DE102011009868B4 - Method for producing a cellular core layer for lightweight panels - Google Patents

Method for producing a cellular core layer for lightweight panels Download PDF

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DE102011009868B4
DE102011009868B4 DE102011009868.2A DE102011009868A DE102011009868B4 DE 102011009868 B4 DE102011009868 B4 DE 102011009868B4 DE 102011009868 A DE102011009868 A DE 102011009868A DE 102011009868 B4 DE102011009868 B4 DE 102011009868B4
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standing
hanging
core layer
producing
common
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DE102011009868A1 (en
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Gunter Tannhäuser
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Genima Innovations Marketing GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B32B3/26—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 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
    • B32B3/28—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 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/12—Ships

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

Verfahren zur Herstellung einer zellulären Kernschicht für Leichtbauplatten, bei dem zwei Folien mit darin ausgeformten Pyramiden- oder Kegelstümpfen so ineinander gefügt werden, dass die zwischen jeweils benachbarten ”hängenden” und ”stehenden” Ausformungen sich berührenden Randzonen miteinander verbunden werden, dadurch gekennzeichnet, dass durch eine kongruente Ausführung dieser Pyramiden- oder Kegelformen gemeinsame Berührkanten ermöglicht sind, wobei die gemeinsamen Kanten der ”hängenden” und der sie umstehenden ”stehenden” Pyramiden oder die gemeinsamen Tangenten ”hängender” und der sie umstehender ”stehender” gerader Kegel, durch thermoplastische Ausformung und gleichzeitiges Verschweißen zweier Folien im Twinsheet-Verfahren form- und materialschlüssig durchgehend miteinander verschweißt werden.A method for producing a cellular core layer for lightweight panels, in which two films with pyramid or truncated cones formed therein are joined together so that the between each adjacent "hanging" and "standing" formations touching edge zones are interconnected, characterized in that a congruent execution of these pyramidal or conical shapes common touch edges are possible, the common edges of the "hanging" and the standing around them "standing" pyramids or the common tangents "hanging" and the surrounding them "standing" straight cone, by thermoplastic molding and Simultaneous welding of two foils in a Twinsheet process are welded to each other in a form-fitting and material-locking manner.

Description

Die Erfindung bezieht sich auf ein Verfahren zur Herstellung einer zellulären Kernschicht für LeichtbauplattenThe invention relates to a method for producing a cellular core layer for lightweight panels

Leichtbaupatten werden zumeist als Sandwichstrukturen ausgeführt und bestehen daher aus einem leichten Kern und zug- sowie stauchfesten Deckschichten. Hohe Steife und Tragfähigkeit werden dabei durch die geometrischen Verhältnisse bestimmt: So lange die Kernschicht die beiden Deckschichten auf fester Distanz halten kann, muss bei einer möglichen Durchbiegung die der Last abgewandte Seite gedehnt und die der Last zugewandte Seite gestaucht werden. Hat man stauch- und zugfeste Deckschichten, was mit vergleichsweise geringem Materialaufwand möglich ist, bleibt die Platte also so lange steif, wie sich die Kernschicht nicht verformt.Lightweight batten are usually designed as sandwich structures and therefore consist of a lightweight core and tensile and compression-resistant cover layers. High stiffness and load-bearing capacity are determined by the geometric conditions: As long as the core layer can hold the two cover layers at a fixed distance, the side facing away from the load must be stretched and the side facing the load must be compressed in the case of a possible deflection. If one has compression and tension-resistant cover layers, which is possible with comparatively little material expenditure, the plate thus remains rigid as long as the core layer does not deform.

Als Kernstrukturen dafür sind hochkant aufgebaute Waben- oder Röhrchenstrukturen verbreitet, neben Hartschäumen, die aber nicht duktil sein dürfen und daher meist schwerer sind.The core structures for this are honeycomb or tubular structures that are edgewise, in addition to hard foams, which may not be ductile and therefore are usually heavier.

