CN105102214A - 夹芯结构 - Google Patents

夹芯结构 Download PDF

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CN105102214A
CN105102214A CN201480002301.6A CN201480002301A CN105102214A CN 105102214 A CN105102214 A CN 105102214A CN 201480002301 A CN201480002301 A CN 201480002301A CN 105102214 A CN105102214 A CN 105102214A
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central layer
exterior panel
sandwich
peak
sandwich structures
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道格拉斯·科克斯
法比安·埃布特尔
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Celltech Metals Inc
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Celltech Metals Inc
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Abstract

一种使用芯板(35)的夹芯结构(31)，芯板包括在其中的交替的高峰(39)和低谷(41)。另一个方面，夹芯结构包括至少一个金属芯体(35)和至少一个粘结接合的外部面板(33；37)。夹芯结构的又一个方面，夹芯结构具有在沿一个方向但不沿垂直的方向在芯板(35)中的相邻的高峰(39)之间桥接的突起的梁脊(45)，从而在不同板的方向中达到不同性能。

Description

夹芯结构
相关申请的交叉引用
本申请要求了2013年12月13日提交申请系列号为14/105989的美国实用新型的权益，其通过引用被纳入本文。
背景技术
本发明通常涉及夹芯结构，更具体的涉及包括具有交替高峰和低谷的芯体的夹芯结构。
具有外层和芯体层的金属夹芯结构在工业中是公知的。例如，参考以下美国专利：专利号为7752729，名称为“成型金属扁平材料的方法，制造复合材料的方法和实施这些方法的装置”，2010年7月13日授权给Faehrrolfes等；专利号为7648058，名称为“成型的金属芯体夹芯结构及其制造方法和系统”，2010年1月19日授权给Straza，并且其共同拥有此专利；和专利号为3525663，名称为“具有双轴直线桁架模式的互反曲面蜂窝芯体结构”，1970年8月25日授权给Hale，通过引用它们全部被纳入本文。然而，Hale的专利教导使用竖直操作冲压模以在加热的芯板中成型节点，目的是在所有平面中获得相同的弯曲和剪切应力。以这种方式冲压的芯体在节点成型和节点模式对称期间易于开裂。此外，Faehrrolfes的专利不利的在其伸长波动芯体的成型期间要求润滑以降低开裂，其产生后面的问题是外板需要粘结接合。还值得注意的是Faehrrolfes需要复杂机构以在每个工件成型期间连续调整成型辊位置，这导致公差精度顾虑和单个部件内以及部件和部件刚度不一致。Faehrrolfes波动模式在所有方向均是对称的。
