KR20090104506A - Light weight sandwich panels composed of sheets with dimple array and a manufacturing method of the same - Google Patents

Abstract

PURPOSE: A light weight sandwich board material containing a thin film having regular uneven arrangement and a manufacturing method thereof are provided to ensure low production costs and simple process by forming a sandwich board with only two boards and performing junction on one plane. CONSTITUTION: A method for manufacturing a light weight sandwich board material containing a thin film having regular uneven arrangement comprises the steps of: processing a plurality of regular protrusions(20a,20b) on the boards(10a,10b); arranging two boards processed from the above step so that protrusions of two boards are vertically faces with each other; and bonding protrusions facing each other.

Description

LIGHT WEIGHT SANDWICH PANELS COMPOSED OF SHEETS WITH DIMPLE ARRAY AND A MANUFACTURING METHOD OF THE SAME}

The present invention relates to a lightweight sandwich plate composed of a thin plate having a plurality of regular irregularities and a manufacturing method thereof.

Conventional sandwich plate structures consist of a top / bottom face sheet and a core disposed therebetween. The top / bottom faceplate is composed of a material of high strength / density, and the core is made of styrofoam. It is composed of low density porous materials and lattice materials.

1 shows the shape of several sandwich plate structures with lattice intermediates. The lattice-shaped intermediate material or porous material is composed of several closed rooms, making it difficult to utilize space.

Recently, a new truss structure has been introduced as a new intermediate material (H. N. G. Wadley, N. A. Fleck, A. G. Evans, 2003, Composite Science and Technology, Vol. 63, pp.2331 ~ 2343). The truss structure, which is designed for optimum strength through precise calculations, has the advantage that the internal space is opened and the space is utilized while having the mechanical properties comparable to the honeycomb lattice.

The most common truss type is the pyramid truss. The pyramid truss is configured such that four equilateral triangular lattice forms an inclined plane and the square lattice forms a lower (or upper) plane, which is advantageous for making a rectangular plate structure. As another truss structure, an octet truss (R. Buckminster Fuller, 1961, US Patent 2,986,241) in which a tetrahedron and an octahedron are combined. In this structure, each element forms an equilateral triangle with each other.

In the 21st century, the Kagome truss, which transformed the octet truss, was announced (S. Hyun, AM Karlsson, S. Torquato, AG Evans, 2003, Int J. of Solids and structures, Vol. 40, pp.6989). -6998).

FIG. 2 shows the shape of a sandwich plate material having a pyramid, an octet, and a kagome truss structure as an intermediate material, and a face sheet attached thereto. Kagome truss is known to have less variation in stiffness of the structure according to the direction than pyramid trusses and octet trusses, and has excellent resistance to buckling, stability of post-buckling deformation, and energy absorption capacity.

As a separate sandwich board, a plate having a plurality of regular shells (dimpled) is used as an intermediate material, and a face plate is attached to the upper and lower parts. Egg-box (M. Zupan, C. Chen, NA Fleck, International Journal of Mechanical Sciences, Vol. 45, pp. 851 ~ 871, 2003) or hemispherical uneven plate (5, Sung-Yong et al., Korean Society of Mechanical Engineers, Vol. 30, No. 6, pp. 653-661, 2006; Korean Patent Publication No. 10-2005-0100763).

3 shows the shape of a sandwich plate having an plate having irregularities as an intermediate material. This sandwich plate has the advantage of high productivity and high absorbed energy due to deformation during compressive load by applying thin plate forming technology in the step of forming the intermediate material.

Sandwich plate so far is composed of three or more members, such as the middle material and the upper / lower face material, the process is complicated and expensive because the intermediate material and the upper face material, and between the intermediate material and the lower face material to be bonded. Also, in the case of truss or lattice intermediate material, the productivity is lower than that of dimpled shell intermediate material, while sandwich plate material having dimpled shell intermediate material has truss or lattice type intermediate weight strength. Inferior to sandwich board.

In order to solve the above problems, an object of the present invention is to have a three-dimensional space structure inside the thin upper / lower two sheets having a regular arrangement of irregularities of a certain shape are joined so that the protruding parts of the plate face each other The present invention provides a lightweight sandwich plate having an intermediate material and a method of manufacturing the same.

