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
  • B32B5/02—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 structural features of a fibrous or filamentary layer
  • B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
  • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D99/00—Subject matter not provided for in other groups of this subclass
  • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
  • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
  • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
• • 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
  • B32B5/14—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 a layer differing constitutionally or physically in different parts, e.g. denser near its faces
  • B32B5/142—Variation across the area of the layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • 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
  • B32B5/18—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 features of a layer of foamed material
• • 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
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/08—Interconnection of layers by mechanical means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29L2031/3005—Body finishings
  • B29L2031/3017—Floor coverings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29L2031/3076—Aircrafts
• • 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
  • B32B2250/00—Layers arrangement
  • B32B2250/03—3 layers
• • 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
  • B32B2250/00—Layers arrangement
  • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• • 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
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0261—Polyamide fibres
  • B32B2262/0269—Aromatic polyamide fibres
• • 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
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • 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
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0221—Vinyl resin
  • B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/025—Polyolefin
• • 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
  • B32B2266/00—Composition of foam
  • B32B2266/02—Organic
  • B32B2266/0214—Materials belonging to B32B27/00
  • B32B2266/0264—Polyester
• • 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
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/02—Cellular or porous
  • B32B2305/022—Foam
• • 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
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/07—Parts immersed or impregnated in a matrix
  • B32B2305/076—Prepregs
• • 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
  • B32B2323/00—Polyalkenes
• • 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
  • B32B2323/00—Polyalkenes
  • B32B2323/04—Polyethylene
• • 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
  • B32B2327/00—Polyvinylhalogenides
  • B32B2327/06—PVC, i.e. polyvinylchloride
• • 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
  • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2605/00—Vehicles
  • B32B2605/18—Aircraft
• • 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
  • B32B2607/00—Walls, panels
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T50/00—Aeronautics or air transport
  • Y02T50/40—Weight reduction

Definitions

• the invention relates to a sandwich construction composite structure and a method for their preparation.
• composite structures are considered, which can be used as floor panels in aircraft.
• floor panels in modern day civilian wide-body aircraft are core composite structures based on honeycomb structures (phenol-coated aramid paper). These honeycombs are provided on both sides with thin cover layers of glass and / or carbon fibers.
• honeycomb structures phenol-coated aramid paper
• areas of local load introduction and / or edge areas of the floor panels are optimized by prepreg blocks / core filler masses.
• the fillers are highly filled epoxy resins. These are pressed into the open honeycomb cells and then cured together with the cover layers. Although this procedure can be implemented locally additional reinforcement, but it also creates additional steps and a not inconsiderable extra weight.
• Connection points are realized by inserts made of metal / composite (torlon) or also by glass insert or prepreg plugs (so-called glass plugs).
• the first (inserts) are glued in after completion of the bond and are optionally provided with threads.
• the latter prepreg plugs are cut from hardened fiber composite laminate and placed in the honeycomb and / or glued before the cover layer application. After completion of the composite, a hole can be made in the inserts.
• honeycomb density must be selected in the honeycomb selection, which is the required one in both the x- and y-direction as well as in the z-direction mechanical properties are sufficient. It can therefore be assumed that the honeycomb to be processed represents a compromise between mechanical properties and optimum weight.
• the glued-in inserts in particular prepreg plugs and / or pads / are for reasons already described with the covering skins preferably connected via a prepreg resin. Over the period of use it can come in this area for cover skin detachment, which is synonymous with the fact that the connection of the floor panels is no longer sufficiently given to the floor grate, which may result in a reduced load capacity.
• a composite construction in particular a sandwich-type composite panel, preferably comprises two outer layers lying parallel to one another.
• a foam completely fills the space between the outer layers, at least in some areas.
• the outer layers are interconnected by spacers and the spacers are connected via a cured plastic to the outer layers.
• the honeycomb intermediate layers can be replaced.
• adhesive lines of the honeycomb on the outer layers each consist of individual adhesive dots. As a result, crack propagation, which often occurs in glue lines, is avoided.
