EP3013916A1 - A laminated element, and a method of assembling and an assembly of a laminated element and another element - Google Patents

A laminated element, and a method of assembling and an assembly of a laminated element and another element

Info

Publication number
EP3013916A1
EP3013916A1 EP13734025.3A EP13734025A EP3013916A1 EP 3013916 A1 EP3013916 A1 EP 3013916A1 EP 13734025 A EP13734025 A EP 13734025A EP 3013916 A1 EP3013916 A1 EP 3013916A1
Authority
EP
European Patent Office
Prior art keywords
loose end
laminated
end portion
core
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13734025.3A
Other languages
German (de)
French (fr)
Inventor
Marcel Cees ELENBAAS
Original Assignee
Bv Scheepswerf Damen Gorinchem
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bv Scheepswerf Damen Gorinchem filed Critical Bv Scheepswerf Damen Gorinchem
Publication of EP3013916A1 publication Critical patent/EP3013916A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • B32B2419/00—Buildings or parts thereof

Definitions

  • a laminated element and a method of assembling and an assembly of a laminated element and another element
  • the present invention pertains to a laminated element comprising a core and at least a sheet.
  • Laminated elements are widely known and often used for building lightweight structures.
  • Lamination is a technique of manufacturing a material in multiple layers, so that the
  • composite material achieves improved strength, stability, appearance or other properties from the use of differing
  • a laminated element is usually permanently assembled by heat, pressure, welding or adhesives.
  • laminated elements such as composite sandwich panels in which the core is sandwiched between two or more resin impregnated fibrous sheets are applied in several structures such as boats or the like.
  • boats or the like For manufacturing large structures including laminated parts it is desired to be able to create a strong joint between separate laminated parts and between a laminated part and any adjacent other element.
  • the laminated element is placed against an adjacent other element, whereas portions of the outer surfaces of the laminated element and the adjacent other element at both sides of the adjacent boundaries form a connection area for receiving a resin impregnated fibrous layer thereon.
  • the layer is pressed against both the laminated element and the adjacent other element at the connection area and the resin is cured, hence forming a joint between the laminated element and the adjacent other element.
  • the laminated element according to the invention wherein the sheet comprises a fixed portion which is attached to the core and a loose end portion which is
  • the laminated element according to the invention is an advantageous intermediate product since its loose end portion can be attached to an adjacent other element in order to fix the laminated element and the adjacent other element to each other.
  • the loose end portion remains at place after manufacturing the laminated element according to the invention, such that an operator does not need to locate a separate layer, for example a resin impregnated fibrous layer, on the laminated element and the adjacent other element upon assembly thereof.
  • the loose end portion may be located at an edge of the core and/or extend beyond an edge of the core. The latter condition can be determined by guiding the loose end portion along the surface of the core such that the loose end portion forms the extension of the fixed portion.
  • a transition between the fixed portion and the loose end portion may be located at a distance from an edge of the core. This provides the opportunity to receive and sandwich a sheet of the adjacent other element between the loose end portion and the core, for example if the adjacent other element is also a laminated component having a sheet including a loose end portion similar to the laminated element.
  • the overlapping sheet portions of an assembly of the laminated element and such an adjacent other element may create a great shear strength, hence providing a robust joint. In this way the joint may form an integral part of a structure without loss of strength due to secondary bonding.
  • the core has appropriate bonding characteristics for reliably adhering the sheet of the adjacent other element to the core of the laminated element.
  • the loose end portion may extend, for example, from the transition up to or beyond the edge of the core.
  • the sheet may be made of a fibrous material whereas its fixed portion comprises a cured resin which adheres to the core.
  • the laminated element comprises a sandwich construction wherein the core is made from a
  • the core may have numerous appearances.
  • the core may be rigid, such as a flat or curved rigid panel or board.
  • the core may be flexible, such as a bendable sheet.
  • the core may be a
  • the laminated intermediate product is further laminated with the mentioned sheet so as to form an embodiment of the laminated element according to the invention.
  • the core is a laminated intermediate product itself, it may be a composite having a substrate which is sandwiched between skins. In that case the substrate including the skins may be sandwiched between the fixed portions of the sheets, hence forming an embodiment of the laminated element according to the invention.
  • sandwich panels typically in ship constructions both sandwich panels and solid laminated can be used. Furthermore, a combination is possible, in which a sandwich panel transcends into a single skin laminate by bringing outer skins thereof together. Such a single skin panel may also form the core of the laminated element.
  • the loose end portion may be free from adhesive material. This means that the adhesive material can be applied upon assembly of the laminated element and another element. The adhesive material can be applied to the loose end portion before or after placing it onto another element. In the latter case, if the sheet is made of a fibrous material which has to be
  • the resin can be pumped therein under pressure or drawn into the loose end portion by vacuum.
  • the adhesive is formed by the resin, whereas the fibrous material forms a matrix for receiving and containing the resin.
  • a practical embodiment of manufacturing a laminated element of which the loose end portion is free from adhesive is laying the sheet, which is still without resin/adhesive, on the core, and maskering the intended loose end portion, for example by means of a foil, a Teflon sheet or the like.