Ein Nachteil von Waben- und Röhrchenstrukturen ist jedoch die kleine Fläche, die zur Verbindung mit den Deckschichten zur Verfügung steht und ihre geringe Schubfestigkeit ohne feste Verklebung. Dies wurde bereits durch die Entwicklung von Kernen mit Doppelpyramiden-Struktur nach DE 10 2008 007 516 A1 bzw. WO 2009/097 836 A1 überwunden.A disadvantage of honeycomb and tube structures, however, is the small area available for connection to the cover layers and their low shear strength without firm bonding. This has already been postulated by the development of nuclei with double pyramidal structure DE 10 2008 007 516 A1 respectively. WO 2009/097 836 A1 overcome.

Es besteht aber das Problem, dass die Kernschichten derartiger Strukturen in der Querrichtung durchlässig sind. Das macht sie für Anwendungen, die auch bei einseitig beschädigten Deckschichten gasdicht bleiben oder kein Wasser aufnehmen sollen, wie z. B. Bootsrümpfe oder Behälter, ungeeignet.However, there is a problem that the core layers of such structures are permeable in the transverse direction. This makes them suitable for applications that remain gas-tight even in the case of one-sided damaged cover layers or do not absorb water, such as: As boat hulls or containers, unsuitable.

Auch ist die Tragfähigkeit all derartiger Strukturen bei knickender Belastung dann an der Grenze, wenn sich die distanzgebenden Elemente selbst verformen. Dies kann zwar durch höhere Wandstärke – durch dickere Folien oder geringeres Tiefziehverhältnis bei der Ausformung – vermieden werden, bedeutet aber höheren Materialeinsatz und größeres Gewicht. Diese Nachteile treten u. a. in den früheren Patenten DE 692 09 474 T2 , GB 601 674 A , DE 10 2004 062 264 A1 und DE 10 2008 007 516 A1 durchwegs auf.Also, the load-bearing capacity of all such structures at kinking load is then at the limit, if the dissipative elements deform themselves. Although this can be avoided by higher wall thickness - thicker films or lower thermoforming ratio in the molding - but means higher material usage and greater weight. These disadvantages occur, inter alia, in the earlier patents DE 692 09 474 T2 . GB 601 674 A . DE 10 2004 062 264 A1 and DE 10 2008 007 516 A1 consistently on.

Um diese Nachteile zu überwinden, wird eine Kernstruktur vorgeschlagen, bei der zwei Folien mit darin ausgeformten Pyramiden- oder Kegelstümpfen so ineinandergefügt sind, dass die zwischen jeweils benachbarten ”hängenden” und ”stehenden” Ausformungen sich berührenden Randzonen form- und materialschlüssig miteinander verbunden und durch das sog. Twinsheet-Verfahren hergestellt werden.In order to overcome these disadvantages, a core structure is proposed in which two films with pyramidal or truncated cones formed therein are interlocked in such a way that the edge zones which come into contact between adjacent "hanging" and "standing" formations are positively and materially connected to each other and through the so-called twinsheet process can be produced.

So werden also die Kanten der ”hängenden” und die der sie umstehenden ”stehenden” Pyramiden, oder die gemeinsamen Tangenten ”hängender” und der sie umstehender ”stehender” gerader Kegel miteinander verschweißt, wie dies bei thermoplastischer Ausformung und gleichzeitigen Verschweißung zweier Folien im sog. Twinsheet-Verfahren möglich ist. Zwar sind Kernstrukturen bekannt, bei denen entsprechende Ausformungen ineinander rasten, oder durch Schweißpunkte an den Pyramiden-Abschnitten mit nicht ausgeformten Partien der Gegenbleche oder -Folien verbunden sind. Ohne zusätzlichen Aufwand weisen diese aber keine geschlossenen, dichten Zellen auf und erfordern für vergleichbare Steife zudem höhere Wandstärken – sie sind daher erheblich schwerer. Denn bei der erfindungsgemäß hergestellten Struktur wird wesentlich höhere Steife und insbesondere Kickbelastbarkeit dadurch erzielt, dass – neben der Verrastung oder Verbindung der Pyramiden- oder Kegelstümpfe mit der jeweils gegenüberliegenden Fläche – die Kanten der ausgeformten oberen und unteren Strukturelemente durchgehend miteinander verbunden werden.Thus, the edges of the "hanging" and the standing around them "standing" pyramids, or the common tangents "hanging" and the surrounding them "standing" straight cone welded together, as in thermoplastic molding and simultaneous welding of two films in the so-called Twinsheet method is possible. Although core structures are known in which corresponding formations snap into each other, or are connected by welds on the pyramid sections with non-formed parts of the counter sheets or films. Without additional effort, however, these have no closed, dense cells and also require higher wall thicknesses for comparable rigidity - they are therefore considerably heavier. Because in the structure according to the invention substantially higher stiffness and in particular Kickbelastbarkeit achieved in that - in addition to the locking or connection of the pyramid or truncated cones with the respective opposite surface - the edges of the molded upper and lower structural elements are connected to each other throughout.

