GB2153408A - Foam boards - Google Patents

Foam boards Download PDF

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Publication number
GB2153408A
GB2153408A GB08502406A GB8502406A GB2153408A GB 2153408 A GB2153408 A GB 2153408A GB 08502406 A GB08502406 A GB 08502406A GB 8502406 A GB8502406 A GB 8502406A GB 2153408 A GB2153408 A GB 2153408A
Authority
GB
United Kingdom
Prior art keywords
board
sections
lugs
hard foam
recesses
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.)
Granted
Application number
GB08502406A
Other versions
GB2153408B (en
GB8502406D0 (en
Inventor
Wolfgang Pip
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rohm GmbH
Roehm GmbH Darmstadt
Original Assignee
Rohm GmbH
Roehm GmbH Darmstadt
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 Rohm GmbH, Roehm GmbH Darmstadt filed Critical Rohm GmbH
Publication of GB8502406D0 publication Critical patent/GB8502406D0/en
Publication of GB2153408A publication Critical patent/GB2153408A/en
Application granted granted Critical
Publication of GB2153408B publication Critical patent/GB2153408B/en
Expired legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/40—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/22—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns
    • B29C66/227—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of repetitive interlocking undercuts, e.g. in the form of puzzle cuts
    • B29C66/2272—Teardrop-like, waterdrop-like or mushroom-like interlocking undercuts
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A foam board comprising a plurality of plastics foam sections joined together along their edges by the interengagement of recesses and lugs provided on adjacent sections which are of substantially equal thickness. The lugs are preferably sinusoidal and constructed as integral projections of one of the two adjacent sections. The assembled boards are suitable for the production of large mouldings of laminar construction with a foam core.