The gist of the present invention for achieving the above object is as follows.

(1) a first step of processing a plurality of regular protrusions on the plate, a second step of arranging the two plate materials processed in the first step up and down so that the protrusions of each other face each other, and the protrusions facing each other; Sandwich plate manufacturing method comprising a third step.

(2) In (1), in the first step, the protrusions are processed in the shape of a triangular pyramid, and in the second step, the two plate members are disposed so that the opposite triangular pyramids are rotated 180 degrees with respect to each other. Sandwich board manufacturing method characterized by the arrangement.

(3) The method of manufacturing a sandwich sheet according to (1) or (2), wherein in the first step, the sheet made of metal is deep drawn or embossed.

(4) The sandwich plate production method according to (1) or (2), wherein in the first step, the plastic is injection molded or embossed after extrusion molding.

(5) The method according to (1) or (2), wherein in the first step, the protrusions are processed into a lattice arrangement or a staggered arrangement.

(6) The sandwich plate manufacturing method according to (1) or (2), wherein in the third step, the protrusions are joined by one of a process selected from resin bonding, soldering, brazing, welding, and fusion.

(7) The sandwich plate manufacturing method according to (3), wherein in the third step, the protrusions are joined by spot welding or projection welding.

(8) The method for manufacturing a sandwich plate according to (1), wherein in the first step, the protrusion is processed into a pyramid shape or a truncated cone shape.

(9) The method according to (1) or (2), wherein after the third step, the space between the two sheets is filled with one selected from a porous material, a fluid, a resin, a metal, and a ceramic. .

(10) The sandwich board material manufactured according to the sandwich board manufacturing method as described in (1) or (2).

As seen above, the present invention is for a light weight sandwich plate has the following advantages.

(1) The conventional sandwich plate is composed of three or more members such as an upper / lower face sheet and a core, and is joined in two planes, such as between an upper face and an upper portion of an intermediate portion and between a lower face and an intermediate portion of a lower portion. Although produced through the process of the present invention, in the present invention, the protrusions arranged on each of the two sheets serve as an intermediate material, and the remaining portions that do not protrude and serve as face plates serve to form a sandwich plate with only two plates. The joining is done on only one plane, so the manufacturing cost is low and the process is simple.

(2) The design of the protrusions serving as intermediate materials is optimally designed to have the highest strength according to the use such as triangular pyramids and square pyramids, and the size and arrangement intervals of the protrusions are adjusted, so that the design flexibility can be obtained to have the desired mechanical performance.

(3) When metal plate is used as a material, it is possible to apply thin plate forming technology to the processing of protrusions and to use simple and well-established techniques such as electric spot welding for joining the protrusions, thereby reducing production cost and facilitating mass production. .

Hereinafter, the configuration and the preferred embodiment of the present invention will be described in detail with reference to FIGS. 4 to 8.

Preferred Embodiments

4 (a) and 4 (b) are side and perspective views, respectively, of a sandwich plate 100 according to a preferred embodiment of the present invention. The sandwich plate 100 includes two sheets 10a and 10b disposed at an upper portion and a lower portion thereof, and a plurality of regular protrusions 20a and 20b are formed at each plate 10a and 10b. The protrusions 20a and 20b of the upper and lower plate members 10a and 10b are disposed to face each other and are joined to each other to form a joint 30.

The protrusions 20a and 20b are processed to form an integral part with the plate materials 10a and 10b, and when the metal thin plate is used as the material, the protrusions 20a and 20b are thin plates such as deep drawing or embossing. It can be processed using molding techniques. When plastic is used as a material, the protrusions 20a and 20b can be formed by embossing immediately after extrusion molding, and if the sandwich plate 100 is small, the protrusions 20a and 20b by injection molding of plastics. It is also possible to prepare the plate member (10a, 10b) is formed.

In the embodiment of Fig. 4, in order to obtain a structure similar to that of the sandwich plate having the Kagome truss shown in Fig. 2C as an intermediate material, the protrusions 20a and 20b are processed into a substantially triangular pyramid shape.