  • a high viscosity resin that easily impregnates in the sheet in a direction perpendicular to the sheet but does not or only limited
  • the intended fixed portion of the sheet is applied to the intended fixed portion of the sheet or a part thereof.
  • the high viscosity resin may be applied only in a strip of the intended fixed portion which extends along the intended loose end portion in order to create an air tight strip that separates the loose end portion from the remaining sheet.
  • the remainder of the intended fixed portion of the sheet may be impregnated in a traditional way by means of hand lamination, vacuum infusion, or the like.
  • the core may be pre-impregnated before the sheet is laid on the core.
  • the loose end portion may comprise an uncured or partially cured resin before assembling the laminated element with another element.
  • the loose end portion may comprise a dried but not fully cured resin, also called a B-stage resin.
  • the loose end portion comprising uncured or partially cured resin is also known as a prepreg.
  • the resin of the prepreg can be melted and cured, for example melted by heat and cured by means of UV radiation or the like.
  • the sheet is a first sheet and the laminated element comprises at least a second sheet that comprises a fixed portion which is attached to the fixed portion of the first sheet and a loose end portion which is located at the loose end portion of the first sheet but separate from the core and the first sheet.
  • the adjacent other element also comprises a laminated component having first and second sheets including corresponding loose end portions.
  • the number of sheets can be extended in order to create a still greater shear strength.
  • the invention is also related to an assembly of the laminated element as described hereinbefore and another element, wherein in assembled condition the laminated element is fixed to the other element through a joint between the other element and the loose end portion of the sheet of the laminated element.
  • the laminated element having a sheet including a loose end portion can be prepared in a conditioned environment and the assembly can be made at a different location.
  • the assembly is an integral product in which the joint in fact also forms a laminated connection of the other element and the loose end portion. It is noted that at a joint a smooth outer surface can be achieved.
  • the joint may be substantially flush.
  • an assembly including a weakened area between the core of the laminated element and the other element may be created, for example for creating a pivot at the joint.
  • the core of the laminated element and the other element may be located remote from each other, whereas the joint bridges the gap.
  • the weakened area comprises the initial loose end portion.
  • the other element may also comprise a core and a sheet, wherein the sheet of the other element comprises a fixed portion which is attached to the core of the other element and a loose end portion which is separate from the core of the other
  • the loose end portion of the other element may also overlap the sheet of the laminated element at the core of the laminated element, such that a portion of the sheet of the laminated element is also sandwiched between the loose end portion of the other element and the core of the laminated element. This improves the strength of the connection between the laminated element and the other element further.
  • the loose end portion thereof may overlap the loose end portion of the other element and be fixed thereto. This means that the loose end portion of the other element is sandwiched between the loose end portions of the first and second sheets of the
  • shear strength due to overlapping loose end portions may be more relevant than an adhesive or resin that holds the loose end portions together.
  • shear strength between layers may be stronger than secondary bonding.
  • the other element is made from a different material, for example a metallic structure.
  • the invention is also related to a method of assembling a laminated element as described hereinbefore and another element, wherein the laminated element and the other element are brought to each other in a desired mutual position, after which the loose end portion of the laminated element is adhered to the other element.
  • Vacuum and/or pressure may be employed to compress the loose end portion and remove air from between the loose end portion and the other element.
  • the loose end portion of the laminated element may be laid onto the other element and a resin to the loose end portion may be provided thereto, after which the resin is cured. Hence, the resin is supplied at a late stage in the assembling process.
  • the resin-containing loose end portion of the laminated element is laid onto the other element and the resin is cured.
  • Fig. 1 is a sectional view of two similar embodiments of the laminated element according to the invention.
  • Fig. 2 is a similar view as Fig. 1, but illustrating alternative embodiments of the laminated element according to the invention.
  • Figs. 3-8 are similar views as Fig. 1, but showing successive steps of the method of assembling alternative
  • FIGs. 9-11 are perspective views of different embodiments of the laminated element according to the invention.
  • Fig. 1 illustrates an embodiment of the method of assembling two laminated elements 1, 1' according to the
  • the embodiments of the laminated elements 1, 1' are flat horizontally oriented panels which have a similar
  • Each of the panels 1, 1' comprises a core 2, 2', a first sheet 3, 3' and a second sheet 4, 4', respectively.
  • laminated element 1 each comprise fixed portions 3a, 4a,
  • the fixed portion 3a of the first sheet 3 is directly fixed to the core 2 and the loose end portion 3b of the first sheet 3 is separate from the core 2. This means that the loose end portion 3b may contact the core 2 but it is not attached thereto.
  • the fixed portion 4a of the second sheet 4 is directly fixed to the fixed portion 3a of the first sheet 3 and the loose end portion 4b of the second sheet 4 is separate from the loose end portion 3b of the first sheet 3 as well as from the core 2. This means that the fixed portion 3a of the first sheet 3 is sandwiched between the core 2 and the fixed portion 4a of the second sheet 4.
  • the loose end portions 3b, 4b of the first and second sheets 3, 4, respectively, are shown as stiff portions in Fig. 1 for clarity reasons, but they may be flexible and look like drooping flags.
