EP1728936A2 - Structured material web made from a web material and method of making - Google Patents

Abstract

The material sheet (100) has a flat and three-dimensional rough structuring (102,103) which acts as a strengthener and the section adjoining the rough structuring has fine structuring (105) with finely structured elements whose dimensions are smaller than those of the rough structured elements. An area of fine structuring can be provided around the edges. The fine structuring can be undulating, beaded, folded or have a diamond, hexagonal, rhomboid or other structure. The sheet material can be made from metal, plastics, paper or cardboard, fibre webbing for example. Independent claim describes method for making structured material sheet by incorporating rough structured elements and smaller dimensioned fine structured elements.

Description

The invention relates to a structured material web of a sheet material, in particular sheet material web, with a coarse structure comprising coarse structure elements and stiffening, which is formed flat and three-dimensional, and to methods for producing.

Background of the invention

For efficient lightweight construction, especially in the automotive, aerospace, construction and design sectors, as well as for household appliances and apparatus, ever higher demands are placed on the design with regard to a high degree of rigidity, high fatigue strength and favorable acoustic properties with low weight. Here, multidimensionally stiffening structures of thin materials can play a special role, because they give the component despite reduced wall thickness high rigidity, favorable acoustic properties and an attractive design.

Numerous methods are known for providing a thin material web, such as sheet metal or plastic film, with stiffening structures. In order to improve the bending and buckling stiffness of components, mechanically structured materials, such as dimpled sheets, are known. However, these purely mechanically structured materials require high Plastifizierungsreserven of the starting material, since when structuring using mechanical forming and embossing tools a large plasticization of the material occurs. Furthermore, the stiffening is known by a bead, which gives the component but only in one direction increased rigidity. Perpendicular to the component remains bending, thrust and torsionally soft.

From the document EP 0 693 008 B1 Beulstrukturierte material webs are known, which are made on the basis of a self-organized structuring process out of a curved shape out. Thus, thin-walled sheets and foils can be structured in a materially and multi-dimensionally gentle manner in comparison to purely mechanical embossing methods (cf. DE 198 56 236 A1 ). The beulstrukturierten material webs are then in a special Straightening process in which the structures are completely preserved, converted into the flat shape. The multi-dimensional buckling structures produced in this way are also called "vault structures". They have a regular structuring with wrinkles and traps enclosed between the folds.

In the known buckling / vault structuring method, in the curved and internally partially supported material web, initially with a slight external pressure load, namely at the beginning in the elastic material behavior of the material web, sinusoidally revolving structural waves, which have only a very small amplitude. If the external pressure load against the curved material web is then increased, an unstable state is created, which triggers a dynamic breakdown (spontaneous denting) in the elastic-plastic material behavior of the material web. This complex process can be described by the non-linear laws of mechanics (nonlinear geometrical deformation of shells), thermodynamics and material (non-linear, elastic-plastic flow curve), far away from the equilibrium state. These, self-organizing, Beulstrukturen can the so-called "dissipative structures" (see. I. Prigogine et al .: "Dialogue with nature "; F. Mirtsch et al .: "Corrugated Sheet Metal on the Basis of Self-organization", First International Industrial Conference Bionic 2004, Hannover Messe, Germany in: Progress - Reports VDI Series 15, p. 299 - 313 ) be assigned.

From the document DE 10 2004 044 509 A1 For example, a method is known for welding vaulted sheets to a flat frame by welding. However, it is not possible to produce a tight joint connection

In the further processing of multi-dimensionally structured materials, especially when cutting and joining structured sheets and foils, however, there are still significant deficits, because there are - in contrast to the smooth sheet metal - only a few experiences. Desirable would be thin-walled sheets and foils with a large multi-dimensional rigidity with the help of large and deep structures, which, however, are similar to further process well as the well-known smooth sheet metal. In the case of further processing, especially the tight joining plays a special role Role. For this purpose, the edge of the structured material web must be flat or at least almost flat.

There is therefore a need for material webs on the one hand with high multidimensional rigidity, which is achieved by means of large and deep structures, and on the other hand, good processability when used in the various fields of application. In this case, as far as possible, the methods known for planar material webs such as cutting, joining and forming should be usable.

Summary of the invention

The object of the invention is to provide a structured material web of a web material with a coarse structure comprising coarse structure elements and stiffening, in which the processability is improved.

This object is achieved by a structured material web according to independent claim 1 and a method for producing a structured material web according to independent claim 22. Advantageous embodiments of the invention are the subject of dependent subclaims.

According to one aspect of the invention, a structured material web of a web material, in particular sheet material web, having a coarse structure comprising coarse and stiffening coarse structure is formed, which is formed flat and three-dimensional, wherein at least one adjoining the coarse patterning section is formed with fine structure comprising fine structure elements and dimensions of Fine structure elements are smaller than dimensions of the coarse structure elements.

According to a further aspect of the invention, a method is provided for producing a structured material web from a sheet material, in particular sheet material web, in the planar and three-dimensional coarse structuring comprehensive and stiffening coarse structure elements and adjacent to the roughing at least a section with a fine structure elements comprehensive fine structuring are formed, wherein the fine structure elements are produced with dimensions that are smaller than dimensions of the coarse structure elements.

In addition to the stiffening coarse patterning, which can be formed using a wide variety of patterning technologies, the structured material web has a fine structuring in at least one section adjacent to the coarse patterning. Although the fine structuring has a somewhat less stiffening effect than the rough structuring. In this way, it is possible to partially equip the coarse-structured material web with a fine structure, which can be tightly connected to a flat frame or even adjacent metal sheets using conventional joining processes, such as welding, gluing or mechanical joining. In this case, the fine structures preferably have a structure depth, namely a clear structure height which corresponds approximately to the wall thickness of the material web to be joined, that is to say the material thickness without structure depth. The fine structuring is preferably developed and technically adapted according to the laws of controlled self-organization. In this way, the material of the material web during structuring is only slightly plasticized and spared. The remaining plasticizing reserves can be used for secondary forming processes or / and they increase the fatigue strength in the later dynamic operating behavior (Wöhler curve) of the finished product.