发明内容根据本发明，夹芯结构使用其中包括交替高峰和低谷的芯板。另一个方面，夹芯结构包括至少一个金属芯体和至少一个粘结接合外部面板。另一个方面，夹芯结构在相邻高峰之间具有沿一个方向但不沿垂直方向的突起的梁脊桥接，从而在不同的板的方向上达到不同性能。另一方面使用至少三个层叠芯体。此外，弧形弯曲和/或基本垂直折叠外表面与本芯体和外板结构的其他方面一起完成。仍然在另一方面中，泡沫位于芯板和相邻外板之间。又一方面包括具有外围凸缘的夹芯结构，外围凸缘可以被镶边或角偏移。此外，又一方面提供制造芯体结构的方法，包括在成型期间、粘结应用之后加热期间张紧芯板，和/或预切通过成型辊供给的料坯。
本夹芯结构和方法优于先前的构造。例如，本夹芯结构和方法优点是不需要在芯体材料上的、用于其中高峰和低谷的成型的润滑剂，从而允许粘结剂轻易地被应用到芯体，而不需要移除不需要的润滑剂或昂贵的粘结制剂。此外，本夹芯结构和方法允许高峰和低谷以非常迅速、重复和低成本的方式被成型在芯体中，没有Hale和Faehrrolfes专利的开裂顾虑。此外，本夹芯结构和方法有利于增强并且抵抗厚度压缩，还有利于存在非对称弹性、剪切刚度、剪切强度和长度收缩因素性能，这增强了夹芯结构产品成型和易于制造。通常，本夹芯结构的垂直折叠、弧形弯曲和泡沫填充提供了额外的强度优势，并且本发明的特征可以从以下说明和所附权利要求，以及附图中确定。
附图说明
图1是表示夹芯结构的分解示意图；
图2是沿着图1的线2-2的截面图，表示夹芯结构；
图3是表示用于夹芯结构中的成型芯板的真实立体图；
图4A是沿着图3的线4A-4A的截面图，表示芯板；
图4B是沿着图3的线4B-4B的截面图，表示芯板；
图5A和5B是表示芯板特征的曲线图；
图6A是表示用于产生夹芯结构的第一实施方式制造过程的概略图；
图6B和6C是表示在制造过程中使用不同张紧结构的概略侧视图；
图7是表示在制造过程中使用的压纹辊上的销的放大侧视图；
图8是表示图7的压纹辊上的销的真实视图；
图9是表示销的相互关系的局部前视图，销从用于制造过程的协作压纹辊伸出；
图10是表示压纹辊销之一的放大侧视图；
图11是表示用于产生夹芯结构的第二实施方式制造过程的概略图；
图12A-12D是表示制造具有可选的外围凸缘的夹芯结构的过程的系列截面图；
图13A和13B是表示具有可选镶边凸缘的夹芯结构的系列截面图；
图14A和14B是表示具有内锁榫槽凸缘的夹芯结构的系列截面图；
图15是表示弧形弯曲夹芯结构的截面图；
图16是表示层叠芯体夹芯结构的构造的截面图；
图17是表示层叠芯体夹芯结构的另一构造的截面图；
图18A和18B是表示在夹芯结构中使用的泡沫的系列截面图；
图19是表示泡沫填充夹芯结构的变体的截面图；
图20是表示夹芯结构的的折叠构造的截面图；
图21是表示图20的夹芯结构的折叠构造的转角的局部放大视图；
图22是表示图20的折叠夹芯结构的泡沫填充变体的截面图；
图23是表示图20的折叠夹芯结构的不同的泡沫填充构造的截面图；
图24表示用于弯曲图15的夹芯结构的模具；
图25表示圆柱构造的夹芯结构；
图26是表示使用夹芯结构的卡车和拖车的侧视图；
图27是表示使用夹芯结构的建筑物墙体和楼层的示意图；和
图28是表示使用夹芯结构的可移动车库门的真实示意图。
具体实施方式
从图1-4B中可以观察到夹芯结构31。夹芯结构31包括第一大致平坦的外部面板33、中间芯板35和相对的第二大致平坦的外部面板37。此外，芯板35包括交替的高峰39和低谷41，每个高峰39和低谷41的外表面由大致平坦的面43限定。此外，突起梁脊45沿着第一宽度方向W但不沿垂直长度方向L桥接或横跨在相邻高峰39之间，那里形成更陡峭和陡斜的凹陷47。由于当芯板从初始平坦的工件板被成型为所需轮廓时，凹陷产生在梁脊的背面，凹陷47沿着第二方向L位于相邻高峰39之间，然而每个凹陷平行于梁脊45延长。每个梁脊45稍微低于相邻高峰39的大致平坦面43。板33、35和37优选是金属的，例如低碳钢或铝，但是任何或者全部的这些板可以交替地为不锈钢或其他金属材料，尽管一些优选制造步骤和最终产品性能可能不同并且不太令人满意。在芯板35的轧制/进给方向L的金属晶粒结构相比在横向轧制/横向进给方向W的金属晶粒结构也是不同的。