  • the loose end portions 3b, 4b, 3b', 4b' are located at outer edges or side edges of the cores 2, 2'.
  • the loose end portions 3b, 3b' and 4b, 4b' extend from transitions between the fixed and loose end portions at distances from the outer edges up to beyond the respective outer edges.
  • the locations of the transitions between the fixed portions 3a, 4a, 3a' and 4a' and the respective loose end portions 3b, 4b, 3b', 4b' substantially coincide in each of the laminated elements 1, 1' in this case, but may deviate in an alternative embodiment.
  • Fig. 1 further shows by arrows that the laminated elements 1, 1' are brought to each other such that the cores 2, 2' are adjacent to each other and aligned, whereas outer edges of the cores 2, 2' face to each other.
  • the loose end portions 3b, 4b of the sheets 3, 4 and 3b', 4b' of the sheets 3', 4' of both laminated elements 1, 1' are laid onto each other such that at the adjacent edges of the cores 2, 2' of both laminated elements 1, 1' a stack of loose end portions is created, alternating from both laminated elements 1, 1'.
  • the loose end portion 3b of the first sheet 3 of the left laminated element 1 is laid on the core 2' of the right laminated element 1', the loose end portion 3b' of the first sheet 3' of the right
  • the overlapping loose end portions 3b, 4b, 3b', 4b' are provided with a curable resin and compressed and cured, for example by means of vacuum and UV radiation, respectively. Due to the compressed overlapping loose end portions 3b, 4b, 3b', 4b' a robust joint 5 having a
  • the loose end portions 3b, 4b of only the left laminated element 1 extend beyond the outer edge of its core 2, whereas the fixed portions 3a, 4a are attached to its core 2 up to its outer edge.
  • the transition between the loose end portions 3b', 4b' and the respective fixed portions 3a', 4a' is located at a distance from the edge of its core 2'.
  • the loose end portions 3b', 4b' extend from the transition up to the outer edge of the core 2'. In this case the resulting joint 5 only overlaps the core 2' of the right laminated element 1'.
  • the laminated element 1 is suitable to be fixed to another element which does not have a laminated structure, but any other element (not shown) .
  • the loose end portion 3b of the sheet 3 can be fixed to the other element in order to join the laminated element 1 and the other element.
  • the other element is a laminated element, as well.
  • the sheets 3, 4 of the laminated element 1 are made of a fibrous material.
  • the fixed portions 3a, 4a are attached to the core 2 by means of curable resin.
  • the loose end portions 3b, 4b may be prepared in different manners before assembly of the laminated elements 1, 1'.
  • the loose end portions 3b, 4b, 3b', 4b' may be free from any adhesive.
  • the loose end portions 3b, 4b, 3b', 4b' may be impregnated with curable resin just before assembling the laminated elements 1, 1' or after laying the loose end portions 3b, 4b, 3b', 4b' of both laminated elements 1 onto each other.
  • the loose end portions 3b, 4b, 3b', 4b' are partially or fully impregnated with a curable resin and provided with protection means to prevent the resin from curing during transport to the location of assembly, for example.
  • This may be achieved by covering the impregnated loose end portions 3b, 4b temporarily, for example by means of Teflon foils.
  • the sheets 3, 4 may be impregnated and placed onto the core 2, whereas only the fixed portions 3a, 4a are cured, for example by means of heat, IR or UV radiation.
  • the resin-containing loose end portions 3b, 4b may be prevented from curing, for example by means of shielding them.
  • Figs. 3-8 illustrate consecutive steps of an embodiment of the method of assembling a final product 6, as shown in Fig. 8, from different laminated elements 1, 11.
  • Fig. 3 shows two similar horizontally oriented laminated elements 1 which are comparable to those shown in Fig. 1, but in this case the laminated elements 1 have additional three sheets 7, 8, 9 including loose end portions located at the upper sides of both laminated elements 1.
  • Fig. 4 shows that both horizontally oriented laminated elements 1 are located next to each other and the loose end portions of the sheets 3, 4, 7-9 of both laminated elements 1 are laid onto each other at the upper sides and lower sides of both laminated elements 1.
  • a supporting block 10 for guiding the loose end portions of the sheets 7-9 and a vertically oriented laminated element 11 are supplied as illustrated in Figs. 4 and 5.
  • the vertically oriented laminated element 11 also comprises a core and sheets including loose end portions.
  • Figs. 6 and 7 illustrate how the loose end portions of the laminated elements 1 and 11 are laid onto each other and are guided about the supporting block 10.
  • the loose end portions may be impregnated with a resin. After compressing the loose end portions and curing the resin a robust right angle joint 5 is obtained, see Fig. 8
  • a sandwich panel having a core 2 of lightweight material like foam, honeycomb structure or the like.
  • the panel may be flat or curved.
  • the core 2 itself may be a laminated intermediate product, for example the core 2 may comprise a substrate that is sandwiched between skins, or being a single skin panel.
  • Fig. 9 shows an embodiment of a double curved panel 1 including a single sheet 12 at one side of the core 2. A fixed portion 12a of the sheet 12 is attached to the core 2 and a loose end portion 12b of the sheet 12 is separate from the core 2. The loose end portion 12b can be used for forming a joint with another element.