An advantageous embodiment of the invention can provide that in the at least one section with the fine structuring a length shortening adapted to the roughing is formed. A shortening of the length of the material web in the sections of the fine structuring is therefore advantageous because the material web is also shortened in length by the coarse patterning - d. H. Ruffle opposite the flat initial shape of the not yet structured material web experiences. The two length cuts through coarse and fine patterning are adjusted to be substantially the same. This avoids a long edge (draft / "tailor") or a long center ("bowl").

In a further development of the invention, it is preferably provided that the at least one section includes a border section with the fine structuring.

A preferred embodiment of the invention provides that a transition structure is formed between the edge portion and the rough patterning.

In an expedient embodiment of the invention, it is provided that the at least one section with the fine structuring comprise a transition section which is formed between sections with the coarse patterning.

An advantageous embodiment of the invention may provide that the at least one section with the fine structuring in the region transverse to a running direction comprises substantially flat sections formed. This is possible because during buckling or vault structuring process, the length shortening (gathering) across the production direction is considerably less than in the production direction. Further details will be described below.

In a further development of the invention, it is preferably provided that the fine structuring is formed by means of one or more structural elements from the following group of structural elements: wave structure, leaking bead structure, wrinkle structure, rhombic structure, rhombic structure, rectangular shape, heart shape and hexagonal structure.

A preferred development of the invention provides that the fine structuring is connected to the coarse patterning via a bead.

In an expedient embodiment of the invention, it is provided that the fine structuring is a self-organizing structuring. Such structures are known, for example, in the form of a bulge / bulge structure with depressions and surrounding folds or as wave structures with calottes and surrounding beads.

An advantageous embodiment of the invention can provide that the at least one section with the fine structuring has a support section.

In a further development of the invention, it is preferably provided that the at least one section with the fine structuring has a joining section.

A preferred development of the invention provides that coarse structuring is formed by wave-shaped structuring with beads and domes enclosed by the beads, the beads being formed integrally and with a radius of curvature opposite to the curvature of the calottes. The beads differ greatly from the folds formed during buckling-vaulting in terms of their bending radius in relation to the thickness of the material web. These relationships are also influenced by the material properties of the material web and by the shape of the support elements and by the thickness and the Shore hardness of the elastic intermediate layer (for the three-dimensional wave-like structuring / bead formation). The following two statements quantify these relations by way of example. In a first case, soft aluminum sheet of thickness 0.3 mm is provided with a crest-shaped (hexagonal with slightly curved folds / beads) structure of key width 33 mm. The ratio of the bending radius of the bead to the material thickness (3D-wave) is 13. The ratio of bending radius of the fold to thick material (buckling / vault structure) is 5. In a second case, stainless steel sheet (4301) of thickness 0.25 mm with a wappenförmigen structure of the wrench size 33 mm provided. The ratio of bending radius of the bead to the material thickness is 16. The ratio of bending radius of the fold to the material thickness is 7. In both cases, an elastic intermediate layer of thickness 4 mm and the Shore hardness 60 was used for the generation of the bead.

An advantageous embodiment of the invention can provide that the calottes in a central Kalottenbereich have a shape which is at least approximate to a spherical shell shape. The spherical shell shape arises from the fact that with the help of the elastic intermediate layer of the dynamic breakdown as in buckling / Völbstrukturieren cushioned and slowed down. This gives the beads a gentler radius of curvature than the folds. Therefore, with a further increase in the compressive force (on the elastic intermediate layer), the calottes can form uniformly round. This is with the folds and the dynamic formed by the punch Hollow bulges and vault structures are not.

In a further development of the invention, it is preferably provided that the beads are formed integrally according to one or a combination of a plurality of geometric basic shapes from the following group of geometric basic shapes: triangle, quadrangle, in particular square, rectangle, rhombus or parallelogram, pentagon, hexagon and octagon.

A preferred embodiment of the invention provides that the beads are formed according to a uniform geometric basic shape.

In an expedient embodiment of the invention, it is provided that the beads are formed in all directions, namely in the production direction and transversely to the production direction, each with a substantially uniform bead height.

An advantageous embodiment of the invention can provide that for at least a part of the calotte a Kalottenoberfläche is broadly diffuse reflective, wherein at least the part of the calotte is formed with the broadly diffusely reflecting Kalottenoberfläche as deep calotte.

In a further development of the invention, it is preferably provided that a dome surface is directionally reflective for at least part of the dome, wherein at least the part of the dome with the directionally reflecting dome surface is formed as flat dome.

A preferred embodiment of the invention provides that the roughing is a self-organizing structuring.

In an expedient embodiment of the invention it is provided that the web material is a material or a combination of materials selected from the following group of materials: metal, plastic, fibrous materials, in particular paper and paperboard, fibrous tissue and mesh fabric.

An advantageous embodiment of the invention can provide that the web material is formed in a sandwich construction, in which at least one intermediate web is arranged between two outer webs.

A preferred development of the invention provides that the web material is anodized aluminum sheet.

In the following, further embodiments of the invention will be explained in more detail, with the example for bulge in the field of roughing / völbstrukturierten material webs for other coarse structures arise analogously, especially in the advantageous use of wave structuring with calottes and surrounding beads. While the folds in the buckling structure arise as a result of a dynamic folding process, which in turn is comparable to a buckling, the beads are formed as a curved portion with a comparatively larger radius of curvature, so that a kind of waveform is produced in section, but a half-wavelength of the beads is less than is a half wavelength of the beads enclosed by the beads.

