NL1024360C2 - Emergency lighting unit, lighting device and method for illuminating a floor surface in a room. - Google Patents

Description

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Brief indication: Method for applying a thermoplastic plastic insert unit in a thermoplastic plastic sandwich product.

The invention relates to a method for applying a thermoplastic plastic insert unit in a thermoplastic plastic sandwich product, consisting of a core layer of a thermoplastic plastic and at least one cover layer of a fiber-reinforced thermoplastic plastic and adhering the thermoplastic plastic insert unit to at least one cover layer by adding ultrasonic energy.

A method for applying a local reinforcement in a thermoplastic sandwich plate is known in the art, for example: from the

European patent application EPO 383 409. The method known from it comprises applying a local reinforcement in a thermoplastic sandwich plate by means of injection molding a thermoplastic plastic in the sandwich plate. In order to provide a point of attachment in the local reinforcement, a metal insert can be provided in the still-injection-molded plastic, as described in EP 06 719 92. Another method for arranging a plastic insert unit in a sandwich plate with at least one thermoplastic fiber-reinforced cover layer is known in the art, for example from US patent application US 20 5,437.7 5 0. The method known therefrom comprises placing and bonding a plastic insert unit in a sandwich plate, consisting of 2 fiber-reinforced thermoplastic cover layers that are glued on a core layer consisting of a plurality of strips of aramid paper or another thin, lightweight material, which are glued and deformed in such a way that a field of honeycomb cells has been created. This method consists of drilling a hole through the sandwich plate, placing a thermoplastic plastic insert unit in the hole and then fusing the thin edges on top of the plastic insert unit with the fiber-reinforced thermoplastic cover layers by adding ultrasonic energy.

Another method in which the welding of a thermoplastic plastic insert unit into a sandwich plate with fiber-reinforced thermoplastic cover layers glued to a honeycomb is described is US 5,536,344; this method 1024630

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I describes the application of a plastic insert unit by means of I

I rotary welding. I

The object of this invention is a method for applying an I

Thermoplastic plastic insert unit in a thermoplastic plastic

I to provide a sandwich product and apply thermoplastic I

I plastic insert units in a thermoplastic sandwich product

I optimize and simplify, saving costs and weight

I can become. I

I 10 I

The word "sandwich product" used as such in the present invention

I comprises a thermoplastic sandwich product with at least one flat or I

I substantially flat section, examples of which are: a flat plate; a light I

I curved product, a folded product, a slightly curved three-dimensional I

I shaped product, etc. I

The method according to the present invention for applying an I

Thermoplastic plastic insert unit in a thermoplastic plastic

I sandwich product generally consists of drilling a hole in the I

Top layer of the thermoplastic sandwich product, the size of I

I at least the largest diameter of the body of the plastic insert unit. I

I The thermoplastic plastic insert unit is then inserted into the hole in the I

I placed a thermoplastic sandwich product, after which by adding I

I ultrasonic energy and pressure, heat is generated at the interfaces between I

The thermoplastic plastic insert unit and the fiber-reinforced thermoplastic I

Plastic cover or cover layers where, by adding sufficient heat, the I

I The above mentioned interfaces can fuse. I

I After cooling, the thermoplastic plastic insert unit is fixed in the I

I thermoplastic sandwich product. I

On the one hand, the bottom of the flange I

I of the thermoplastic plastic insert unit are fixed on the top I

I of the upper cover layer of the thermoplastic sandwich product and I

I, on the other hand, if the correct dimensions for the thermoplastic plastic I

I insert unit is selected, a simultaneous adhesion can be between the bottom of I

The thermoplastic plastic insert unit and the top of the lower I

I 1024630 I

3-coating of the thermoplastic sandwich product. And of course with an insert unit without flange, the bottom of the insert unit can be fixed on the top of the bottom cover layer of the thermoplastic sandwich product.

The plastic insert unit generally has a circular flange that is larger in diameter than the diameter of the body of the plastic insert unit.

The thermoplastic plastic material of the insert unit should preferably be the same or at least compatible with the thermoplastic plastic in the fiber-reinforced cover layer or cover layers and the thermoplastic plastic in the core.

In a preferred form for the method of the present invention, the top cover layer is removed from the plastic insert unit in the form of the largest diameter. After this, only a portion of the thermoplastic core material is preferably removed in order to increase the tolerance on the dimensions of the insert unit.

It can also give a positive effect on the (lower) visibility of the impression of the adhesion between the insert unit and the lower cover layer. A further extension of the method of the present invention is to include a thin ring the size of the largest diameter of remove the body of the thermoplastic plastic insert unit from the top cover layer, for example with a hollow drill.