  • An alternative embodiment of the panel 1 of Fig. 9 may comprise more than one sheet at one side of the core 2 or one or more sheets at opposite sides of the core 2.
  • Fig. 10 shows a hull section 13 of a boat.
  • the hull section 13 can be built in a factory where other cooperating hull sections are built, as well.
  • the different hull sections are prepared for transport to and assembly at a different hull sections
  • hull section 13 is provided with sheets which have a fixed portion that is attached to a core of the hull section 13 and a loose end portion which is separate from that core.
  • Fig. 10 only shows one loose end portion 14 for illustrative reasons, but in practice several loose end portions may be present at different locations at the hull section 13, particularly at reinforcement beams thereof.
  • the different hull sections can be placed against each other and fixed to each other by means of the method of
  • Fig. 11 shows an embodiment of a laminated element 15 including a core 2 and two sheets 16, 17 that are disposed at opposite sides of the core 2.
  • the core 2 is provided with tubes 18 that can be connected to a cooperating other element which may also be a laminated element.
  • the core 2 is brought to the cooperating other element and the tubes 18 are connected to tubes of the cooperating other element.
  • the laminated element 15 can be fixed to the cooperating other element by means of attaching the loose end portions of the sheets 17, 18 thereto.
  • the laminated element may be provided with alternative functional elements, such as cable or pipe connections, electromagnetic shielding, local structural elements, etc.
  • the invention provides the opportunity to manufacture modular building blocks, which can be assembled in a simple way at another location, whereas strong joints can be achieved. Besides, smaller and less complex tools and/or moulds can be applied than in conventional techniques of manufacturing large laminated products. The assembly can take place in an industrial environment; clean room conditions are not required.
  • the element to which the laminated element is assembled may be a non-laminated element, for example a metal plate.
  • the loose end portion of the laminated element can be fixed to the metal plate upon assembly without further

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Abstract

A laminated element (1) comprises a core (2) and at least a sheet (3). The sheet (3) comprises a fixed portion (3a) which is attached to the core (2) and a loose end portion (3b) which is separate from the core (2). In assembled condition of an assembly of the laminated element and another element (1') the laminated element (1) is fixed to the other element (1') through a joint (5) between the loose end portion (3b) of the sheet (3) and the other element (1').

Description

A laminated element, and a method of assembling and an assembly of a laminated element and another element
The present invention pertains to a laminated element comprising a core and at least a sheet.
Laminated elements are widely known and often used for building lightweight structures. Lamination is a technique of manufacturing a material in multiple layers, so that the
composite material achieves improved strength, stability, appearance or other properties from the use of differing
materials. A laminated element is usually permanently assembled by heat, pressure, welding or adhesives. For example, laminated elements such as composite sandwich panels in which the core is sandwiched between two or more resin impregnated fibrous sheets are applied in several structures such as boats or the like. For manufacturing large structures including laminated parts it is desired to be able to create a strong joint between separate laminated parts and between a laminated part and any adjacent other element.
In a conventional manufacturing method the laminated element is placed against an adjacent other element, whereas portions of the outer surfaces of the laminated element and the adjacent other element at both sides of the adjacent boundaries form a connection area for receiving a resin impregnated fibrous layer thereon. The layer is pressed against both the laminated element and the adjacent other element at the connection area and the resin is cured, hence forming a joint between the laminated element and the adjacent other element.
It is an object of the present invention to provide a laminated element which can be fixed to another element in an easy way.
This is achieved by the laminated element according to the invention, wherein the sheet comprises a fixed portion which is attached to the core and a loose end portion which is
separate from the core.
The laminated element according to the invention is an advantageous intermediate product since its loose end portion can be attached to an adjacent other element in order to fix the laminated element and the adjacent other element to each other. The loose end portion remains at place after manufacturing the laminated element according to the invention, such that an operator does not need to locate a separate layer, for example a resin impregnated fibrous layer, on the laminated element and the adjacent other element upon assembly thereof. This
accelerates the assembly process, hence providing quick
assembly .
The loose end portion may be located at an edge of the core and/or extend beyond an edge of the core. The latter condition can be determined by guiding the loose end portion along the surface of the core such that the loose end portion forms the extension of the fixed portion.
A transition between the fixed portion and the loose end portion may be located at a distance from an edge of the core. This provides the opportunity to receive and sandwich a sheet of the adjacent other element between the loose end portion and the core, for example if the adjacent other element is also a laminated component having a sheet including a loose end portion similar to the laminated element. The overlapping sheet portions of an assembly of the laminated element and such an adjacent other element may create a great shear strength, hence providing a robust joint. In this way the joint may form an integral part of a structure without loss of strength due to secondary bonding. In case of sandwiching a sheet of an adjacent other element between the loose end portion and the core, it is advantageous if the core has appropriate bonding characteristics for reliably adhering the sheet of the adjacent other element to the core of the laminated element.
The loose end portion may extend, for example, from the transition up to or beyond the edge of the core.