It has been found that beulstrukturierte webs can be provided transversely to their direction with a smooth edge and in their direction with a finely textured edge that can be easily add to a frame, without causing disturbing differences in length between the beulstrukturierten area and the smooth or fine-textured edge disturbing undulations, distortions or a "frog" occur in the structured material web. Numerous examples based on steel sheets structured in this way have confirmed this, for example with a conventional steel sheet, such as those used on buses. These surprising effects and the embodiments of the method will be described in more detail below.

When Beulstrukturieren shirring, ie the length reduction of beulstrukturierten material web against the smooth material web used is relatively low. These length reductions result from the following process parameters, such as structure depth, structure size, which is generally defined as the hexagon wrench size, material thickness and material properties. This material shortening is approximately <0.5% transverse to the structuring direction of the material web and approximately <1.0% along the structuring direction. Nevertheless, it is possible to produce a smooth edge without distortions of the edge transversely to the structuring direction of the material web by partially exposing the process pressure for the formation of the buckling structures in the material web during buckling structuring. This results in a gentle curvature of material, which forms itself virtually between the beulstrukturierten area and the smooth edge region of the web. This gentle curvature stabilizes the material web in such a way that the difference in length of approximately <0.5% between the gathered, beulstrukturierten area and the smooth edge area is compensated. This is preferably achieved when a broad edge is selected transversely to the direction of travel of the material web.

In the direction of the web, this simple measure, namely the partial exposure of the process pressure, does not lead to the goal if a distortion-free, beulstrukturierte material web with a flat, lateral edge should be achieved without disturbing edge waves. Surprisingly, however, it has been shown that adapted fine structures of the edges compensate the difference in length of approximately <1.0% between the beulstrukturierten area and the finely structured edge area so far that no disturbing edge waves occur in the web more.

Surprisingly, this also succeeds if a bead, in particular an approximately step-shaped, narrow longitudinal bead, is additionally formed between the bulge-shaped / wavy coarse-structured region of the material web and the finely structured edge region. It could have been expected that this longitudinal bead on the edge causes a disturbing, locally geometric extension of the slightly gathered material web and thereby causes distortion of the material web. However, the opposite was stated. Obviously, the bead stabilizes the structured material web. This can be explained as follows: The advantages of the bead are that it acts as an additional stiffening of the structured material web and that it also causes a decoupling between the beulstrukturierten, middle region of the material web on the one hand and their finely textured edge region on the other hand, and so instabilities between two adjacent, differently formed structures are avoided. A conceivable one disadvantageous difference in length between the two gathered, structured areas and the bead, which is preferably a step-shaped, narrow longitudinal bead, is compensated by the large stiffnesses of the adjacent, wide, beulstructured or finely structured regions of the material web.

It resulted from the finely structured edge with approximately stepped longitudinal bead yet another positive effect for the use of full beulstrukturierten material webs / metal sheets: Already in full-surface Beulstrukturieren undesirable effects such as corrugations, "frog" or "bowl" in the web occur, the one good flatness of the beulstrukturierten material web can significantly affect. This is especially true for higher strength sheets such as stainless steel or hard or semi-hard rolled sheets or fibrous materials or composites.

It could have been expected that these unwanted effects would be even greater if the structured material webs / metal sheets were additionally provided with finely structured edges and with a bead, because this would make the structuring process even more complicated. However, the opposite is the case: with the help of the bead and the finely textured edges, the flatness of the structured material web is significantly improved. The improved flatness even remains even if the edge regions (beading and fine structures) are separated again from the structured material web. This can be explained as follows: When structuring the web, the structuring roller moves in such a way that press their support elements transversely to the direction of the web to be structured against the concave side of the web and wherein the convex side of the web is pressurized. The material web is thereby somewhat gathered in its running direction, so that depressions / calottes and adjacent folds / bulges form virtually free. This forming process can be considered in a very rough approximation as a deep drawing, wherein the thin material in the running direction of the web flows slightly (into the troughs).

In contrast, takes place transversely to the direction of the web approximately an ironing stretch of the thin material, because the web transversely to its direction by supporting elements (on the structuring roller) is fixed by form and frictional engagement and therefore can not or only very little flow. This also explains why the gathering (shortening of the material web) during buckling structuring transversely to the running direction is less pronounced than in the running direction of the structured material web. However, this only applies to the large central area of the structured material web.

In the lateral edge regions of the structured material web, another deformation behavior is evident. Here, the web can also nachlauf something transversely to its direction, because the material is not hindered at the free edge. This results in spatially different gathers of the structured material web in their middle on the one hand and at their edges on the other. This also explains why the "bowl" or the "frog" can be formed by a "long middle" (meaning elongation through reduced gathering) when structuring the entire surface in their midst. These interfering influences are all the more serious, the higher-strength and more elastic the material behavior of the material web. Here, steel and aluminum sheet show a fundamentally different behavior.

Surprisingly, these disturbing influences, which significantly worsen the flatness, the stability and the acoustic behavior, are thereby eliminated or at least greatly reduced by equipping the structured material web at its edges with a bead, preferably a stepped longitudinal bead, and with adapted fine structures. By the bead, the web is fixed at its edges by form and frictional engagement, so that the thin material, similar to the middle of the material web, not or only slightly can flow. As a result, the troughs at the edges of the structured material web can not form deeper than in their midst. Therefore, the good flatness of the thus structured material web is maintained even if its edge region (bead plus finely textured edge) is separated again. In this way, a "beulstrukturierte material web with trimmed edge".

In particular, the finely structured edges of the structured material web consist of either wave-shaped or polyhedral structures and are adapted in such a way as to cause gathering (shortening), which is approximately the shortening of the beulstrukturierten Material web corresponds and wherein at the same time the texture depths at the edges are much lower than that of the troughs of the buckling structures. In this case, such wave lengths are preferably selected as wavy fine structures, which are obtained when a smooth material is provided at the edge with a stepped longitudinal bead and bent over a roller. As a result, uniform, wavy structures often appear on the edge of the thin material web. It can also be provided that the material web is flat between two wave amplitudes. So smooth edge surfaces are achieved, which facilitate the joining very much.
These fine structures can be used in all polyhedral coarse structures, such as hexagonal, crest-shaped, wavy or faceted structures.