• the foam is preferably a hard closed cell foam
• ambient (oxygen, moisture) conditions are reduced to a reduced extent, and preferably local, to the composite construction interior and corresponding oxidation and aging problems are avoided.
• By a different accumulation of the spacer elements and their targeted alignments it is possible to achieve different strengths and stiffness in some areas. So there can be saved material and weight, where the loads are lower.
• the spacers are preferably rod-shaped in the area between the outer layers. This does not exclude that the spacers adjacent to the outer layers include bends or bends. But in the intermediate area, they are preferably straight because they can absorb tensile or compressive forces so well.
• a rod is understood in particular as an element of preferably constant cross-section. In particular, the ratio of the largest diameter to the smallest diameter is smaller than 2.
• the spacers may be round or square. A possible kinking is delayed by the surrounding foam.
• the spacers in the area between the outer layers are largely straight or unbent. So both tensile and compressive forces are well received.
• the individual spacers are aligned according to a predetermined rule.
• a positioning device can be given a desired distance.
• the spacers are thus not randomly distributed and / or aligned. This makes it possible, on the one hand, to effect a locally varied strength and / or rigidity on the one hand, depending on the loads due to a larger spacer density, and / or, on the other hand, to effect a locally targeted alignment of the strength and / or rigidity by local alignment of the spacers.
• the outer layers are at least partially penetrated by the spacers.
• the spacers may at least partially have pointed ends. In particular at least 20%, preferably at least 50% and most preferably virtually all spacers have pointed ends.
• the tip can be achieved by making the cut to cut the spacer to an angle of 60 ° - 85 ° degrees to the cross section of the spacer. This has the following advantages: both the outer layer, as well as the foam can be drilled so better without a buckling of the spacer occurs. In cases where the spacer applies (as described below) to the inside of the outer layers, this is facilitated by the increased with the decreasing cross-section flexibility.
• the density of the spacers is at least partially greater than 3 spacers per square centimeter and in particular greater than 10 spacers per square centimeter. This ensures sufficient stability.
• the density of the spacers may be greater than in portions of the composite structure removed therefrom.
• the density increase in said attachment area or at the edge is preferably at least 50% compared to the remaining distribution density.
• At least 50%, preferably at least 80%, of the spacers are oriented in such a way between the outer layers that their angular deviations from the outer layer orthogonal are greater than 15 °, these regions preferably being of the sections of the composite construction which serve for their attachment, are removed.
• no spacer in the intermediate region is also aligned only in regions parallel to the plane of the outer layers. Virtually all spacers are preferably in contact with both outer layers.
• the spacers are each aligned in one of these orientations.
• This is advantageous for feeding the composite plate with the spacers.
• one or more alignments can be simply specified in a processing machine.
• this arrangement simplifies determination of strength in all orientations.
• the composite construction comprises an outer layer spacing bridging insert part or a comparable filler, wherein at least one of the spacers at least partially penetrates the insert part or the filling substance.
• a suitable filling substance is any substance which, after a filling or curing process that may have been carried out, is suitable for absorbing pressure forces. By the penetration, the connection of the insert part with the outer layers can be improved, since the spacers are in turn connected to the outer layers.
• an intermediate product comprising two outer layers and an intermediate foamed layer is first prepared, and spacers are introduced into the region located between the outer layers by penetrating at least one of the outer layers, and then an outer layer or the spacers hardened or introduced there plastic hardened.
• a plurality of spacers are largely incorporated in a foamed layer, and a sandwich assembly is created by using outer layers, and the spacers are pressed into the outer layers from the inside or the spacers attach to an inner side of the outer layers Subsequently, a plastic hardens and the spacers are connected to the outer layers.
• dry fibers can be used to form the outer layers and / or the spacers. These are added after the formation of the composite construction with an infusion process with the resin and cured.
• prepreg fibers can be used, which are already mixed with resin, over hardening retarder prevents the resin from premature curing.
• combined methods are possible in which on one side of a composite construction, a dry outer layer, ie a layer which is not initially provided with resin, is used and on the other side a prepreg fiber board is used to form the outer layer.