在芯板35的交替的高峰和低谷之间的梁脊45和凹陷47的定位在成型期间和之后赋予芯板对称性能或特征。例如，长度收缩系数fs，它是初始芯板长度与成型的最终板长度之比，相比于在横向轧制/横向进给方向W的大约1.0为收缩系数fs，在轧制方向L为至少1.08，更优选的为至少1.10。此外，相比于轧制/进给方向L，芯板35在横向轧制/横向进给方向W的平面外剪切刚度为至少1.3倍，更优选的至少1.4倍：
[L]-GWT/GLT≥1.3。
此外，相比于轧制/进给方向L，芯板35在横向轧制/横向进给方向W的平面外剪切强度为至少1.05倍，更优选的至少1.1倍：
[L]-τWT/τLT≥1.05。
这些特征展示为显示在图5B中的曲线中的数据。换而言之，由于梁脊和凹陷定向和定位，成型芯板35可以围绕平行于方向W的轴被扭转或弯曲，比在垂直方向围绕平行于方向L的轴容易的多。这可以在将会在下文中更详细的说明的制造和折叠部件成形中有利的被使用。可以理解的是，在成型后芯板厚度会改变。该不对称芯体成型比现有结构中所需的对称有非常大的不同。
本夹芯结构31的、外板结合到芯板之处的、横跨截面厚度(如图2所示)抗压强度如图5A曲线中所示地被预估。该特殊夹芯芯体层的相对密度可以被如下计算：
ρ*＝fs·tc/C
其中tc是芯体层的初始板厚度，C表示芯体层高度，fs是在长度方向L的收缩系数。因此，高峰和低谷单元或起伏的周期排列的非对称特性，在一个方向通过突起梁脊连接并且在其他方向通过陡峭的凹陷分开，有利于提供不同方向的成型和最终产品性能和特性。
图6A表示用于制造夹芯结构31的第一制造过程和设备。在这个配置中，延长的芯板金属35的卷围绕固定到用于芯板金属分配的机械或支撑架的轴61转动。芯板35沿着方向L被连续供给进入张紧夹送辊63，并且随后进入围绕各自轴67转动的一对压纹或成型辊65之间。在每个芯板35的完整成型期间，压纹辊65的轴67彼此以固定距离固定设置，并且在成型操作期间不被调整。可以理解的是，这些轴67的一个或两个可以被移动，用于保持或初始化压纹辊设置，然而，不可预期的是，当形成芯板的高峰和谷底时压纹辊65之间空间变化，从而在单个部件或部件到部件内提供公差一致性和可重复性。
牵引设定的张紧夹送辊69被设置在压纹辊65的下游。可替代的，在图6B或6C所示组合之一中，在压纹辊65之前和/或之后，“挡泥板状”加压臂71可以从机器外壳73挠性地延伸。每个加压臂71可以与近端铰链和偏斜弹簧挠性或刚性地连接。加压臂71和/或张紧辊63和69可以互换，以当通过压纹辊65在芯板35中形成高峰和谷底时，在临近芯板35的上游和下游部分最好提供相同张紧和摩擦。然而，值得注意的是，不需要横向或侧面板张紧从而提供理想的期望的收缩系数差，以阻止在成型中板金属断裂；而侧面张紧或夹紧可以被使用，但不会看到期望的优点。