5 shows an example of the triangular pyramidal pyramid shaped protrusions 20: 20a and 20b. The protruding portion 20 includes three inclined surfaces 22 extending from the plate materials 10: 10a and 10b, and a horizontal surface 24 connecting the upper ends of the inclined surfaces 22, so that the tip of the upper part of the triangular pyramid is cut off. Has In addition, the boundary portion to prevent stress concentration at the boundary portion or the boundary portion between the inclined surface 22 and the horizontal surface 24 or the like where the inclined surface 22 is formed from the plate 10 or the processing of the protrusion 20 can be made easily. It is preferable to give a predetermined curvature to the. For this purpose, the protrusion 20 shown in FIG. 5 also includes curved surfaces 26, 28. Of course, it will be readily understood that the boundary portion between the inclined surface 22 and the inclined surface 22 of the protrusion 20 may be curvature processed.

In manufacturing the sandwich plate 100 illustrated in FIG. 4 using two sheets 10a and 10b having a plurality of protrusions 20a and 20b processed in the shape of a triangular pyramid, a cargo gorus is used as an intermediate member. In order to realize the structure and characteristics similar to those of the sandwich plate, in the step of placing the plate 10a positioned above and the plate 10b positioned below, the projections 20a and 20b of the opposite triangular pyramids are 180 with respect to each other. It is also to be rotated.

As shown in Fig. 4, the two protruding portions 20a and 20b facing each other are joined by a bonding process such as resin bonding, soldering, brazing, welding, fusion, or the like. Sandwich board 100 can be manufactured.

As an example, FIG. 6 shows the process of continuously joining the board | plate materials 10a and 10b of a metal material by welding. By joining and pressurizing the outer side of the portions 20a and 20b of the plate materials 10a and 10b supplied from the upper side and the lower side in contact with the welding electrode 200 in order to weld the protrusions 20a and 20b, Let 30 be formed continuously. In the enlarged view of the part by which welding is made of FIG. 6, the figure on the left shows a spot welding process, and the figure on the right shows a projection welding process.

<Example of configuration change>

Figure 7 is another embodiment of the projections 20: 20a, 20b applicable to the sandwich plate material according to the present invention. The square pyramid of FIG. 7 (a) has a shape similar to a pyramid truss, and a pyramid such as a square pyramid has a high stiffness or stiffness compared to a truncated cone for compression or shear load in a specific direction. The truncated cone of Fig. 7 (b) is easy to process and has no orientation in strength and stiffness with respect to shear load.

8 shows various joining shapes of the protrusions 20: 20a and 20b. Figure 8 (a) is a form in which the upper triangular pyramid of the upper plate and the lower triangular pyramid of the lower plate in the same manner and bonded, Figs. 8 (b) and (c) show the junction shape of the square pyramid and the truncated cone, respectively.

9 (a) and 9 (b) are perspective views of an embodiment in which protrusions 20: 20a, 20b formed on plate 10: 10a, 10b are processed in the form of a right angle lattice arrangement and a staggered arrangement, respectively. The arrangement of the protrusions 20 is not limited thereto, and may be variously changed according to characteristics required for the sandwich plate.

Additional Embodiments of Configuration

After manufacturing the sandwich plate 100 according to the preferred embodiment of the present invention, the empty space between the plate (10a, 10b) for the purpose of adding the thermal insulation performance, noise and vibration blocking performance, other mechanical properties and other functions of the plate In addition to the step of filling with any one of a porous material, a fluid, a resin, a metal, a ceramic, a multi-functional high-performance lightweight sandwich plate can be produced.

In addition, by adding a separate sandwich plate on the sandwich plate consisting of two sheets (10a, 10b) to manufacture a sandwich plate of a multi-layer structure, or by adding a simple flat plate on both sides of the sandwich plate may have a smooth appearance. . FIG. 10 is a cross-sectional view of such an embodiment, and FIG. 10 (a) shows an embodiment in which two separate plates 10a 'and 10b' with protrusions are processed, and FIG. 10 (b) shows a simple flat plate 50a. , The example which added 50b) is shown.