In another embodiment, the polyhedral fine structures at the edge of the material web consist of smaller hexagonal or crest-shaped structures, which are preferably adapted to the larger hexagonal or crest-shaped structures in the middle of the material web. This is achieved by a further surprising effect: if a thin material web is provided with buckling structures only in its middle and its edges are relieved of buckling, i. not beulrued, edge structures, such as depressions and wrinkles, form spontaneously and run freely towards the edge. These shallow hollows with their gentle folds, which develop freely on the edge, are created by initiation of the inner, adjacent buckling structures.

The refinement of the fine structures preferably takes place with the aid of geometrically adapted support elements, for example on a roller or roller in continuous operation or with the aid of geometrically adapted shaping tools, such as punches and dies in discontinuous operation.

In an analogous manner, the fine structures can also consist of quadrilaterally offset or rhombic structures. In this way, can be dispensed with a bead, because no disturbing transitions occur with instabilities between the beulstrukturierten center and the finely textured edge of the web or the metal sheet. However, it can also be a bead between the beulstrukturierten center of the web and its finely textured edge are arranged to further stiffen the web.

One embodiment is that the structured material web is produced with a finely structured / smooth edge in a two-stage, preferably continuous process. In this case, a smooth material web is structured in the first step by the material web is supported from its curvature out on its inside by supporting elements and from the outside, preferably applied by means of an elastic roller with pressure. The material web is preferably provided over the entire surface with the structure. This allows for structuring different web widths a high flexibility when using the same support roller and the same elastic pressure roller. Alternatively, a smooth edge in the running direction of the structured material webs can be obtained if lateral recesses are provided in the elastic pressure roller.

A smooth edge transversely to the direction of the material web is achieved in that the pressurization is interrupted in predetermined lengths of the material web. This can be achieved either by an adapted recess of the elastomer on the pressure roller and / or by an adapted, stepwise delivery of the support element roller. In the second step, the fine structures are produced by means of forming tools, preferably by roll forming on the edge of the material web. It can also be generated at the same time a longitudinal bead. Between the first and the second step and after the second step, the web can be directed.

Another embodiment is that the structured material web is produced with a finely textured / smooth edge in an integrated, single-stage, preferably continuous process, wherein the two steps mentioned take place simultaneously. The center of the support element roller is equipped with its support elements for the production of the larger structures. The two ends of the support element roller are equipped with the support elements or shape contours for producing the fine structures and possibly for the longitudinal bead. The pressure roller has in its center an elastomer for the pressurization (for structuring) and at both ends of the incorporated shape contours for the production of fine structures. These shape contours can consist of rigid or elastic materials.

A further embodiment provides that initially a bulge / wave-structured material web is produced, oriented and then cut to form, for example, structured sheet metal sections. The metal sheets structured in this way can also have smooth edges transversely to their running direction. You can also have laterally smooth edges. In a following separate step then the fine structures and possibly a bead at the edges of the web are introduced by means of adapted forming or embossing tools, preferably by two opposing each other oppressive roles. These forming and embossing tools are made of rigid or elastic materials. The fine structures and possibly the bead can be attached to all sides of the structured metal sheet.

A further embodiment consists in that finely structured regions are introduced alternatively or additionally in the middle coarsely structured region of the structured material web, namely between two regions of the coarse texturing, optionally using at least one bead. This is possible because during buckling / wave structuring the material is only slightly plasticized and because there are still large plasticizing reserves available for the secondary introduction of fine structures. In this way, structured, preferably beulstrukturierte material webs and metal sheets can be produced, which are easy to add not only at their edges but also in their middle, coarse-structured area thermally, mechanically or by screws or gluing, for example, in the field of fine structuring.

It can further be provided that the coarse-structured material web not only receives fine structures at its edge portions, but is also provided with transition structures. These transition structures are preferably disposed between the coarse structures and the fine structures and have a smaller feature size and depth than the coarse feature elements. The transition structures have the advantage that although they are less rigid than the coarse structure elements, but a smoother transition from the coarse to give the fine structures. The transition structures are preferably formed in the case of a roll-shaped coarse patterning in that a structurally appropriate fanning out of folds of the coarse patterning takes place. Surprisingly, such fan-out are observed in soft contours when the originally flat material web gathers as a result of the coarse structuring and, as a result of the differences in length, virtually "rejects" the flat regions by itself and thereby folds gently. This produces preferably wrinkles according to the "Y-principle", in each case three folds converge to form a star point. Such gentle wrinkles of the transition structures are then reinforced by means of geometrically adapted mechanical shaping and embossing tools or rollers. This protects the material of the material web. However, geometrically similar transition structures can also be produced with the aid of embossing tools or rollers.

Furthermore, it may be provided that the manufacturing process directly connects the formation of the fine / transition structuring with the cutting / separating of the structured material web. As a result, a step is saved. In this way, a coarse-structured material web, which is optionally provided with transition structures, integrated assembled and equipped with fine structures or with other transition structures. Preferably, a separating shearing blade is used, which separates the material web obliquely. In this way, the temporal gravity remains low in a direction transverse to the material web. In each case at the location or in its vicinity, the structuring tool for the fine / transitional structuring of the material web intervenes spatially and temporally. In this way, the forces acting on the material edge and thus the machine cost remains relatively low. An additional hold-down device can ensure that the material web is fixed with low pressure.