成型销81的形状可以在图7-10中得到最好的体现。每个销具有大致圆柱形侧壁83，侧壁83具有大致0.668英寸的直径85以及大约1.0英寸的中心点到中心点间距87。此外，每个销距离每个压纹辊65辊筒的圆柱形表面91的总高度89为大约0.536英寸(参见图6B)。梁脊成型部分和相邻销的顶部之间的“独立”尺寸93为大约0.433英寸，而进给方向销到销中心点间距95为大约1.0英寸。低谷成型顶平面尺寸97为大约0.220英寸，远端圆角半径99为大约0.224英寸，并且近端侧壁83和圆柱辊筒表面91之间的较小的半径或倒角具有大约0.157英寸的半径尺寸101。此外，半径103为大约0.118英寸，而反转半径105为大约0.157英寸。最后，尺寸107为大约0.433英寸。因此，可以看出，主要是在每个压纹销81的任何部分或辊筒表面91的工件接触区域上均没有尖角，而对市售低碳钢和铝而言，每个销的直径不小于每个销伸出辊筒的高度。对更坚硬的金属而言，像不锈钢，销直径可以小于高度。然而，对所有的防止断裂的金属工件板类型而言，销的直径应当总是大于独立高度93。虽然根据工件材料类型和所需夹芯性能，精确尺寸可以改变，相关的尺寸比例有利地在制造期间阻止板断裂，还最大化高峰和谷底之间的压碎强度和抗破碎性。压纹辊由工具钢制成，随后硬化，以减少磨损，无需工件润滑下。
回到图6A，输送带129将芯板35移入涂布辊121，涂布辊121具有从位于粘结剂站的供给料斗125或管流出的液体粘结剂帘123。辊121输送液体粘结剂到面43上(参见图3和4A)，面43基本是芯板的、优选在芯板的两个面上被粘结剂涂覆的仅有的部分。可替代的并且不优选的，粘结剂可以通过自动或手动操作的方式喷洒或涂刷到芯板的面上。值得注意的是，在环境温度、湿度和压力下，芯板35被成型，并且将粘结剂施加于其上。
此后，大致平坦的外表面板33和37的卷在方向L连续供给，并且在芯板35上方或下方堆叠。预热炉127将板加热，更具体的将粘结剂加热到大致在200-300°F之间的温度，更优选的是到大约250°。预热炉127使用顶部和底部火焰、电阻元件或光，并且置于粘结剂涂布辊121的下游。
低乙烯基传动带128随后在层压站移动仍然持续伸长但正在预热的夹芯板，传送带128包括上环状乙烯带130，其沿着厚度T向下施加小于20磅每平方英尺的压力，优选大约5磅每平方英尺的压力。层压站在隔热箱或炉131内，隔热箱或炉131包含至少10个，优选30个上管状棒132和相同数量的下管状棒，用于从其辐射热量以加热板材到350-450°F的温度，更理想的是400°F，加热30秒或更少，更优选的15秒或更少。这导致非常迅速的粘结夹芯结构31的“绿色”固化。此外，每个带128和130具有至少10英尺的供给长度L，优选至少30英尺，从而提供大致均匀但适度的层压压力到它们之间的一个或多个伸长夹紧结构。随后，在层压带下游的冷却单元或冷却站133中，风扇吹动空气经过液体输送冷却管或制冷管，然后，切割刀135、喷水切割器、激光切割器或相似切割器被用于切割最终的且冷却了的夹芯结构31为所需长度，其随后被包装或发送给顾客。
图11表示用于预切割坯料或板的不同的工艺构造。在这个视图中，预切割芯板35通过在供给方向从压纹机外壳73伸出的台面或台架141被手动或自动机械供给到成型或压纹辊65。该台面或台架构造可以替代或添加到辊或带输送器129使用，如图6中所示。图11还示出了压纹辊75上游和下游的一对加压臂71。
随后，成型芯板35通过涂布辊121粘结涂覆。芯板35随后手动或自动堆叠在预切割外层板33和37之间。夹芯板随后被供给到预热炉127，并且夹芯板随后升高温度同时在层压带128和130之间被层压或压缩，以使它们之间充分粘接，如图6A所述。这些层压板随后可选地通过冷却单元133被冷却，并且随后被包装。当它们堆叠在一起和层叠时，各种夹具或销可以被用于适当地对齐板。