As mentioned above, although preferred embodiments, modified embodiments, and additional embodiments of the present invention have been described, the scope of the present invention is not limited to the above embodiments, and various modifications may be made without departing from the essential and essential features of the present invention. Of course, variations are possible. For example, it can be designed to have a desired mechanical performance by adjusting the material, thickness and concave-convex portion size, shape, arrangement method, arrangement density of the material thin plate. The foregoing embodiments are, therefore, to be considered in all respects only as illustrative and not restrictive, and the scope of the present invention is to be understood to include the matters set forth in the appended claims and all modifications that may be understood therefrom. do.

1 is a perspective view of a conventional sandwich plate having a lattice-shaped intermediate member

Figure 2 (a) to (c) is a perspective view of a conventional sandwich plate material having a pyramid, an octet and a kagome truss structure as an intermediate material and a face plate attached to the upper and lower sides, respectively.

(A) is a perspective view of the conventional intermediate material which has egg-plate-shaped unevenness | corrugation, (b) is a perspective view of the conventional sandwich board material which uses the plate which has hemispherical unevenness | corrugation as an intermediate | middle material.

Figure 4 (a) is a side view of the sandwich plate according to the present invention completed by joining the two sheets of the plate having the protrusions to face each other, the projections (b) is a perspective view.

5 is a perspective view showing an example of the shape of a protrusion formed on a sheet according to the present invention;

6 is an explanatory view of spot welding or projection welding for continuously joining protrusions of a sheet of metal material.

7A and 7B are perspective views showing another example of the shape of a protrusion.

(A)-(c) is a perspective view which shows the various joining shape of a protrusion.

Figure 9 (a) is a perspective view of a plate material processing a plurality of protrusions in a rectangular lattice arrangement according to the present invention, (b) is a perspective view of a plate material processing a plurality of protrusions in the form of a staggered arrangement.

Figure 10 (a) is a cross-sectional view of an embodiment of a multi-layer sandwich plate in which a separate sandwich plate is further laminated on a sandwich plate consisting of two sheets, (b) is both sides of the sandwich plate manufactured according to the present invention Cross-sectional view of an embodiment to add a simple plate to have a smooth appearance.

Description of the main parts of the drawing

10, 10a, 10b: plate 10a ', 10b': plate

20, 20a, 20b: projection 30: junction

50a, 50b: simple flat plate 100: sandwich plate

Claims (10)

A first step of processing a plurality of regular protrusions on the sheet, A second step of arranging the two sheet materials processed in the first step up and down so that the protrusions of each other face each other, and Sandwich plate manufacturing method comprising a third step of bonding the protrusions facing each other. The method of claim 1, In the first step, the protrusion is processed into the shape of a triangular pyramid, In the second step, sandwich plate production method characterized in that the two plates are arranged so that the opposite triangular pyramid is rotated 180 degrees with respect to each other. The method according to claim 1 or 2, In the first step, a sandwich plate manufacturing method characterized in that the deep drawing or embossing the plate made of metal. The method according to claim 1 or 2, In the first step, a plastic sheet manufacturing method characterized in that the injection molding or embossing after extrusion molding. The method according to claim 1 or 2, In the first step, the sandwich plate manufacturing method characterized in that for processing in the shape of the grid arrangement or staggered arrangement. The method according to claim 1 or 2, In the third step, the sandwich plate manufacturing method, characterized in that for joining the protrusions by one of the processes selected from resin bonding, soldering, brazing, welding, fusion. The method of claim 3, In the third step, the sandwich plate manufacturing method characterized in that for joining the projections by spot welding or projection welding. The method of claim 1, In the first step, the sandwich plate manufacturing method characterized in that for processing the protrusions in the shape of a pyramid or truncated cone. The method according to claim 1 or 2, After the third step, the sandwich plate manufacturing method characterized in that the space between the two sheets of the material selected from the porous material, fluid, resin, metal, ceramic. The sandwich board | plate material manufactured by the sandwich plate manufacturing method of Claim 1 or 2 characterized by the above-mentioned.

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