The sheet may be made of a fibrous material whereas its fixed portion comprises a cured resin which adheres to the core. In a specific embodiment the laminated element comprises a sandwich construction wherein the core is made from a
lightweight material like foam or a honeycomb structure, whereas opposite sides of the core comprise fixed portions of sheets of fibrous material. It is noted that the core may have numerous appearances. The core may be rigid, such as a flat or curved rigid panel or board. Alternatively, the core may be flexible, such as a bendable sheet. Furthermore, the core may be a
laminated intermediate product itself; in this case the
laminated intermediate product is further laminated with the mentioned sheet so as to form an embodiment of the laminated element according to the invention. If the core is a laminated intermediate product itself, it may be a composite having a substrate which is sandwiched between skins. In that case the substrate including the skins may be sandwiched between the fixed portions of the sheets, hence forming an embodiment of the laminated element according to the invention.
It is noted that typically in ship constructions both sandwich panels and solid laminated can be used. Furthermore, a combination is possible, in which a sandwich panel transcends into a single skin laminate by bringing outer skins thereof together. Such a single skin panel may also form the core of the laminated element.
The loose end portion may be free from adhesive material. This means that the adhesive material can be applied upon assembly of the laminated element and another element. The adhesive material can be applied to the loose end portion before or after placing it onto another element. In the latter case, if the sheet is made of a fibrous material which has to be
impregnated with a resin, the resin can be pumped therein under pressure or drawn into the loose end portion by vacuum. The adhesive is formed by the resin, whereas the fibrous material forms a matrix for receiving and containing the resin.
A practical embodiment of manufacturing a laminated element of which the loose end portion is free from adhesive, is laying the sheet, which is still without resin/adhesive, on the core, and maskering the intended loose end portion, for example by means of a foil, a Teflon sheet or the like. A high viscosity resin that easily impregnates in the sheet in a direction perpendicular to the sheet but does not or only limited
impregnate in a direction within the plane of the sheet, is applied to the intended fixed portion of the sheet or a part thereof. For example, the high viscosity resin may be applied only in a strip of the intended fixed portion which extends along the intended loose end portion in order to create an air tight strip that separates the loose end portion from the remaining sheet. The remainder of the intended fixed portion of the sheet may be impregnated in a traditional way by means of hand lamination, vacuum infusion, or the like. In case of vacuum infusion, the core may be pre-impregnated before the sheet is laid on the core.
Alternatively, the loose end portion may comprise an uncured or partially cured resin before assembling the laminated element with another element. In case of a fibrous material of the sheet the loose end portion may comprise a dried but not fully cured resin, also called a B-stage resin. The loose end portion comprising uncured or partially cured resin is also known as a prepreg. The resin of the prepreg can be melted and cured, for example melted by heat and cured by means of UV radiation or the like.
In a particular embodiment the sheet is a first sheet and the laminated element comprises at least a second sheet that comprises a fixed portion which is attached to the fixed portion of the first sheet and a loose end portion which is located at the loose end portion of the first sheet but separate from the core and the first sheet. This embodiment provides the
opportunity to receive and sandwich a second sheet of the adjacent other element between the loose end portion of the second sheet and the loose end portion of the first sheet, if the adjacent other element also comprises a laminated component having first and second sheets including corresponding loose end portions. Of course, the number of sheets can be extended in order to create a still greater shear strength.
The invention is also related to an assembly of the laminated element as described hereinbefore and another element, wherein in assembled condition the laminated element is fixed to the other element through a joint between the other element and the loose end portion of the sheet of the laminated element. The laminated element having a sheet including a loose end portion can be prepared in a conditioned environment and the assembly can be made at a different location. The assembly is an integral product in which the joint in fact also forms a laminated connection of the other element and the loose end portion. It is noted that at a joint a smooth outer surface can be achieved. The joint may be substantially flush.
It is also noted that an assembly including a weakened area between the core of the laminated element and the other element may be created, for example for creating a pivot at the joint. In such a case the core of the laminated element and the other element may be located remote from each other, whereas the joint bridges the gap. The weakened area comprises the initial loose end portion.
The other element may also comprise a core and a sheet, wherein the sheet of the other element comprises a fixed portion which is attached to the core of the other element and a loose end portion which is separate from the core of the other
element, wherein in assembled condition the loose end portion of the other element overlaps the loose end portion of the
laminated element, and the loose end portion of the laminated element is fixed to the core of the other element and the loose end portion of the other element is fixed to the loose end portion of the laminated element. In this case two laminated elements according to the invention are assembled. The loose end portion of the laminated element is sandwiched between the core and the loose end portion of the other element. As described hereinbefore, the overlapping loose end portions appear to provide great shear strength.
The loose end portion of the other element may also overlap the sheet of the laminated element at the core of the laminated element, such that a portion of the sheet of the laminated element is also sandwiched between the loose end portion of the other element and the core of the laminated element. This improves the strength of the connection between the laminated element and the other element further.
If the laminated element comprises a second sheet the loose end portion thereof may overlap the loose end portion of the other element and be fixed thereto. This means that the loose end portion of the other element is sandwiched between the loose end portions of the first and second sheets of the
laminated element. It is noted that increasing the number of overlapping sheets improves the shear strength. The effect of shear strength due to overlapping loose end portions may be more relevant than an adhesive or resin that holds the loose end portions together. In other words, shear strength between layers may be stronger than secondary bonding.