Dies ist auch der entscheidende Unterschied zur zunächst ähnlich erscheinenden Lösung in US 4.495.237 A , in der keine Verbindung der Kanten angestrebt wird.This is also the decisive difference to the initially similar solution in US 4,495,237 A , in which no connection of the edges is desired.

Dies kann auch das Problem der Schrauben- und Nagelhaltung in derartigen Strukturen verbessern, weil ein senkrecht eindringendes Befestigungselement ausreichender Länge neben der Deckschicht zwei Materialschichten des Kernes – und zwar fast immer schräg – durchdringt. Ferner ist es auch bei beliebig verlaufenden Schnitten durch die Struktur nicht möglich, auf tiefgehende Leerstellen zu treffen, die ein Befestigen von Kanten an der Struktur dadurch erschweren, dass ein Kleberauftrag in die Tiefe der Struktur wegsacken kann.This can also improve the problem of screw and nail retention in such structures, because a vertically penetrating fastener of sufficient length in addition to the top layer two material layers of the core - and almost always obliquely - penetrates. Furthermore, even with random cuts through the structure, it is not possible to encounter deep voids that make it difficult to secure edges to the structure by allowing an application of adhesive to sag into the depth of the structure.

Die Erfindung wird in den anliegenden Zeichnungen 1 bis 3 näher dargestellt:The invention is illustrated in the attached drawings 1 to 3 shown in more detail:

1 zeigt die Ausformung von nach oben stehenden Pyramidenstümpfen 1 bis 9 (gerastert) aus der Grundfolie 10, während exemplarisch vier von der oberen Folie 11 nach unten ausgeformte Pyramidenstümpfe 12 bis 15 so in den unteren Pyramidenstümpfen 1 bis 9 (liniert) fluchten, dass sich im Twinsheet-Verfahren neben verschweißender Pyramidenabschnitten, z. B. 16 und 17, auch verschweißende gemeinsame Kanten, z. B. 18 bis 20 ergeben. 1 shows the formation of upstanding truncated pyramids 1 to 9 (screened) from the base film 10 while exemplarily four from the top sheet 11 downwardly shaped truncated pyramids 12 to 15 so in the lower pyramid stumps 1 to 9 (ruled) are aligned, that in the Twinsheet method in addition to welding pyramid sections, z. B. 16 and 17 , also welding common edges, z. B. 18 to 20 result.

2 zeigt, wie sich bei Durchschneiden in beliebiger Richtung (die Schnittlinie 21 ist möglichst ungünstig gewählt) immer Schnittkanten angeschnittener Flächen, z. B. 22 bis 25, ergeben, die eine druckfeste Verbindung mit entlang der Schnittfläche aufzubringenden Abschluss kanten (nicht dargestellt) ermöglichen. 2 shows how when cutting in any direction (the cutting line 21 is chosen as unfavorable) always cut edges of cut surfaces, z. B. 22 to 25 , which provide a pressure-resistant connection with applied along the cut surface end edges (not shown).

3 zeigt eine Ausführung mit geraden Kegelstümpfen, z. B. 26 und 27. Sie hat den Vorteil möglicher höherer Fertigungstoleranzen, weil hier nicht wie bei im Querschnitt rechteckigen oder sternförmigen Pyramiden deren Kanten genau zueinander fluchten müssen, sondern beim Ineinanderfügen zwangsweise Berührtangenten (z. B. 28, 29) entstehen und somit ein leichter Versatz der Elemente weniger stört. Hier nicht ausgeführt ist die – ebenfalls mögliche – Kombination von Kegel- und Pyramidenabschitten auf einer oder zwischen zwei Folien. 3 shows a design with straight truncated cones, z. B. 26 and 27 , It has the advantage of possible higher manufacturing tolerances, because here, as is the case with pyramids which are rectangular or star-shaped in cross section, their edges do not have to be exactly aligned with one another, but when they are joined together forcibly touch tangents (eg. 28 . 29 ) and thus less disturbing a slight offset of the elements. Not possible here is the - also possible - combination of conical and pyramidal sections on one or between two foils.