• At least one outer layer preferably both outer layers of the fiber composite construction are prepreg layers or uncured resin fibers or fiber layers which are cured together with the spacers (20-25).
• a fiber strand or fiber thread suitable for a sewing process or a dry reinforcement process may be provided by a foamed layer or by a foamed layer Layer and at least one outer layer can be pressed or pulled and subsequently the fiber strand or fiber thread can be mixed with resin and cured. This particularly describes a dry sewing method.
• 1 is a perspective view of a corner of a composite panel
• FIG. 3 is a view of the intermediate stage of FIG. 2,
• FIG. 4 shows the composite panel of FIG. 1 in section A-A
• Fig. 6 shows a variant of the composite plate with a sewing technique
• Fig. 7 is a schematic view for explaining an insert part
• the composite panel of Figure 1 comprises a sandwich construction having two outer layers 10 and a layer 30 of foam 35 therebetween.
• the outer layers 10, also referred to as cover skin, have a high fiber content which is bonded to a mat via a synthetic resin are. They are in particular outer layers with a regular fiber arrangement, such as a fabric. It is also an irregular fiber arrangement, such as a nonwoven, possible.
• a plurality of spacers is integrated in addition to the foam 35, the latter being not visible in FIG. 1.
• the spacers are connected to the outer layers 10 with synthetic resin. This results in a sandwich construction, which also has a high strength regardless of the intermediate foam layer.
• the section AA of FIG. 1 is shown in FIG. 4.
• the x-axis lies in the cut and there is a 45 ° angle between the cutting plane and the xy plane.
• the spacers 20 and 22 shown in Fig. 4 are inclined in the composite plate 1.
• the composite plate 1 a plurality of spacers 20, 22, 23, so that also on each section in the x-axis at an angle from -45 ° to the xy plane, as well as positive and negative 45 ° alignment with the yz plane going through the y axis, similar sectional images are possible.
• other arrangements of the spacers are possible, wherein the angular orientation may differ and the individual spacers also need not lie in individual planes.
• the spacers are placed according to a predetermined pattern.
• each individual spacer is assigned by the processing machine a certain orientation at a particular location. Also, a quasi randomly determined by the processing machine alignment of the spacers can be determined.
• a plurality of the spacers penetrate the outer layers completely (reference numeral 20) or partially (reference numeral 22).
• Other spacers 23 abut flat against at least one of the inwardly facing sides of the outer layers 10.
• Fig. 2 shows a view corresponding to Fig. 4, but in which the upper outer layer is not shown.
• the foam layer 35 is shown, and a plurality of the spacers 20 protrude upward from the foam layer 35.
• the spacers 20 have a multiplicity of different angular orientations.
• the construction of the composite panel according to FIG. 4 can be produced in different ways.
• the inner foam layer 35 is foamed or provided as a semifinished product and underneath an optional lower outer layer 10 is placed. Subsequently, a plurality of spacers 20 is pressed or injected into the foam in an automatic process. This creates the intermediate stage shown in FIG. Although the spacers are accommodated in the foam 35 in this intermediate stage, they have not penetrated into the lower outer layer 10 yet.
• the second outer layer is placed from above and pressed with the intermediate stage so that the second outer layer comes into contact with the foam 35.
• a part of the spacers presses in the upper outer layer and another part in the lower outer layer, so that the structure shown in Fig. 4 results.
• an intermediate stage may also be provided, with a foam layer from which the spacers protrude on both sides, and an outer layer is subsequently applied from both sides.
• FIG. 5 shows an image of a spacer 20 which is in contact with both outer layers 10.
• the spacer 20 does not drill through the outer layers 10, but adheres to the inner contour of the outer layers between the foam 35 and the outer layers 10 at.
• a further spacer 20 is shown, which is at an approximately 90 ° angle to the first-mentioned spacer and pierces the image plane.
• the sandwich construction with the foam 35 and the two outer layers 10 may first be made without the connecting spacers 20.