Description

SPECIFICATION Hard foam boards The present invention relates to hard foam boards. More particularly it relates to hard foam boards of large surface area which are suitable, for example, for the manufacture of large mouldings of multi-layer construction.
The size of hard foam boards is limited by their method of manufacture. Multi-layer mouldings with a core of hard foam are often required which are larger than the rough size of standard commercial hard foam boards, which means that the core must be made up of several sections. Whereas this is readily possible in the case of flat mouldings, the production of curved mouldings presents considerable difficulties if individual parts of the core layer have to be adapted to a curved shape of large-surface area.
One solution to the problem which has been proposed is that of adhesively bonding a plurality of hard foam boards at their abutting edges. However, this has not proved very successful since the deformation characteristics of the adhesive joint, particularly during thermal deformation, are different from the characteristics of the homogeneous layer of foam. There is therefore a need for large-surface boards of hard foam which can be deformed and processed like integral boards.
According to one aspect of the present invention we provide a hard foam board comprising a plurality of hard foam sections joined together along their edges by the interengagement of recesses and hard foam lugs provided on adjacent sections, the recesses, lugs and sections, at least in regions adjacent their joined edges, being of substantially equal thickness.
The boards according to the invention can be heated to a temperature at which they are thermally deformable and may be cylindrically bent or spherically deformed in the desired manner. It is desirable to tape over the junction with an adhesive strip during the deformation and then remove this strip again before any covering layers are laminated on.
The recesses and lugs may be produced by any conventional method of cutting contours in hard foam materials. Many hard foam materials can satisfactorily be cut with heated wire; in other cases, machining tools such as milling cutters, scroll saws or compass saws may be suitable. The edges of two board sections may be placed one over the other and cut simultaneously, thereby forming I ugs and recesses which will automatically fit exactly together.
It would be possible to cut recesses on both sides at the abutting edges of two board sections and to insert separately produced lugs of hard foam material of the same or similar thickness to that of the edges of the board sections. However, the lugs may be constructed as integral projections from one of the two abutting sections. Preferably, the edge of each board section is formed by a curve which either consists solely of arcs merging with one another or contains rectilinear portions merging into arcs and is free from angular boundary lines.
Typically, the new boards are more than 2 square metres, generally more than 5 square metres in area and are made up of from 2 to 10 or more sections, each of which may be more than 1 square metre in area.
Preferably, all the sections of the board are of the same thickness. This may be, for example, between 0.5 and 5 cm. In special cases, the board may have a varying thickness, but the sections must be of equal thickness at least at their line of contact. In particular cases, it may be required to join board sections of different thickness in which case it will be necessary to trim the junction to make both board edges the same thickness.
The sections are preferably joined together without adhesive and are held together solely by the interlocking of the lugs and recesses. This has the advantage that the board made up of a plurality of sections behaves like an integral board during deformation and lamination.
Suitable hard foams are those with a compressive strength according to DIN 53421 of not less than 0.1 N/mm2 and a tensile strength of not less than 0.4 N/mm2, measured according to DIN 53455 at 20 C. Polymethacrylimide foam with a weight per unit of volume of from 20 to 500 kg/m3 is particularly suitable. Other foams which may be used include, for example, foamed polyvinyl chloride, polyurethane, polypyromellitic acid imide, polysulphone and polyether-ether ketone.
The new boards are particularly suitable for the manufacture of large mouldings of laminar construction. In such constructions, layers of metal, glass fibre or carbon fibre plastics or of sheet materials of similar high tensile strength are laminated on over the entire area of the foam board and so as to cover the junctions on one or both sides. Structures of this kind are used in vehicles, ships and aircraft and in space travel.
An embodiment of the invention will now be described by way of example and with reference to the accompanying drawing which is a partial perspective view of two sections joined together.
Two sections of board are joined by means of lugs 1 which engage in correspondingly shaped undercut recesses 2. The construction is such that the interval between two lugs 1 and 1' forms a recess 2.
1. A hard foam board comprising a plurality of hard foam sections joined together along their edges by the interengagement of recesses and hard foam lugs provided on adjacent sections, the recesses, lugs and sections, at least in regions adjacent their joined edges, being of substantially equal thickness.
2. A board as claimed in claim 1, wherein each lug is formed as an integral projection of its respective section.
3. A board as claimed in claim 1 or 2, wherein the lugs have broadened heads and the recesses have corresponding undercuts.
4. A board as claimed in claim 1,2 or 3, wherein