A further embodiment consists in the fact that several process steps are linked together directly to a quasi-continuous overall process in order to drastically reduce the throughput time and to improve the economic efficiency. In the continuous structuring machine, the flat material web is at the same time in the middle region with coarse textures and at the lateral edges (in the running direction) with fine textures and optionally

Provided coarse structures. Then the straightening takes place in the flat plane. Finally, in the integrated machine, the edge of the material web is simultaneously separated perpendicular to its running direction and with fine and / or transitional structures. This creates a quasi-flat component with high stiffness on all sides, which can be easily joined on all sides.

A material web formed and produced in the manner described above can, optionally after suitable further processing, be used in various applications by utilizing the described advantageous properties. When using the material web in the various applications, there are specific advantages that have their starting point in the special construction of the material web. Advantageously, a frame construction can be used. Depending on the field of application, the material is suitably used: steel, aluminum, titanium, magnesium or alloys thereof.

Description of preferred embodiments of the invention

Fig. 1

einen Abschnitt einer hexagonal strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 2

einen Abschnitt einer hexagonal strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 3

einen Abschnitt einer wappenförmig strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 4

einen Abschnitt einer versetzt-viereckig strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 5

einen Abschnitt einer rautenförmig strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 6A, 6B

jeweils einen Abschnitt einer hexagonal strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 7

einen Abschnitt einer wappenförmig strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 8

einen Abschnitt einer hexagonal strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 9

einen Abschnitt einer wappenförmig strukturierten Materialbahn in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 10

einen Abschnitt einer hexagonal strukturierten Materialbahn mit einem feinstrukturierten Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 11

einen Abschnitt einer hexagonal strukturierten Materialbahn mit einer Übergangsstruktur und einem feinstrukturierten Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 12

einen Abschnitt einer hexagonal strukturierten Materialbahn mit Übergangsstrukturen und einem feinstrukturierten Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 13

einen Abschnitt einer hexagonal strukturierten Materialbahn mit einem ebenen Randabschnitt in Aufsicht (oben) und im Querschnitt (links und rechts);

Fig. 14

einen Abschnitt einer hexagonal strukturierten Materialbahn mit einem mittleren feinstrukturierten Abschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 15

einen Abschnitt einer räumlich facettenförmig strukturierten Materialbahn mit einem feinstrukturierten Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 16

einen Abschnitt einer räumlich facettenförmig strukturierten Materialbahn mit einem feinstrukturierten Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 17

einen Abschnitt einer räumlich facettenförmig strukturierten Materialbahn mit einem ebenen Randabschnitt in Aufsicht (oben) und im Querschnitt (unten und rechts);

Fig. 18

eine schematische Darstellung einer Vorrichtung zum Herstellen einer Materialbahn mit einer Grobstrukturierung und einer Feinstrukturierung im Randbereich im Querschnitt (links) und in Aufsicht (rechts);

Fig. 19

eine schematische Darstellung einer Vorrichtung zum Herstellen einer Materialbahn mit einer Grobstrukturierung und einer Feinstrukturierung im Randbereich im Querschnitt (links) und in Aufsicht (rechts);

Fig. 20

eine schematische Darstellung einer Vorrichtung zum Herstellen einer Materialbahn mit einer Grobstrukturierung und einer Feinstrukturierung im Randbereich im Querschnitt;

Fig. 21

eine schematische Darstellung einer Vorrichtung zum Herstellen einer Materialbahn mit Grob- und Feinstrukturierung im Querschnitt, die beim Feinstrukturieren ein integriertes Schneiden ermöglicht; und

Fig. 22

eine schematische Darstellung einer Vorrichtung zum Herstellen einer Materialbahn mit Grob- und Feinstrukturierung im Querschnitt.

The invention is explained below with reference to embodiments with reference to figures of a drawing. Hereby show:

Fig. 1

a section of a hexagonal structured material web in plan view (top) and in cross section (bottom and right);

Fig. 2

a section of a hexagonal structured material web in plan view (top) and in cross section (bottom and right);

Fig. 3

a section of a crest-shaped structured material web in plan view (top) and in cross section (bottom and right);

Fig. 4

a section of a staggered-square structured material web in plan view (top) and in cross-section (bottom and right);

Fig. 5

a section of a diamond-shaped structured material web in plan view (top) and in cross section (bottom and right);

Fig. 6A, 6B

in each case a section of a hexagonally structured material web in plan view (top) and in cross section (bottom and right);

Fig. 7

a section of a crest-shaped structured material web in plan view (top) and in cross section (bottom and right);

Fig. 8

a section of a hexagonal structured material web in plan view (top) and in cross section (bottom and right);

Fig. 9

a section of a crest-shaped structured material web in plan view (top) and in cross section (bottom and right);

Fig. 10

a section of a hexagonal structured material web with a finely structured edge section in plan view (top) and in cross section (bottom and right);

Fig. 11

a section of a hexagonal structured material web with a transition structure and a finely structured edge portion in plan view (top) and in cross section (bottom and right);

Fig. 12

a section of a hexagonal structured material web with transition structures and a finely structured edge section in plan view (top) and in cross section (bottom and right);

Fig. 13

a section of a hexagonal structured material web with a flat edge portion in plan view (top) and in cross section (left and right);

Fig. 14

a section of a hexagonal structured material web with a middle fine structured section in plan view (top) and in cross section (bottom and right);

Fig. 15

a section of a spatially facet-structured material web with a finely structured edge portion in plan view (top) and in cross section (bottom and right);

Fig. 16

a section of a spatially facet-structured material web with a finely structured edge portion in plan view (top) and in cross section (bottom and right);

Fig. 17

a section of a spatially facet-structured material web with a flat edge portion in plan view (top) and in cross section (bottom and right);

Fig. 18

a schematic representation of an apparatus for producing a material web with a roughing and a fine structuring in the edge region in cross section (left) and in supervision (right);

Fig. 19

a schematic representation of an apparatus for producing a material web with a roughing and a fine structuring in the edge region in cross section (left) and in supervision (right);

Fig. 20

a schematic representation of an apparatus for producing a material web with a roughing and a fine structuring in the edge region in cross section;

Fig. 21

a schematic representation of an apparatus for producing a material web with coarse and fine structuring in cross-section, which enables an integrated cutting during fine structuring; and

Fig. 22

a schematic representation of an apparatus for producing a material web with coarse and fine structuring in cross section.