Alternatively, the other element is made from a different material, for example a metallic structure.
It is noted that the word 'overlap' is used for
conditions in which a sheet lays on an underground and at least partly covers the underground. It should not be interpreted as necessarily covering the underground entirely.
The invention is also related to a method of assembling a laminated element as described hereinbefore and another element, wherein the laminated element and the other element are brought to each other in a desired mutual position, after which the loose end portion of the laminated element is adhered to the other element.
Vacuum and/or pressure may be employed to compress the loose end portion and remove air from between the loose end portion and the other element.
The loose end portion of the laminated element may be laid onto the other element and a resin to the loose end portion may be provided thereto, after which the resin is cured. Hence, the resin is supplied at a late stage in the assembling process.
Alternatively, the resin-containing loose end portion of the laminated element is laid onto the other element and the resin is cured.
The invention will hereafter be elucidated with
reference to drawings illustrating embodiments of the invention schematically .
Fig. 1 is a sectional view of two similar embodiments of the laminated element according to the invention,
illustrating an embodiment of the method of assembling the laminated elements according to the invention.
Fig. 2 is a similar view as Fig. 1, but illustrating alternative embodiments of the laminated element according to the invention.
Figs. 3-8 are similar views as Fig. 1, but showing successive steps of the method of assembling alternative
embodiments of the laminated element. Figs. 9-11 are perspective views of different embodiments of the laminated element according to the invention.
Fig. 1 illustrates an embodiment of the method of assembling two laminated elements 1, 1' according to the
invention. The embodiments of the laminated elements 1, 1' are flat horizontally oriented panels which have a similar
structure, but alternative shapes are conceivable. Each of the panels 1, 1' comprises a core 2, 2', a first sheet 3, 3' and a second sheet 4, 4', respectively. The sheets 3, 4 of one
laminated element 1 each comprise fixed portions 3a, 4a,
respectively, and loose end portions 3b, 4b, respectively.
The fixed portion 3a of the first sheet 3 is directly fixed to the core 2 and the loose end portion 3b of the first sheet 3 is separate from the core 2. This means that the loose end portion 3b may contact the core 2 but it is not attached thereto. The fixed portion 4a of the second sheet 4 is directly fixed to the fixed portion 3a of the first sheet 3 and the loose end portion 4b of the second sheet 4 is separate from the loose end portion 3b of the first sheet 3 as well as from the core 2. This means that the fixed portion 3a of the first sheet 3 is sandwiched between the core 2 and the fixed portion 4a of the second sheet 4. The loose end portions 3b, 4b of the first and second sheets 3, 4, respectively, are shown as stiff portions in Fig. 1 for clarity reasons, but they may be flexible and look like drooping flags.
In both laminated elements 1, 1' the loose end portions 3b, 4b, 3b', 4b' are located at outer edges or side edges of the cores 2, 2'. The loose end portions 3b, 3b' and 4b, 4b' extend from transitions between the fixed and loose end portions at distances from the outer edges up to beyond the respective outer edges. The locations of the transitions between the fixed portions 3a, 4a, 3a' and 4a' and the respective loose end portions 3b, 4b, 3b', 4b' substantially coincide in each of the laminated elements 1, 1' in this case, but may deviate in an alternative embodiment.
Fig. 1 further shows by arrows that the laminated elements 1, 1' are brought to each other such that the cores 2, 2' are adjacent to each other and aligned, whereas outer edges of the cores 2, 2' face to each other. The loose end portions 3b, 4b of the sheets 3, 4 and 3b', 4b' of the sheets 3', 4' of both laminated elements 1, 1' are laid onto each other such that at the adjacent edges of the cores 2, 2' of both laminated elements 1, 1' a stack of loose end portions is created, alternating from both laminated elements 1, 1'. The loose end portion 3b of the first sheet 3 of the left laminated element 1 is laid on the core 2' of the right laminated element 1', the loose end portion 3b' of the first sheet 3' of the right
laminated element 1' is laid on the loose end portion 3b of the first sheet 3 of the left laminated element 1, the loose end portion 4b of the second sheet 4 of the left laminated element 1 is laid on the loose end portion 3b' of the first sheet 3' of the right laminated element 1', and finally the loose end portion 4b' of the second sheet 4' of the right laminated element 1' is laid on the loose end portion 4b of the second sheet 4 of the left laminated element 1. The overlapping loose end portions 3b, 4b, 3b', 4b' are provided with a curable resin and compressed and cured, for example by means of vacuum and UV radiation, respectively. Due to the compressed overlapping loose end portions 3b, 4b, 3b', 4b' a robust joint 5 having a
relatively high shear strength is created.