• the spacers 20 are introduced by the material of one of the outer layers 10 in the sandwich construction so that the individual spacers are in contact with both outer layers 10. Unless the spacers 10 are sufficiently guided during insertion by a guide element, they have a sufficient strength and bending stiffness that the insertion takes place without upsetting or kinking.
• FIG. 6 shows a further variant in which a sewing method is used.
• the spacer 20 has a yarn-like flexibility so that it can be passed through the sandwich pack with a needle (not shown). At the bottom it is interwoven with a bobbin thread 28, so that the loops shown result in the needle retraction.
• double-stitched or double-chain stitches or modified knotting techniques can be used as sewing methods.
• Fig. 8 shows a sewing process in an intermediate stage in which loops are formed on one side of the composite structure. This method is also called tufting.
• a processing step not shown, but indicated by the arrows, the loops are folded over and thus form part of the composite construction outside. Since sufficient rigidity of the spacers 20 results upon curing, it is not absolutely necessary to use a conventional sewing method, as e.g. in Fig. 9 is shown.
• a unilateral thread is used, which is guided on one side of the composite structure and guided on the opposite side like a loop to the opening of the adjacent loop and sewn there.
• an optional insert part 40 is shown. This has a central bore 42 which passes through the entire composite panel 1.
• the hole is chamfered on one side and serves to secure the composite panel, for example with a screw connection. Since high compression forces occur on the outer side of the composite panel in the case of a screw connection, a special pressure rigidity is necessary here. This is made possible by the insert part 40.
• the insert part initially consists of a stack of a plurality of layers of glass fiber fabric, such as more than 20 layers. Preferably, these layers are dry, so not interspersed with resin and become only in the steps explained below the wetting and curing to a hard insert part, which can absorb the forces mentioned. Since preferably no resin is still present in the insert part.
• the insert part can be penetrated by the spacers without much resistance. Since the stack does not have any particular hardness prior to use of the plastic, it is possible for the spacers to penetrate through the stack of glass fiber layers. Furthermore, it can be seen in FIG. 7 that the density of the spacers in the surroundings of the insert part is increased. This also allows targeted forces are absorbed, resulting in the attachment of the composite panel. If, in addition to the layers of the insert part, the covering skins, ie the outer layers, are also penetrated, then in addition the bond strength of the overall composite in this region is increased.
• the attachment area of the composite panel 1 it is not necessary for the attachment area of the composite panel 1 to use a separate insert part.
• the density of the spacers can be increased there such that the fastening forces can be well absorbed.
• the spacers can be made in each of the above-mentioned embodiments via rowing.
• Rowing is a fiber package with a multitude of individual fibers. In a carbon fiber winding, for example, 1000 or more individual fibers (filaments) can be used.
• the diameter of the spacers can vary greatly depending on the conditions of use. Preferably spacers in a diameter range of 0.5 mm 2 to 3 mm 2 are used. For applications where stitching is used, the smaller cross sections are preferred. If the spacers are inserted through one of the outer layers, that the inherent rigidity of the spacers is essential, then the larger cross sections are used rather.
• bistable fibers or fiber bundles can be used. These are resin-impregnated fibers that have been partially cured in an upstream process step. By partial hardening they have at least largely lost their stickiness. The curing temperature conditions liquefy the resin of the bistag material, resulting in good adhesion. Wet fibers are also referred to as prepregs. In this case, the spacers, so in particular the Rowings, already impregnated with resin, or impregnated. About Christsverzogerer prevents the crosslinking reaction starts prematurely. Rather, it can be started by the production of the component, in particular by a supply of heat.
• the dry fibers are not mixed with the resin in this sense. Instead, they are mixed with the resin after preparation of the composite panel described above and then cured. Combined methods are also possible, using dry fibers on one side and prepregs on the other side of the composite board. The latter may be particularly advantageous if a lower resin impregnation is sufficient on a side of the composite panel coming in for installation and, for example, a sewing process with dry fibers can be performed better and a higher resin impregnation strength properties for the side of the composite panel used for external application improved.
• pultrusion infusion is also conceivable here because of the large number of components required.