Claims (2)

Verfahren zur Herstellung einer zellulären Kernschicht für Leichtbauplatten, bei dem zwei Folien mit darin ausgeformten Pyramiden- oder Kegelstümpfen so ineinander gefügt werden, dass die zwischen jeweils benachbarten ”hängenden” und ”stehenden” Ausformungen sich berührenden Randzonen miteinander verbunden werden, dadurch gekennzeichnet, dass durch eine kongruente Ausführung dieser Pyramiden- oder Kegelformen gemeinsame Berührkanten ermöglicht sind, wobei die gemeinsamen Kanten der ”hängenden” und der sie umstehenden ”stehenden” Pyramiden oder die gemeinsamen Tangenten ”hängender” und der sie umstehender ”stehender” gerader Kegel, durch thermoplastische Ausformung und gleichzeitiges Verschweißen zweier Folien im Twinsheet-Verfahren form- und materialschlüssig durchgehend miteinander verschweißt werden.A method for producing a cellular core layer for lightweight panels, in which two films with pyramidal or truncated cones formed therein are joined together so that the between each adjacent "hanging" and "standing" formations touching edge zones are interconnected, characterized in that a congruent execution of these pyramidal or conical shapes common touch edges are possible, the common edges of the "hanging" and the standing around them "standing" pyramids or the common tangents "hanging" and the surrounding them "standing" straight cone, by thermoplastic molding and simultaneous welding of two foils in a twinsheet process, in a form-fitting and material-locking manner, are continuously welded together. Verfahren zur Herstellung einer zellulären Kernschicht für Leichtbauplatten nach Anspruch 1, dadurch gekennzeichnet, dass die ausgeformten Kegel- oder Pyramidenstümpfe auch mit den nicht ausgeformten Bereichen zwischen den Ausformungen des gegenüberliegenden Strukturelements verschweißt werden.A method for producing a cellular core layer for lightweight panels according to claim 1, characterized in that the shaped conical or truncated pyramids are also welded to the non-formed areas between the formations of the opposing structural element.
DE102011009868.2A 2011-01-31 2011-01-31 Method for producing a cellular core layer for lightweight panels Expired - Fee Related DE102011009868B4 (en)

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CN105082635A (en) * 2015-08-26 2015-11-25 杭州电子科技大学 Multicycle energy absorbing structure
CN106592853B (en) * 2016-11-07 2019-11-22 北京建筑大学 Concrete Sandwich Panel and preparation method thereof

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB601674A (en) * 1945-01-23 1948-05-11 Naum Gabo Improvements in or relating to plate-like structures
US4495237A (en) * 1983-06-10 1985-01-22 Patterson Fred R Pyramidal core structure
DE69209474T2 (en) * 1991-12-26 1996-11-28 Lucien Poincelet Device for the production of floors or various sandwich panels and elements used for their production
DE102004062264A1 (en) * 2004-12-23 2006-07-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Building element, in particular wall cladding, and method for its production
DE102008007516A1 (en) * 2008-02-05 2009-08-06 Genima Innovations Marketing Gmbh Core structure for the construction of multilayer plates or shells

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB601674A (en) * 1945-01-23 1948-05-11 Naum Gabo Improvements in or relating to plate-like structures
US4495237A (en) * 1983-06-10 1985-01-22 Patterson Fred R Pyramidal core structure
DE69209474T2 (en) * 1991-12-26 1996-11-28 Lucien Poincelet Device for the production of floors or various sandwich panels and elements used for their production
DE102004062264A1 (en) * 2004-12-23 2006-07-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Building element, in particular wall cladding, and method for its production
DE102008007516A1 (en) * 2008-02-05 2009-08-06 Genima Innovations Marketing Gmbh Core structure for the construction of multilayer plates or shells

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