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (17)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Hard foam boards The present invention relates to hard foam boards. More particularly it relates to hard foam boards of large surface area which are suitable, for example, for the manufacture of large mouldings of multi-layer construction. The size of hard foam boards is limited by their method of manufacture. Multi-layer mouldings with a core of hard foam are often required which are larger than the rough size of standard commercial hard foam boards, which means that the core must be made up of several sections. Whereas this is readily possible in the case of flat mouldings, the production of curved mouldings presents considerable difficulties if individual parts of the core layer have to be adapted to a curved shape of large-surface area. One solution to the problem which has been proposed is that of adhesively bonding a plurality of hard foam boards at their abutting edges. However, this has not proved very successful since the deformation characteristics of the adhesive joint, particularly during thermal deformation, are different from the characteristics of the homogeneous layer of foam. There is therefore a need for large-surface boards of hard foam which can be deformed and processed like integral boards. According to one aspect of the present invention we provide a hard foam board comprising a plurality of hard foam sections joined together along their edges by the interengagement of recesses and hard foam lugs provided on adjacent sections, the recesses, lugs and sections, at least in regions adjacent their joined edges, being of substantially equal thickness. The boards according to the invention can be heated to a temperature at which they are thermally deformable and may be cylindrically bent or spherically deformed in the desired manner. It is desirable to tape over the junction with an adhesive strip during the deformation and then remove this strip again before any covering layers are laminated on. The recesses and lugs may be produced by any conventional method of cutting contours in hard foam materials. Many hard foam materials can satisfactorily be cut with heated wire; in other cases, machining tools such as milling cutters, scroll saws or compass saws may be suitable. The edges of two board sections may be placed one over the other and cut simultaneously, thereby forming I ugs and recesses which will automatically fit exactly together. It would be possible to cut recesses on both sides at the abutting edges of two board sections and to insert separately produced lugs of hard foam material of the same or similar thickness to that of the edges of the board sections. However, the lugs may be constructed as integral projections from one of the two abutting sections. Preferably, the edge of each board section is formed by a curve which either consists solely of arcs merging with one another or contains rectilinear portions merging into arcs and is free from angular boundary lines. Typically, the new boards are more than 2 square metres, generally more than 5 square metres in area and are made up of from 2 to 10 or more sections, each of which may be more than 1 square metre in area. Preferably, all the sections of the board are of the same thickness. This may be, for example, between 0.5 and 5 cm. In special cases, the board may have a varying thickness, but the sections must be of equal thickness at least at their line of contact. In particular cases, it may be required to join board sections of different thickness in which case it will be necessary to trim the junction to make both board edges the same thickness. The sections are preferably joined together without adhesive and are held together solely by the interlocking of the lugs and recesses. This has the advantage that the board made up of a plurality of sections behaves like an integral board during deformation and lamination. Suitable hard foams are those with a compressive strength according to DIN 53421 of not less than 0.1 N/mm2 and a tensile strength of not less than 0.4 N/mm2, measured according to DIN 53455 at 20 C. Polymethacrylimide foam with a weight per unit of volume of from 20 to 500 kg/m3 is particularly suitable. Other foams which may be used include, for example, foamed polyvinyl chloride, polyurethane, polypyromellitic acid imide, polysulphone and polyether-ether ketone. The new boards are particularly suitable for the manufacture of large mouldings of laminar construction. In such constructions, layers of metal, glass fibre or carbon fibre plastics or of sheet materials of similar high tensile strength are laminated on over the entire area of the foam board and so as to cover the junctions on one or both sides. Structures of this kind are used in vehicles, ships and aircraft and in space travel. An embodiment of the invention will now be described by way of example and with reference to the accompanying drawing which is a partial perspective view of two sections joined together. Two sections of board are joined by means of lugs 1 which engage in correspondingly shaped undercut recesses 2. The construction is such that the interval between two lugs 1 and 1' forms a recess 2. CLAIMS
1. A hard foam board comprising a plurality of hard foam sections joined together along their edges by the interengagement of recesses and hard foam lugs provided on adjacent sections, the recesses, lugs and sections, at least in regions adjacent their joined edges, being of substantially equal thickness.
2. A board as claimed in claim 1, wherein each lug is formed as an integral projection of its respective section.
3. A board as claimed in claim 1 or 2, wherein the lugs have broadened heads and the recesses have corresponding undercuts.
4. A board as claimed in claim 1,2 or 3, wherein each of two adjacent sections is provided with alternate lugs and recesses.
5. A board as claimed in claim 4, wherein the recesses are formed by the intervals between two lugs.
6. A board as claimed in any preceding claims, wherein the join line between two adjacent sections is free from angular transitions.
7. A board as claimed in any preceding claim, wherein the sections are connected, without the use of adhesives and solely by the interlocking of the lugs and recesses.
8. A board as claimed in any preceding claim, consisting of a hard foam material with a compressive strength of not less than 0.1 N/mm2 and a tensile strength of not less than 0.4 N/mm2, measured at 20 C.
9. A board as claimed in claim 8, consisting of polymethacrylimide foam.
10. A board as claimed in claim 9, wherein the weight per unit of volume is from 20 to 500 kg/m3.
11. A board as claimed in any preceding claim wherein the sections have a thickness of between 0.5 and 5 cm.
12. A board as claimed in any preceding claim wherein the board area is greater than 2 square meters.
13. A board as claimed in claim 12 wherein the board area is greater than 5 square meters.
14. A board as claimed in any preceding claim wherein each section has an area of at least 1 square meter.
15. Ahard foam board substantially as hereinbefore described with reference to the accompanying drawing.
16. A moulding comprising a board as claimed in any preceding claim.
17. A moulding as claimed in claim 12, being curved.
GB08502406A 1984-01-31 1985-01-31 Foam boards Expired GB2153408B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19848402652U DE8402652U1 (en) 1984-01-31 1984-01-31 HARD FOAM PANEL