Since the loose end portions 3b, 4b, 3b', 4b' of both laminated elements 1, 1' of Fig. 1 extend beyond the outer edges of their cores 2, 2' the resulting joint 5 overlaps both cores 2, 2'. Fig. 2 shows alternative embodiments of laminated
elements 1, 1' which are different from each other. The loose end portions 3b, 4b of only the left laminated element 1 extend beyond the outer edge of its core 2, whereas the fixed portions 3a, 4a are attached to its core 2 up to its outer edge. In the right laminated element 1' the transition between the loose end portions 3b', 4b' and the respective fixed portions 3a', 4a' is located at a distance from the edge of its core 2'. The loose end portions 3b', 4b' extend from the transition up to the outer edge of the core 2'. In this case the resulting joint 5 only overlaps the core 2' of the right laminated element 1'. It is noted that numerous alternative laminated elements and
combinations of laminated elements based on the same principle of overlapping loose end portions, are conceivable. It is also noted that the laminated element 1 is suitable to be fixed to another element which does not have a laminated structure, but any other element (not shown) . In that case the loose end portion 3b of the sheet 3 can be fixed to the other element in order to join the laminated element 1 and the other element. Hence, in Figs. 1 and 2 the other element is a laminated element, as well.
The sheets 3, 4 of the laminated element 1 are made of a fibrous material. The fixed portions 3a, 4a are attached to the core 2 by means of curable resin. The loose end portions 3b, 4b may be prepared in different manners before assembly of the laminated elements 1, 1'.
The loose end portions 3b, 4b, 3b', 4b' may be free from any adhesive. In this case the loose end portions 3b, 4b, 3b', 4b' may be impregnated with curable resin just before assembling the laminated elements 1, 1' or after laying the loose end portions 3b, 4b, 3b', 4b' of both laminated elements 1 onto each other.
Alternatively, the loose end portions 3b, 4b, 3b', 4b' are partially or fully impregnated with a curable resin and provided with protection means to prevent the resin from curing during transport to the location of assembly, for example. This may be achieved by covering the impregnated loose end portions 3b, 4b temporarily, for example by means of Teflon foils. It is possible to impregnate the loose end portions 3b, 4b with a resin to a B-stage in which the resin is not yet polymerized, although it may be dry. When manufacturing the laminated element 1 the sheets 3, 4 may be impregnated and placed onto the core 2, whereas only the fixed portions 3a, 4a are cured, for example by means of heat, IR or UV radiation. The resin-containing loose end portions 3b, 4b may be prevented from curing, for example by means of shielding them.
Figs. 3-8 illustrate consecutive steps of an embodiment of the method of assembling a final product 6, as shown in Fig. 8, from different laminated elements 1, 11. Fig. 3 shows two similar horizontally oriented laminated elements 1 which are comparable to those shown in Fig. 1, but in this case the laminated elements 1 have additional three sheets 7, 8, 9 including loose end portions located at the upper sides of both laminated elements 1.
Fig. 4 shows that both horizontally oriented laminated elements 1 are located next to each other and the loose end portions of the sheets 3, 4, 7-9 of both laminated elements 1 are laid onto each other at the upper sides and lower sides of both laminated elements 1. A supporting block 10 for guiding the loose end portions of the sheets 7-9 and a vertically oriented laminated element 11 are supplied as illustrated in Figs. 4 and 5. The vertically oriented laminated element 11 also comprises a core and sheets including loose end portions. Figs. 6 and 7 illustrate how the loose end portions of the laminated elements 1 and 11 are laid onto each other and are guided about the supporting block 10. The loose end portions may be impregnated with a resin. After compressing the loose end portions and curing the resin a robust right angle joint 5 is obtained, see Fig. 8
Numerous types of laminated elements 1 are conceivable, for example a sandwich panel having a core 2 of lightweight material like foam, honeycomb structure or the like. The panel may be flat or curved. Furthermore, the core 2 itself may be a laminated intermediate product, for example the core 2 may comprise a substrate that is sandwiched between skins, or being a single skin panel. Fig. 9 shows an embodiment of a double curved panel 1 including a single sheet 12 at one side of the core 2. A fixed portion 12a of the sheet 12 is attached to the core 2 and a loose end portion 12b of the sheet 12 is separate from the core 2. The loose end portion 12b can be used for forming a joint with another element. An alternative embodiment of the panel 1 of Fig. 9 may comprise more than one sheet at one side of the core 2 or one or more sheets at opposite sides of the core 2.
Fig. 10 shows a hull section 13 of a boat. The hull section 13 can be built in a factory where other cooperating hull sections are built, as well. The different hull sections are prepared for transport to and assembly at a different
location. For that reason the hull section 13 is provided with sheets which have a fixed portion that is attached to a core of the hull section 13 and a loose end portion which is separate from that core. Fig. 10 only shows one loose end portion 14 for illustrative reasons, but in practice several loose end portions may be present at different locations at the hull section 13, particularly at reinforcement beams thereof. At the location of assembly the different hull sections can be placed against each other and fixed to each other by means of the method of
assembling as described hereinbefore. Of course, alternative types of large structures assembled by modular sections of laminated elements can be manufactured.
Fig. 11 shows an embodiment of a laminated element 15 including a core 2 and two sheets 16, 17 that are disposed at opposite sides of the core 2. In this embodiment the core 2 is provided with tubes 18 that can be connected to a cooperating other element which may also be a laminated element. Upon assembly the core 2 is brought to the cooperating other element and the tubes 18 are connected to tubes of the cooperating other element. After that, the laminated element 15 can be fixed to the cooperating other element by means of attaching the loose end portions of the sheets 17, 18 thereto. Instead of tubes the laminated element may be provided with alternative functional elements, such as cable or pipe connections, electromagnetic shielding, local structural elements, etc.