• the pultrusion process is a continuous process of material production in which a spacer sandwich construction is first created as described above. Subsequently, it is provided in a closed space, which it passes through, for example, under vacuum with the synthetic resin, which is subsequently heated, for example, under vacuum and cured. During the curing process, presses or rollers ensure that the composite panel produced in this way is dimensionally stable, in particular in terms of thickness.
• the foam 35 is a defined, low, fine and / or closed-cell foam, preferably with a homogeneous density.
• polyurethane foams are suitable because they have a high hardness.
• PVC polyvinyl chloride
• PP polypropylene
• PET polyethylene terephthalate
• PBT polybutylene terephthalate
• PS polystyrene
• EPS expanded polystyrene
• XPS crosslinked polystyrene
• a closed cell foam is used to prevent the foam from filling up with the resin, which in addition to the cost of materials, also increases component weight.
• the foam preferably has a strength to accommodate between 10 and 50% of the compressive loads exerted on the composite structure.
• Tensile loads ie forces that would cause the separation of the composite structure, and shear forces (in the xy plane of FIG. 1) are preferably absorbed by the spacers.
• the resin epoxy resin or a vinyl ester-based resin or the like may be preferably used.
• the thickness of the composite panel may be, for example, 10 mm.
• the thickness of the outer layers is shown schematically in the figures and in particular exaggerated.
• the outer layers can be less than 1 mm thick (for example 0.5 mm) and / or, for example, have a weight of 200 g / m 2 .
• the fibrous material of the outer sizing may comprise the same fibers as the spacers.
• packages of carbon fibers, glass fibers, aramid fiber or the like can be used.
• these fibers have sufficient flexibility that they can be bent, as is necessary when sewing. If the fibers (as described) are put through the foam, sufficient stability is advantageous.
• partially cured or cured fiber rods or pins made of metal or the like can be used. The latter is v.a. then advantageous if the spacers are to be introduced after the creation of the sandwich construction. If stick-like spacers are inserted through the foam, they can also be cut to length so that they look a short distance out of the foam (depending on the application on one or both sides). Then they can be folded over or bent over in a separate working step so that a contact surface enlargement is effected for the subsequent contact with the outer layers.
• the foam as a carrier has several advantages. Since the cells are very small compared to the known from the prior art honeycomb structures and also closed, the edge is already sealed against penetrating moisture. Apart from a possibly provided increase in the spacer density no special insert or other treatment is needed on the edge.
• Pin armored structures have been shown to have excellent damage tolerance. Once introduced damages are absolutely limited in space and do not increase further by the crack-stopping effect of the intact pins.
• a honeycomb structure bonded to the outer panels was used. If these bonds are partially cracked, the crack could continue due to the voltage peaks at the crack end.
• Spacers which are also referred to as pins, however, are to be regarded as singular elements. As a result, they can be distributed freely in the area and individually oriented. So there is the possibility through targeted distribution and orientation of the spacers to shape according to the requirements. This is a very efficient way to design load injections, edge enhancements, etc.
• the foam can serve as thermal and acoustic insulation, ideally replacing additional elements.
• foams reinforced in this way are an interesting alternative to existing honeycomb constructions.
• this material category offers great potential. Force transmission, edge reinforcements, etc. can be easily designed. Due to its very good impact behavior, the risk of growing damage surfaces is minimized. An optimized cover layer connection additionally reduces the range of occurring damages. Foams reinforced according to the invention thus offer a considerable potential for prolonged component life.
• future demands on the composite panels e.g. from the anchoring of additional elements (e.g., kitchen, toilets, ).
• composite structures have been described in relation to their use as floor panels in aircraft.
• there are also many areas of application for the composite structures in applications where a high load-bearing capacity and a low weight are required.
• These can be walls in aircraft use, as well as ceiling elements.
• the use in trains and ships is particularly advantageous.
• the plates need not be flat, but may be curved or bent.
• the thickness of the composite structure does not have to be constant, so that three-dimensional structures with stable outer sides can result, which in each case receive an increased resistance to various loads via spacers.

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• 2014
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• 2015
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