本夹芯结构31的另一个特点可以从图12A-12D中看出。在该配置中，外板33具有外围部201，该外围部201被形成或弯曲为与相对面板37的伸出凸缘部205匹配的偏移的L形凸缘203。粘结剂123将凸缘203和205粘接在一起，而在它们之间没有芯体35。因此，在制造中，在堆叠和层叠之前，芯板被故意切短外围边缘和相邻外部面板的凸缘部分。根据最终使用需要，连接凸缘203和205可以被设置在一个或所有夹芯结构31的外围边缘上。另外可以预期的是，根据相对于连接其上的部件的最终夹芯凸缘的期望位置，两个外部面板可以相对于面板33以所示的偏移的方式被弯曲。
图13A和13B表示另一个变形例，凸缘203和205被分别形成在外部面板33和37中，并且在凸缘之间没有芯板35。然而，在这个视图中，卷边工具在它们自身之上以大致U形方式折叠凸缘203和205，并且将它们互锁在一起以围绕其外围部分产生卷边接头或缝；在这个配置中凸缘之间不需要粘结剂。
可以在14A和14B中看到，仍然是夹芯结构31的另一个变形例，夹芯结构31包括外部面板33和37，在它们之间包夹成型的芯板35，通过粘结剂123或类似方式粘接。粘结剂123，但不是芯板35，存在于凸缘203和205上。在这个配置中，面板的外围凸缘203和205角偏移且向上翻转。这产生大致U形和开放的钩形构造。因此，一对相反定向的构形凸缘203和205在匹配夹芯结构31之间提供榫槽互联接头211。这有利于允许相邻面板的移除，这非常适合用于办公室、住宅或工业建筑215(参见图27)内的墙壁结构或隔断213。如果在榫槽接头211之间使用粘结剂，那么机械和粘结连接被设置在相邻夹芯结构31之间用于永久连接在一起，例如用于建筑物215(参见图27)中的天花板或地板217，用于拖车219(参见图26)的侧墙、天花板或地板，或陆地、水上或天上的交通工具221(参见图26)的车体面板221。
现在参考图16和17，多层芯板，每个具有成型的高峰和低谷，被用于外部面板33和37之间。在图16中，每个芯体35、35’和35”在轧制和横向轧制方向彼此大致对齐。中间平板231和233位于堆叠的芯板35、35’和35”之间，使用粘结剂123在相邻板之间粘接。图17仅使用外部面板33和37，在相邻接触芯板35、35’和35”之间没有中间板。但是在这个结构中，每个相邻芯板的高峰和低谷必须与其他相邻板互补，以使一个高峰上的平面通过粘结剂123粘接到另一个低谷的平面，诸如此类。可以理解的是，至少三个成型芯体层用于一对外侧大致平坦的面板之间，根据所需压缩强度和厚度，四个、五个或更多芯体可以堆叠在它们之间。
图18A和18B示出了在外部面板33层压芯板35上之前，球状或管状、几乎是固态的泡沫251置于芯板35的每个低谷中。泡沫251优选是可膨胀建筑泡沫或可膨胀隔热泡沫，其也可以用于将芯板35粘结到外板33，代替需要的独立的粘接涂覆站。典型的建筑和隔热泡沫材料可以在2005年1月25日授权给Czaplicki等的名为“活性材料”的专利号为6846559，和1976年4月13日授权给Pallo等的名为“可浇注粒状硅质隔热材料”的专利号为3950259的美国专利中找到，两个专利被本文纳入引用。
图19表示可膨胀泡沫位于金属芯板35两侧的视图。在该视图中，泡沫可以注射到成品夹芯结构中或在芯板上放置外部面板之前铸造到芯板的两侧上。
图20和21表示夹芯结构31在三个边角折叠，以使产生的每个折痕271与一系列对齐凹陷47(参见图3和4A)对齐延长，以在这个方向最大化挠性。这也减小了靠近折痕271的两侧的高峰和低谷的结构劣化。夹芯结构31可以在简单的压弯机上以这样的方式弯曲，以使一对相邻壁在折痕271围绕尖端具有大致垂直的相对方向。因此一个或多个弯曲可以在单个部件中产生。例如，图20的部件示出了具有大致多边形或正方形外部形状的封闭盒部分。此外，一个或多个匹配凸缘203/205可以设置在用于粘结、焊接、点焊、铆接、螺栓连接或其他固定的相邻外围端。