Publications (3)

Publication Number Publication Date
GB8502406D0 GB8502406D0 (en) 1985-03-06
GB2153408A true GB2153408A (en) 1985-08-21
GB2153408B GB2153408B (en) 1987-06-24

Family

ID=6762953

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08502406A Expired GB2153408B (en) 1984-01-31 1985-01-31 Foam boards

Country Status (3)

Country Link
DE (1) DE8402652U1 (en)
FR (1) FR2558768B3 (en)
GB (1) GB2153408B (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6789367B1 (en) 1999-02-13 2004-09-14 Qinetiq Limited Sandwich panel, insert therefor, structure comprising sandwich panels and method of joining such panels
EP2524794A1 (en) * 2011-05-18 2012-11-21 EUROCOPTER DEUTSCHLAND GmbH Foam or honeycomb core, rotor blade with foam or honeycomb cores and method of manufacturing such a rotor blade
EP3406432A1 (en) * 2017-05-22 2018-11-28 LM Wind Power International Technology II ApS A device and a method of aligning core elements using such device
EP3527357A1 (en) * 2018-02-20 2019-08-21 Maucher Formenbau GmbH & Co. KG Core and a method for manufacturing and subsequent treatment of same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110406118A (en) * 2019-09-02 2019-11-05 江苏美龙航空部件有限公司 A kind of special-shaped change wall thickness cone cylinder shape composite material foam sandwich construction

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB685893A (en) * 1950-02-25 1953-01-14 Marion Winfield Overhulse Pre-cast concrete slab construction
GB711665A (en) * 1952-05-29 1954-07-07 Carl Gillis Skuthe Improvements in building slabs
GB908260A (en) * 1958-07-31 1962-10-17 Gloucester Stone Company Ltd Improvements in and relating to joints in concrete structural members and structuresincorporating such joints
GB1106751A (en) * 1964-02-19 1968-03-20 Frank Nogossek Improved prefabricated building and constructional elements therefor
GB1166954A (en) * 1967-03-08 1969-10-15 George Guthrie Small Improvements in or relating to Tongued and Grooved Board
GB1195570A (en) * 1966-12-30 1970-06-17 Werner Baumberger A Paving Stone
GB1573147A (en) * 1976-02-13 1980-08-13 Idemitsu Kosan Co Construction material for building

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB685893A (en) * 1950-02-25 1953-01-14 Marion Winfield Overhulse Pre-cast concrete slab construction
GB711665A (en) * 1952-05-29 1954-07-07 Carl Gillis Skuthe Improvements in building slabs
GB908260A (en) * 1958-07-31 1962-10-17 Gloucester Stone Company Ltd Improvements in and relating to joints in concrete structural members and structuresincorporating such joints
GB1106751A (en) * 1964-02-19 1968-03-20 Frank Nogossek Improved prefabricated building and constructional elements therefor
GB1195570A (en) * 1966-12-30 1970-06-17 Werner Baumberger A Paving Stone
GB1166954A (en) * 1967-03-08 1969-10-15 George Guthrie Small Improvements in or relating to Tongued and Grooved Board
GB1573147A (en) * 1976-02-13 1980-08-13 Idemitsu Kosan Co Construction material for building

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6789367B1 (en) 1999-02-13 2004-09-14 Qinetiq Limited Sandwich panel, insert therefor, structure comprising sandwich panels and method of joining such panels
EP2524794A1 (en) * 2011-05-18 2012-11-21 EUROCOPTER DEUTSCHLAND GmbH Foam or honeycomb core, rotor blade with foam or honeycomb cores and method of manufacturing such a rotor blade
EP3406432A1 (en) * 2017-05-22 2018-11-28 LM Wind Power International Technology II ApS A device and a method of aligning core elements using such device
WO2018215447A1 (en) 2017-05-22 2018-11-29 Lm Wind Power International Technology Ii Aps A device and a method of aligning core elements using such device
CN110914047A (en) * 2017-05-22 2020-03-24 Lm风力发电国际技术有限公司 Apparatus and method for aligning core elements using such an apparatus
CN110914047B (en) * 2017-05-22 2021-10-29 Lm风力发电国际技术有限公司 Apparatus and method for aligning core elements using such an apparatus
EP3527357A1 (en) * 2018-02-20 2019-08-21 Maucher Formenbau GmbH & Co. KG Core and a method for manufacturing and subsequent treatment of same

Also Published As

Publication number Publication date
DE8402652U1 (en) 1984-04-26
GB2153408B (en) 1987-06-24
FR2558768B3 (en) 1986-04-04
FR2558768A1 (en) 1985-08-02
GB8502406D0 (en) 1985-03-06

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 19950131