In the following it will be described with reference to Figs. 1 to 22, as in a material web with a three-dimensional stiffening rough patterning portions of the material web, which adjoin the roughing, are formed as sections with a fine patterning. For the same features, the same reference numerals are used in Figs. 1 to 22, where appropriate.

The formation of sections with a fine structuring, optionally in one of the following embodiments, can in principle be used for arbitrarily three-dimensionally coarsely structured material webs, in particular sheet material webs, for example also in the case of coarse-structured material webs which have the buckling / buckling structure known as such with folds and of the trays are enclosed in the folds. Therefore, the formation of the support sections will be described below using the example of a bulge / vault-structured material web, in which the coarse structuring in the form of folds and hollows is formed. In an analogous manner, the coarse patterning can be formed in other embodiments by means of domes and surrounding beads and by means of three-dimensional facets.

1 schematically shows the plan view and the cross section of a hexagonally structured material web 100 with folds 102 and depressions 103. The edge of the material web 100 comprises a longitudinal bead 104 and a wave-shaped fine structure 105.

2 shows schematically the top view and the cross section of a hexagonal structured material web 100 with folds 102 and depressions 103. The edge of this material web 100 consists of a longitudinal bead 104 and a finely structured edge, which is composed of fine corrugations 105 and flat surfaces 106.

3 schematically shows the plan view and the cross section of an emblem-shaped material web 100 with folds 102 and depressions 103. The edge of this material web 100 consists of a longitudinal bead 104 and a finely structured edge which is composed of fine undulations 105 and flat surfaces 106.

4 shows schematically the top view and the cross section of a staggered square-structured material web 100 with folds 102 and depressions 103. The edge of this material web 100 consists of a longitudinal bead 104 and a finely structured edge, which is composed of fine corrugations 105 and flat surfaces 106 ,

5 shows schematically the top view and the cross section of a diamond-shaped structured material web 100 with folds 102 and depressions 103. The edge of this material web 100 consists of a longitudinal bead 104 and a finely structured edge which is composed of fine waves 105 and flat surfaces 106.

FIGS. 6A and 6B schematically show the plan view and the cross section of a hexagonally structured material web 100 with folds 102 and depressions 103 and with an outgoing, finely structured edge. Fig. 6A shows a finely textured edge with leaking folds 107 immediately adjacent to the hexagonal structure and shorter folds 108, each between the folds 107 are arranged. Fig. 6B shows a finely textured edge with leaking folds 107 and 108 immediately adjacent to the hexagonal structure.

7 shows schematically the top view and the cross section of an emblem-shaped structured material web 100 with folds 102 and depressions 103 and with an outgoing, finely structured edge. The finely textured edge consists of leaking pleats 107 immediately adjacent to the crest-shaped structure and shorter pleats 108 each disposed between the pleats 107.

8 shows schematically the top view and the cross section of a hexagonal structured material web 100 with folds 102 and depressions 103 and with diamond-shaped transition structures with folds 109 and depressions 110. The outgoing, finely structured edge consists of folds 107 and folds 108 which conform to the diamond-shaped Immediately connect the transition structure. The areas between the folds 107 and the folds 108 are curved; but they can also be executed.

9 shows schematically the top view and the cross section of an emblem-shaped material web 100 with folds 102 and depressions 103 and with crest-shaped transition structures with their folds 109 and depressions 110. The outgoing, finely structured edge consists of folds 107 and folds 108, which adjoin the immediately connect the crest-shaped transition structure. The areas between the folds 107 and the folds 108 are curved; but they can also be executed.

10 shows schematically the top view and the cross section of a hexagonal structured material web 100 with folds 102 and depressions 103 and heart-shaped transition structures with folds 111 and folds 112. The outgoing, finely structured edge consists of further folds 113, which adjoin the heart-shaped transition structure directly connect. The surfaces between the other folds 113 are curved; but they can also be executed.

11 shows schematically the top view and the cross section of a hexagonal structured material web 100 with folds 102 and depressions 103 and with heart-shaped transition structures with transition structure folds 111 and transition structure folds 112, as well as with further hexagonal smaller transition structures. The leaking, finely textured edge consists of further folds 113, which immediately adjoin the smaller hexagonal transition structure. The surfaces between the other folds 113 are curved; but they can also be executed.

12 schematically shows the plan view and the cross section of a hexagonal structured material web 100 with folds 102 and depressions 103 and with heart-shaped transition structures with transition structure folds 111 and transition structure folds 112, as well as with a plurality of rows of further hexagonal smaller transition structures. The leaking, finely textured edge consists of further folds 113, which immediately adjoin the smaller hexagonal transition structure. The surfaces between the other folds 113 are curved; but they can also be executed.

13 schematically shows the plan view and the cross section of a hexagonally structured material web 100 with folds 102 and depressions 103 and a freely running flat edge 114 in the longitudinal direction (production direction in the continuous bulge structuring process). The fold 115 of the upper hexagonal structure, together with the self-forming, smooth bulges 116, form a common stabilizing transition from the structured area to the flat edge 114.

14 shows schematically the plan view and the cross section of a hexagonal coarsely structured material web 100 with the folds 102 and the depressions 103. A middle fine structuring consists of further folds 117. The right structures are mirror - symmetrically followed by the middle fine structuring. The middle fine structuring advantageously serves, for example, for joining connections in the middle of the hexagonal coarse-structured material web 100.