图22示出了夹芯结构31的折叠盒形结构。然而，在这个结构中，可膨胀泡沫251置于外部面板33和37之间，以封闭芯板35的两侧。相反，图23示出了可膨胀泡沫251完全填充由夹芯结构31定义的中心和封闭区域。如果建筑泡沫251被使用，那么该泡沫和夹芯布置是理想的，适用于建筑物内轻质且特别高刚度的建筑梁柱和桁架、拖车中直立角框架、飞机的撑杆等。
最后，可以从夹芯结构31产生弯曲的外部形状，如图15、24和25所示。在外部面板33和37层压到芯板35以后，为了熔化它们之间的粘结剂，夹芯结构可以通过非限制性示例的方式再加热到大约302°F持续15-30分钟。加热的夹芯结构随后置于模具301中，模具301具有施加适度压力的匹配外腔面303和弧形形状。逐步的，每个板将相对于其他板移动和滑动直至获得所需的弯曲成形，随后粘结剂被重新冷却并且重新成为强力结合方式。这可以提供如图15和24所示的缓和弧形弯曲装置，或采用其极端，具有匹配边缘凸缘的完全圆柱装置，如图25中所示。
图28示出了另一个变形例，其中任何前述公开的夹芯结构被用作门311的一个或多个部分，门311例如是具有铰接在一起的多个相邻夹芯面板的可移动车库门。夹芯结构可替代的是像图27中所示的更小建筑物的门，或图26中所示拖车219的门。还可以理解的是，根据所需成品和处理特征，任何前述实施方式和其特征可以混合并且与任何其他的匹配。
虽然本发明的各种实施方式已经被公开，可以理解的是也可以使用其他变形。例如，焊接、点焊或拉钉接合可以用于替代相邻板之间的粘结接合，但是许多重量、成本和快速组装的优点可能无法实现。此外，其他尺寸和形状可以被设置用于芯板，压纹销等，然而，许多制造优点和性能强度可能无法实现。变形不被认为是脱离本公开，并且所有的修改被包括在本发明的范围和精神内。

Claims (55)

1.一种夹芯结构，包括：
外部面板；
包括交替的高峰和低谷的芯板，所述芯板位于外部面板的中间部分之间；和
连接凸缘，其由连接在一起的所述外部面板的外围部分限定，所述外围部分之间没有所述芯板。
2.根据权利要求1所述的夹芯结构，还包括在凸缘处位于所述外部面板之间的粘结剂，所述粘结剂还将所述芯板的高峰和低谷的大致平坦的外面粘接到所述外部面板的相邻表面，并且所有的板都是金属板。
3.根据权利要求1所述的夹芯结构，其中仅一个所述外部面板具有以偏移方式变形的外围部分，以使其在凸缘处临近其他面板的相对的外围部分放置。
4.根据权利要求1所述的夹芯结构，其中所述外部面板的凸缘被卷折在一起。
5.根据权利要求1所述的夹芯结构，其中凸缘具有钩状弯曲，以使其外围部分以从外部面板的扩展平面方向角度偏移的方式定向，以与相邻的被连接的板的匹配夹芯产生互锁榫槽形状。
6.根据权利要求1所述的夹芯结构，其中由于在所述芯板中特定相邻的高峰之间选择性地定位梁脊和凹陷，所述芯板在一个方向与其他方向相比更易弯曲。
7.根据权利要求1所述的夹芯结构，还包括位于芯板和至少一个相邻的外部面板之间、且粘结芯板和至少一个相邻的外部面板的可膨胀的泡沫。
8.根据权利要求1所述的夹芯结构，其中组合的外部面板和芯板具有由四个外围边缘围成的弧状外形。
9.根据权利要求1所述的夹芯结构，其中芯板和外部面板都是金属板，并且其中具有大致的垂直弯折。
10.根据权利要求1所述的夹芯结构，其中所述外部面板和芯板是拖车夹芯板的部件。
11.根据权利要求1所述的夹芯结构，其中所述外部面板和芯板是建筑物夹芯板的部件。
12.根据权利要求1所述的夹芯结构，其中所述外部面板和芯板是移动门夹芯板的部件。
13.一种夹芯结构，包括
芯板，所述芯板包括交替的高峰和低谷，且具有沿着第一方向但不沿着垂直的第二方向在相邻的高峰之间桥接的突起的梁脊，相对于第二方向，所述芯板沿着第一方向表现出不同的机械性能，