It may be clear that the invention provides the opportunity to manufacture modular building blocks, which can be assembled in a simple way at another location, whereas strong joints can be achieved. Besides, smaller and less complex tools and/or moulds can be applied than in conventional techniques of manufacturing large laminated products. The assembly can take place in an industrial environment; clean room conditions are not required.
The invention is not limited to the embodiments as shown in the drawings and described hereinbefore, which may be varied in different manners within the scope of the claims. For example, the element to which the laminated element is assembled may be a non-laminated element, for example a metal plate. In that case the loose end portion of the laminated element can be fixed to the metal plate upon assembly without further
overlapping any other loose end portions.

Claims

1. A laminated element (1) comprising a core (2) and at least a sheet (3), wherein the sheet (3) comprises a fixed portion (3a) which is attached to the core (2) and a loose end portion (3b) which is separate from the core (2) .
2. A laminated element (1) according to claim 1, wherein the loose end portion (3b) is located at an edge of the core ( 2 ) .
3. A laminated element (1) according to claim 1 or 2, wherein the loose end portion (3b) extends beyond an edge of the core ( 2 ) .
4. A laminated element (1) according to one of the preceding claims, wherein a transition between the fixed portion (3a) and the loose end portion (3b) is located at a distance from an edge of the core (2) .
5. A laminated element (1) according to one of the preceding claims, wherein the sheet (3) is made of a fibrous material and its fixed portion (3a) comprises a cured resin which adheres to the core (2) .
6. A laminated element (1) according to one of the preceding claims, wherein the loose end portion (3b) is free from adhesive material.
7. A laminated element (1) according to claim 5, wherein the loose end portion (3b) comprises an uncured or partially cured resin.
8. A laminated element (1) according to one of the preceding claims, wherein said sheet is a first sheet (3) and the laminated element (1) comprises at least a second sheet (4) that comprises a fixed portion (4a) which is attached to the fixed portion (3a) of the first sheet (3) and a loose end portion (4b) which is located at the loose end portion (3b) of the first sheet (3) and separate from the core (2) and the first sheet ( 3 ) .
9. An assembly of the laminated element (1) according to one of the preceding claims and another element {!'), wherein in assembled condition the laminated element (1) is fixed to the other element ( 1 ' ) through a joint (5) between the loose end portion (3b) of the sheet (3) and the other element ( 1 ' ) .
10. An assembly according to claim 9, wherein the other element ( 1 ' ) also comprises a core (2') and a sheet (3'), wherein the sheet (3') of said other element ( 1 ' ) comprises a fixed portion (3a') which is attached to the core ( 2 ' ) of said other element ( 1 ' ) and a loose end portion (3b') which is separate from the core (2') of said other element (1'), wherein in assembled condition the loose end portion (3b') of said other element (1') overlaps the loose end portion (3b) of the
laminated element (1), and the loose end portion (3b) of the laminated element (1) is fixed to the core (2') of said other element (1') and the loose end portion (3b') of said other element (1') is fixed to the loose end portion (3b) of the laminated element (1) .
11. An assembly according to claim 10, wherein the loose end portion (3b') of the other element (1') also overlaps the sheet (3) of the laminated element (1) at the core (2) of the laminated element (1) .
12. An assembly according to claim 10 or 11 in combination with claim 8, wherein the loose end portion (4b) of the second sheet (4) overlaps the loose end portion (3b') of the other element (1') and is fixed thereto.
13. A method of assembling a laminated element (1) according to one of the claims 1-8 and another element (1'), wherein the laminated element (1) and the other element (1') are brought to each other in a desired mutual position, after which the loose end portion (3b) of the laminated element (1) is adhered to the other element (1') .
14. A method of assembling a laminated element (1) according to claim 5 and another element (1'), wherein the laminated element (1) and the other element (1') are brought to each other in a desired mutual position, laying the loose end portion (3b) of the laminated element (1) onto the other element (1') and providing a resin to the loose end portion (3b), after which the resin is cured.
15. A method of assembling a laminated element (1) according to claim 7 and another element (1'), wherein the laminated element (1) and the other element (1') are brought to each other in a desired mutual position, laying the resin- containing loose end portion (3b) of the laminated element (1) onto the other element ( 1 ' ) and curing the resin.
EP13734025.3A 2013-06-28 2013-06-28 A laminated element, and a method of assembling and an assembly of a laminated element and another element Withdrawn EP3013916A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2013/063665 WO2014206488A1 (en) 2013-06-28 2013-06-28 A laminated element, and a method of assembling and an assembly of a laminated element and another element

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EP3013916A1 true EP3013916A1 (en) 2016-05-04

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Publication number Priority date Publication date Assignee Title
US6284089B1 (en) * 1997-12-23 2001-09-04 The Boeing Company Thermoplastic seam welds
EP1570141B1 (en) * 2002-12-12 2011-01-12 Kingspan Research and Developments Limited Flat or substantially flat roof

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