15 shows schematically the top view and the cross section of a spatially facet-structured material web 100 with the flat diamond-shaped surfaces 118 and 119. The surfaces 118 are arranged spatially offset from one another and are bounded by folds 120. The surfaces 119 are bounded by folding 121. In a perspective view, the surfaces 118 and 119 appear like cubes juxtaposed. All other arrangements correspond to the embodiment in FIG. 1.

16 schematically shows the plan view and the cross section of a spatially facet-shaped structured material web 100 analogous to the embodiment in FIG. 15. The edge region corresponds to the embodiment in FIG. 2.

17 schematically shows the plan view and the cross section of a spatially facet-shaped coarsely structured material web 100. In the direction of travel (arrow direction) of the facet-shaped coarse-structured material web 100, diamond-shaped surfaces 119 lie together on a common surface, which are shown as hatched areas. Therefore, an approximately cut in the middle edge 122 of the diamond-shaped surfaces 119 is located on a common contour line. Thus, a fine structuring is not required here. In the lower view in FIG. 17, an edge 120 can be seen.

FIG. 18 schematically shows a device for fine structuring of an already hexagonal coarsely structured material web 100 in cross section (left) and in plan view (right). An upper embossing roller 123 with embossing elements 124 and a lower embossing roller 125 with embossing elements 126 press from above and below against the edge of the already coarsely structured material web 100. A bead disc 127, which is connected to the upper embossing roller 123, presses from above against the edge of the material web 100 to produce a longitudinal bead 104 (analogous to FIG. 1). The contours of the embossing elements 124 and 126 preferably correspond to the self-initiating folds when a step-folded material web is bent over a roller which has approximately the same diameter as the upper and the lower embossing roller 123, 125. Thus, a material-friendly, almost "isometric" bending instead. If in this way the plasticization of the web material during fine structuring should remain low, may not or only slightly deviate from these laws. A greater deviation from these laws, namely the choice of the shape and the arrangement of the embossing elements 124 and 126, however, is allowed if the material of the material web 100 has sufficient plasticizing reserves. However, the length cuts of coarse and fine structures must be the same or at least approximately equal to avoid distortion, a "cutter" or a "bowl" of the structured material web.

19 schematically shows a device for fine structuring of an already hexagonal coarsely structured material web 100 in cross-section (left) and in plan view (right). The difference to the device in Fig. 18 is that the upper roller 123 has alternately a full embossing element 124 and a flattened element 128. The flattened elements 128 only serve to ensure, together with the embossing elements 126 of the lower roller 125, the feed (transport) of the material web. In this way, the finely structured edge with the wave-shaped structures 105 and the flat surfaces 106 corresponding to FIG. 2 is formed.

Fig. 20 shows schematically the cross section of an apparatus for hexagonal structuring of the material web 100. From above, the support element roller 129 presses with the support members 130 against the web 100. From below, the pressure roller presses with its elastomeric layer 132 against the web 100. This forms the Fold 102 and the troughs 103 in the web 100 from. The fine structure 105 results from the fact that a support disk 134 presses with its contour from below and another support disk 133 with its contour against the edge portion of the material web 100 and thereby finely structured. The contours of the discs 133 and 134 are formed such that either the undulating fine structure 105 (see Fig. 1) or the fine structure 105 with the flat portions 106 (see Fig. 2) is formed. The support contour 131 is annularly attached to the circumference of the support element roller 129 and serves to produce the bead 104 (see Fig. 1 and Fig. 2). The bead 104 in the web of material 100 simultaneously fixes the web of material 100 during the continuous structuring process (mutual unrolling of the support element roller 129 and the pressure roll with its elastomeric layer 132 and connected support disk 134) and thus prevents a lateral (transverse to the direction) Nachfließen the web 100 toward its center.

21 schematically shows the cross section (lower part) and the top view (upper part) of a device for kinematics for a secondary fine structuring of a material web 100. The support elements 136 of the support disk 135 and the support elements 137 of the table support 138 characterize the fine structuring 105 or 106 in the edge portion of the web 100 a. The kinematics with the aid of the two rods 140, the four joints 141, the adjusting lever 142 with its sliding dome 143 in the slot 145 of the slide rail 144 is designed so that a constant force F causes a uniform impressing of the fine structures 105 in the edge portion of the material web 100 , With the help of the approximately horizontal force f against Gleitdorn 143, the support disk 135 is moved rolling from left to right. The devices for introducing the two forces F and f and for the kinematics of the slide rail 144 are not explicitly shown in FIG. 19.

22 shows schematically the cross section (lower part) and the top view (upper part) of a device for secondary fine structuring kinematics with an integrated device for cutting the material web 100. The device for fine structuring the edge section of the material web 100 corresponds to that in FIG 21. Parallel to the fine structuring, the knife edge 146 lowers and separates the structured material web 100. In this simplified representation, the explicit execution of the remaining parts of the scissors, such as guiding and driving the knife edge 146 and hold-down was dispensed with. With the device shown schematically in FIG. 22, in each case only one edge section of the material web 100 can be provided with a fine structure and severed. The other cut-off side of the material web 100 thus does not yet receive a finely structured edge section. This other edge section of the material web 100 can thus likewise obtain a fine structure such that an additional device analogous to FIG. 21 is installed in the device of FIG. 22, so that a rolling device for fine structuring in the form of a support disk 135 with support elements 136 and a table support 138 with support elements 137 each before and behind the cutting blade 146 is installed. This installation is not explicitly shown in FIG. 22. With the aid of the support elements 136 and 137, not only fine structures (cf., FIGS. 1 and 2) but also transition structures can be achieved (see Figures 8 to 12). In addition, a beading element may also be mounted on the support disk 135 or on the table support 138 so that the structured edge of the material web 100 comprises a bead 104 (see FIG. 1). The additional bead 104 is not explicitly shown in FIG. 22.