至少一对外部面板，所述芯板位于所述至少一对外部面板之间，并且至少一个面板的外围部分包括产生连接凸缘的偏移部分。
14.根据权利要求13所述的夹芯结构，其中不同性能包括易弯曲性，并且相比于以第二方向作为旋转轴施加扭矩，在以第一方向作为旋转轴施加扭矩时所述芯板更易弯曲。
15.根据权利要求13所述的夹芯结构，其中性能是平面外剪切刚度，第一方向的所述平面外剪切刚度为第二方向的所述平面外剪切刚度的至少1.3倍。
16.根据权利要求13所述的夹芯结构，其中性能是平面外剪切强度，第一方向的所述平面外剪切强度为第二方向的所述平面外剪切强度的至少1.05倍。
17.根据权利要求13所述的夹芯结构，其中性能是长度收缩系数，所述长度收缩系数是初始长度与最终成型长度相比的比率，沿着第二方向的所述长度收缩系数至少为1.08，其大于沿着第一方向的收缩系数。
18.根据权利要求13所述的夹芯结构，其中所述第二方向是所述芯板的制造进给方向，而所述第一方向是横向进给方向，并且所述芯板是金属。
19.根据权利要求13所述的夹芯结构，还包括：
粘结剂，其将芯板粘接到外部面板；
芯板和面板的至少一个是金属板；
在高峰和低谷的成型期间芯板不需要润滑剂；并且
在室温温度下使用压纹辊进行成型。
20.根据权利要求13所述的夹芯结构，其中所述外部面板具有在一个方向而不在其他方向的永久弯曲定向，以用围绕外部面板的四个外围边缘来限定圆柱弧形的至少部分。
21.根据权利要求13所述的夹芯结构，还包括至少两个另外的金属芯板，每个金属芯板在其中均具有交替的高峰和低谷，芯板在成型后以堆叠的方式相互连接，并且大致平坦的面板邻近堆叠的芯板的外侧表面连接到高峰和低谷。
22.根据权利要求13所述的夹芯结构，还包括位于芯板和至少一个外部面板之间的可膨胀的建筑泡沫。
23.根据权利要求13所述的夹芯结构，还包括位于芯板和至少一个外部面板之间的可膨胀的隔热泡沫。
24.根据权利要求13所述的夹芯结构，其中两个外部面板的外围部分在连接凸缘处接触在一起，没有芯板位于外部面板的外围部分之间。
25.根据权利要求13所述的夹芯结构，其中两个外部面板的连接凸缘限定的外围部分以互锁的方式卷折在一起。
26.根据权利要求13所述的夹芯结构，其中外部面板沿着大致平行于第一方向的方向延长的折痕弯折，而几乎没有降低靠近折痕任意侧的结构性能。
27.一种夹芯结构，包括：
芯板，其包括交替的高峰和低谷；
至少一个外部面板，其连接到芯板；和
泡沫，其将面板粘结到芯板，泡沫为(a)建筑泡沫，或(b)在将外部面板放置在芯板上之前为大致固态形式的泡沫中的至少一个。
28.根据权利要求27所述的夹芯结构，其中所述泡沫是在膨胀之后填充芯板和相邻的至少一个外部面板之间的几乎所有的空间的可膨胀的建筑泡沫。
29.根据权利要求27所述的夹芯结构，其中所述泡沫是在膨胀之后填充芯板和相邻的至少一个外部面板之间的几乎所有的空间的可膨胀的隔热泡沫。
30.根据权利要求27所述的夹芯结构，其中至少一个外部面板包括它们之间包夹芯体的一对外部面板，并且泡沫在芯板的两侧。
31.根据权利要求27所述的夹芯结构，其中所述泡沫在至少一个外部面板连接之前，以球状或粉末、大致固态的形式被初始地置于芯体的低谷中。
32.根据权利要求27所述的夹芯结构，其中附接的泡沫和板的夹芯具有弧形的外部形状。
33.根据权利要求27所述的夹芯结构，其中附接的泡沫和板的夹芯具有垂直弯曲的外部形状。
34.一种夹芯结构，包括：
至少两个大致平坦的板；和
至少三个芯板，每个芯板均具有交替的高峰和低谷；
所述芯板是相互堆叠关系并且大致平坦的板连接到至少一个芯板的外部附着表面。
35.根据权利要求34的所述夹芯结构，还包括位于相邻的一对芯板之间的中间的大致平坦的板，其中所有的板都是金属板。
