约为450μm且在右侧约为300μm。连接片边缘因此在顶部和侧面完全地被热塑性塑料包边。热塑性塑料因此使所述边缘相对于湿气密封,并且使所述边缘在连接区域中被侧向地支撑。
Claims (10)
1.一种夹层式构件,该夹层式构件包括至少一个覆盖层(2)以及一蜂窝状芯部,所述覆盖层包括由具有热塑性基体的增强纤维制成的覆盖子层(2a),所述蜂窝状芯部由纤维素基材料构成并且具有多个连接片(1),其中,所述连接片的末端边缘位于一平面中,所述覆盖层(2)抵靠在该平面上,
其中,所述覆盖层(2)在所述覆盖子层(2a)与所述蜂窝状芯部的连接片(1)之间包括隔离子层(2c),该隔离子层由不带有增强纤维的热塑性材料制成,该隔离子层的热塑性材料的熔化特性与所述覆盖子层(2a)的热塑性基体材料所具有的熔化特性实质上相同,并且
其中,在所述覆盖子层(2a)与所述隔离子层(2c)之间形成有中间子层(2b),该中间子层具有来自所述覆盖子层(2a)的增强纤维和所述隔离子层(2c)的热塑性材料,其中,该中间子层(2b)的增强纤维渗透有所述覆盖子层(2a)的热塑性基体材料的一部分以及所述隔离子层(2c)的热塑性材料的一部分,
所述隔离子层(2c)和所述中间子层(2b)的厚度之和在0.2mm到0.4mm的范围内,
其特征在于,所述蜂窝状芯部的连接片(1)的末端边缘被所述热塑性隔离子层(2c)包边并且由此与所述覆盖层(2)相连接。
2.根据权利要求1所述的夹层式构件,其特征在于,所述蜂窝状芯部的连接片的末端边缘向所述隔离子层中插入的长度或者包边的深度是所述连接片的宽度的80%以上。
3.根据权利要求1所述的夹层式构件,其特征在于,所述隔离子层(2c)的热塑性材料与所述覆盖子层(2a)的热塑性基体材料是相同的热塑性材料。
4.根据权利要求1所述的夹层式构件,其特征在于,所述覆盖子层(2a)具有在0.4mm到0.8mm范围内的厚度。
5.根据权利要求中1所述的夹层式构件,其特征在于,所述隔离子层的厚度为所述连接片的宽度的30%以上且150%以下。
6.根据权利要求1所述的夹层式构件,其特征在于,所述增强纤维是天然纤维、玻璃纤维、碳纤维、聚合物纤维或者它们的组合。
7.一种用于生产根据权利要求1至6中至少一项所述的夹层式构件的方法,其中,覆盖层(2)至少形成在蜂窝状芯部的下侧面或上侧面之一处,并且所述蜂窝状芯部的连接片的末端边缘位于一平面中,所述覆盖层(2)抵靠在该平面上,
该方法包括以下步骤:
-在所述蜂窝状芯部上设置热塑性塑料薄膜,
-在该塑料薄膜上设置半成品件,其中,该半成品件由具有热塑性塑料基体的增强纤维构成,
-在压制模中加热并压制由所述蜂窝状芯部、所述塑料薄膜和所述半成品件构成的组件,并且使得具有彼此实质上相同的熔化特性的热塑性塑料基体和由热塑性材料制成的塑料薄膜至少部分地熔接,
-由所述热塑性塑料薄膜的材料形成隔离子层(2c),
-通过在所述覆盖层(2)的远离所述塑料薄膜的位置处固化具有热塑性塑料基体的增强纤维,形成覆盖子层(2a),以及
-通过在靠近所述塑料薄膜的位置处固化所述覆盖子层(2a)的增强纤维,与所述覆盖子层(2a)的热塑性基体材料的一部分以及与所述隔离子层(2c)的热塑性材料的一部分一起形成所述中间子层(2b)。
8.根据权利要求7所述的方法,其特征在于,为所述覆盖子层提供:
-由增强纤维和未加强热塑性纤维制成的无纺布、纤维编织物或纤维针织物,
-或者带有嵌入的增强纤维的预加强的热塑性塑料板。
9.根据权利要求7所述的方法,该方法包括以下步骤:
-通过施加一温度在加热条件下将所述热塑性塑料基体和所述塑料薄膜熔接,所述温度处于所述热塑性塑料基体和所述塑料薄膜的热塑性塑料的熔化温度范围内,
-以形成所述连接片的末端边缘的包边的方式,使所述塑料薄膜的热塑性塑料环绕所述连接片的末端边缘流动,
-以形成所述覆盖层(2)与所述蜂窝状芯部的连接片(1)之间的牢固连接的方式,冷却所述塑料,并且利用所述热塑性塑料密封所述连接片的末端边缘。
10.根据权利要求7所述的方法,该方法包括以下步骤:
-通过喷洒或蒸发利用水来润湿所述蜂窝状芯部,在所述塑料薄膜设置在所述蜂窝状芯部上之前使所述蜂窝状芯部成型;将润湿的蜂窝状芯部设置在带有凸模和凹模的压制模中,所述凸模和凹模提供了所述夹层式构件的预先确定的形状;并且通过施加压力以及在40℃到200℃范围内的温度下在所述压制模中使润湿的蜂窝状芯部再成型。
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