With the devices described above, a material web can be produced in an analogous manner, in which the coarse structuring in the form of calottes and these surrounding beads is formed wavy. This is possible because with the help of the bead 104, a decoupling from the coarse structure to the fine structure takes place, so that any type of coarse structure - including the facet structure - can be equipped with a fine structure. Also, in the case that a fine structure without additional beading is to arise (corresponding to Fig. 6 to 12), analogous applies to the hexagonal or the crest-shaped structures with wrinkles and for the three-dimensional wave-like structures with beads, because the initiation of the structures based on The laws of controlled self-organization to the dynamic breakdown proceed analogously.

The features of the invention disclosed in the foregoing description, in the claims and in the drawing may be of importance both individually and in any combination for the realization of the invention in its various embodiments.

Claims (33)

A structured material web made of a web material, in particular a sheet material web, having a coarse structure comprising coarse structure elements and stiffened by at least one section adjoining the coarse patterning with a fine structure comprising fine structure elements, dimensions of the fine structure elements being smaller than dimensions of the coarse structure elements. Material web according to claim 1, characterized in that in the at least one section with the fine structuring adapted to the coarse patterning Längeneinkürzung is formed. Material web according to claim 1 or 2, characterized in that the at least one section with the fine structuring comprises an edge portion. Material web according to claim 3, characterized in that a transition structure is formed between the edge portion and the roughing. Material web according to at least one of the preceding claims, characterized in that the at least one section with the fine structuring comprise a transition section which is formed between sections with the roughing. Material web according to at least one of the preceding claims, characterized in that the at least one section with the fine structuring in the region transverse to a running direction comprises substantially flat sections formed. Material web according to at least one of the preceding claims, characterized in that the fine structuring is formed by means of one or more structural elements from the following group of structural elements: wave structure, expiring Bead structure, pleat structure, rhombic structure, rhombic structure, rectangular shape, heart shape, hexagonal structure and facet structure. Material web according to at least one of the preceding claims, characterized in that the fine structuring is connected via a bead with the roughing in combination. Material web according to at least one of the preceding claims, characterized in that the fine structuring is a self-organizing structuring. Material web according to at least one of the preceding claims, characterized in that the at least one section with the fine structure has a support portion. Material web according to at least one of the preceding claims, characterized in that the at least one section with the fine structuring has a joining portion. Material web according to at least one of the preceding claims, characterized in that coarse structuring is a wavy structuring. Material web according to claim 12, characterized in that the wave-like structuring is formed with beads and the beads enclosed by the beads, wherein the beads are formed integrally and with a radius of curvature which is opposite to the curvature of the calotte. Material web according to claim 13, characterized in that the calottes in a central Kalottenbereich have a shape which is at least approximated to a spherical shell shape. Material web according to claim 13 or 14, characterized in that the beads are formed contiguously according to one or a combination of a plurality of basic geometrical forms of the following group of basic geometric shapes: triangle, quadrangle, in particular square, rectangle, rhombus or parallelogram, pentagon, hexagon (Hexagon ) and octagon. Material web according to at least one of claims 13 to 15, characterized in that the beads are formed according to a uniform geometric basic shape. Material web according to at least one of claims 13 to 16, characterized in that the beads are formed in all directions, namely in the production direction and transversely to the production direction, each having a substantially uniform bead height. Material web according to at least one of claims 13 to 17, characterized in that for at least a portion of the calotte a Kalottenoberfläche is broadly diffuse reflective, wherein at least the part of the calotte is formed with the broadly diffusely reflecting Kalottenoberfläche as deep calotte. Material web according to at least one of claims 13 to 18, characterized in that for at least part of the calotte a Kalottenoberfläche is directionally reflective, wherein at least the part of the calotte is formed with the directionally reflective Kalottenoberfläche as a flat calotte. Material web according to at least one of the preceding claims, characterized in that the coarse structuring is a self-organizing structuring. Material web according to at least one of the preceding claims, characterized in that the web material is a material or a combination of materials selected from the following group of materials is: metal, plastic, fibrous materials, in particular paper and paperboard, fiber fabrics and mesh fabrics. Material web according to at least one of the preceding claims, characterized in that the web material is formed in a sandwich construction, in which at least one intermediate web is arranged between two outer webs. Material web according to at least one of the preceding claims, characterized in that the web material is anodized aluminum sheet. Method for producing a structured material web from a web material, in particular sheet material web, in which surface and three-dimensional coarse structuring comprising coarse structure elements and stiffening coarse structuring and adjacent to the coarse texturing at least a portion are formed with a fine structure comprising fine structure elements, wherein the fine structure elements are produced with dimensions that are smaller are as dimensions of the coarse structure elements. A method according to claim 24, characterized in that in the at least one section with the fine structuring adapted to the coarse patterning length reduction is formed. A method according to claim 24 or 25, characterized in that the at least one section with the fine structure is formed comprising a peripheral portion. A method according to claim 26, characterized in that between the edge portion and the coarse structuring a transition structure is formed. Method according to at least one of claims 24 to 26, characterized in that the at least one section with the fine structuring is formed comprising a transition section which is produced between sections with the roughing becomes. Method according to at least one of claims 24 to 28, characterized in that the at least one section with the fine structuring is formed in the region transverse to a running direction with substantially planar sections. Method according to at least one of claims 24 to 29, characterized in that the structured material web is separated in the region of the at least one section with the fine structuring, while the at least one section is formed with the fine structuring. Method according to at least one of claims 24 to 30, characterized in that the coarse structuring and the fine structuring are formed simultaneously in a continuous patterning process. A method according to claim 31, characterized in that the continuous structuring process is carried out by means of unwinding of supporting components and pressure components, between which a starting material to be structured is arranged. A method according to claim 31, characterized in that by a circumferential support member (131) a bead between the coarse structure and the fine structure is formed and the material web is fixed laterally.

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