36.根据权利要求34所述的夹芯结构，其中堆叠的所述芯板的高峰和低谷彼此大致对齐。
37.根据权利要求34所述的夹芯结构，还包括位于至少一个芯板和相邻板之间的可膨胀的泡沫。
38.根据权利要求34所述的夹芯结构，还包括在所述芯板相邻的高峰之间沿第一方向但不沿垂直的第二方向桥接的升高的梁脊，从而允许芯板围绕平行于第一方向的轴比围绕平行于第二方向的轴更易弯曲。
39.一种夹芯结构，包括：
由金属制成的外部面板；
包括交替的高峰和低谷的芯板，所述芯板是金属板并且位于外部面板之间；和
板的夹芯，其当在最终制造状态中具有弧形外部形状和四个外围边缘。
40.根据权利要求39所述的夹芯结构，其中在最终制造状态中板的夹芯具有圆柱外部形状，并且在最终制造状态中两个外围边缘相互重叠。
41.根据权利要求39所述的夹芯结构，其中在弧形成型以前板在大致平坦的外部状态下粘结在一起。
42.根据权利要求39所述的夹芯结构，还包括位于至少两个板之间的泡沫。
43.一种夹芯结构，包括：
由金属制成的外部面板；和
其中包括交替的高峰和低谷的金属芯板，所述芯板粘贴在外部面板之间以产生夹芯；
所述夹芯在折痕弯折以产生至少两个相邻且大致垂直的壁，而几乎没有降低邻近折痕两侧的夹芯的结构抗压性能。
44.根据权利要求43所述的夹芯结构，还包括位于至少一对板之间的可膨胀的泡沫。
45.根据权利要求43所述的夹芯结构，其中设置另外的折痕弯折以使板产生封闭的盒状截面形状。
46.根据权利要求43所述的夹芯结构，其中所述芯板包括相邻高峰之间沿一个方向但不沿垂直的方向桥接的升高的梁脊，从而使得芯板沿与弯折的板的折痕同心的方向更易弯曲。
47.一种制造夹芯结构的方法，所述方法包括对芯板施加张力，同时在室温温度下使用成型辊在芯板中形成交替的高峰和低谷，并且在芯板和成型辊之间不使用润滑剂。
48.根据权利要求47所述的方法，还包括：
(a)在位于成型辊之间的芯板形成高峰和低谷后，将粘结剂施加到相对的高峰和低谷表面的最外平面；和
(b)在小于20磅每平方英尺的压力下将外部面板层压到芯板平面上。
49.根据权利要求48所述的方法，还包括：
(a)在施加粘结剂以后预热堆叠的外板和芯板；和
(b)在比步骤(a)更高的热量下并且在几乎均匀的压力下层压组件；和
(c)在层压之后使用冷却单元冷却层压板。
50.根据权利要求47所述的方法，还包括：
(a)在外部面板之间产生外围凸缘，在外围凸缘之间没有芯板位于它们之间；和
(b)在外围凸缘处将外部面板卷折在一起。
51.根据权利要求47所述的方法，其中在高峰和低谷形成期间，使用接触芯板的至少一个压紧轮对芯板施加张力。
52.根据权利要求47所述的方法，其中在高峰和低谷形成期间，使用接触芯板的至少一个偏压臂对芯板施加张力，以在芯板成型的同时仅在进给方向产生张力。
53.根据权利要求47所述的方法，还包括在芯板内的高峰和低谷的整个形成期间，在成型辊之间独立地进给芯板的切割坯料，所述成型辊具有平行并且以固定位置间隔的旋转轴。
54.根据权利要求47所述的方法，其中每个成型辊具有以相对于大致圆柱形的辊筒表面以独立高度突出的一组成型销，每个销的横向直径不小于该销的独立高度，并且半径定位为从每个销的侧壁到辊筒表面。
55.根据权利要求47所述的方法，还包括：
使用压纹辊形成高峰和低谷；
沿着第一方向但不沿着垂直的第二方向产生桥接在相邻的高峰之间的突起的梁脊；和
在形成高峰和低谷期间，芯板在第二方向的收缩比在第一方向的收缩更大，而芯板的垂直于压纹辊的轴的外围边缘不收缩。
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