In the preferred form and the extension of the present invention, it may be necessary to first place the thermoplastic plastic insert unit, with the aid of pressure and speed, into the thermoplastic sandwich product, after which the insert unit is inserted into the insert unit by adding ultrasonic energy (pressure). the sandwich product is fixed.

A further extension of the method of the present invention is the surprising discovery that by making the hole in the upper cover layer of the thermoplastic sandwich product smaller in diameter than the largest diameter of the body of the thermoplastic plastic insert unit and / or divide the cross-section in the upper cover, at most the size of the largest diameter of the body of the insert, into at least 2 or more parts or a combination of both and hereafter the method of the 1024630

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I follow the present invention, the structural integrity of the insert unit in I

The sandwich product is enlarged. I

I The above is caused on the one hand by the enlargement of the I

I bonding surface between the thermoplastic plastic insert unit and the I

Thermoplastic sandwich product and on the other hand the strengthening of the I

Stability of the hole, by folding the upper cover layer, with respect to I

I of the tensile strength of the thermoplastic plastic insert unit from the thermo-I

I plastic sandwich product. This creates the possibility of the dimension and I

I thereby further reduce the weight of the insert unit, I

Which is of great importance in the aircraft industry. I

A further extension of the present invention is the application of an I

I insert unit without flange, this fixes the bottom of the insert unit I

I on the top of the lower cover layer of the thermoplastic I

I sandwich product. I

I 15 I

I A thermoplastic plastic sandwich product consists of at least one I

Fiber-reinforced thermoplastic cover layer, connected to a core consisting of I

I from a thermoplastic plastic, the possible connecting layer between I

The cover layer and the core consist of a thermoplastic plastic. I

The thermoplastic plastic of the cover layer or cover layers is preferably I

I identical or at least compatible with the thermoplastic plastic of the I

I core. The thermoplastic plastic of the cover layer or cover layers and core are I

I not limited. Examples thereof are PEI, polyetherimide (Ultem from General I

I Electric); PES, polyether sulfone; PC, polycarbonate, etc. I

The thermoplastic core material of the thermoplastic sandwich product can I

I have been reinforced with fibers or with nano particles or not. Examples of I

Forms of cores are: isotropic foam; anisotropic foam; thermoplastic I

I honeycomb; straws extruded together; low density chopped fibers, I

I etcetera. I

The thermoplastic sandwich product can contain one or more intermediate layers. I

I Viewed from a cost and weight point of view, the above intermediate layer, cf I

I layers, can only be used in sandwich products, where no glue film I

I is used, as with sandwich products manufactured via the so-called in- I

I situ foaming method, see EP 0 636 463 of applicant. I

I 1 0 24 6 3 0 I

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The choice of fiber in the core material, the cover layer or layers, the intermediate layer or layers and in the plastic insert unit is in no way limited. Inorganic fibers such as glass fibers, metal fibers, carbon fibers and organic fibers such as aramid fibers can be used as desired, as can natural fibers, provided that they are resistant to the conditions prevailing during the performance of the process.

The fibers in the coating or coatings, the interlayer or interlayers may or may not be oriented, the length and orientation are in no way limited.

Knits, fabrics, mat, cloth and unidirectional fibers are different manifestations thereof.

The fibers in the plastic insert unit may or may not be oriented. The length and orientation of the fibers is in no way limited, short fibers, long fibers and unidirectional fibers are different embodiments thereof.

A preferred form of a thermoplastic sandwich product consists of two cover layers of fiber-reinforced polyetherimide and a core of polyetherimide foam, the core being manufactured via the so-called in-situ foam process, see EP 0 636 463 of applicant.

This results in a core layer of anisotropic foam, which is characterized by a high compressive strength in a direction perpendicular to the cover layer. The thermoplastic sandwich product obtained in this way is characterized by a relatively high bending stiffness, a low weight and very good fire-resistant properties. The high compressive strength and the homogeneous distribution of the foam over the surface has a positive effect on the application of the thermoplastic plastic insert unit by means of ultrasonic energy.

The areas of application of the above-mentioned preferred form are: interior products of aircraft, trains, boats, etc.

It is also possible that the thermoplastic material of the core is significantly different from the thermoplastic of the fiber-reinforced cover layer, for example PEI in-situ foam with PC fiber-reinforced cover layers, see NL 1020640 of the applicant. Hereby it is generally necessary to drill a hole and to remove all or almost all of the core material.

It is clear to everyone who has been trained in the subject field that all kinds of variations and modifications can be developed in the field of education.

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The present invention which provides for the insertion of a plastic insert unit in an I

describes a thermoplastic sandwich product using ultrasonic energy, I

without departing from the scope and content of the invention. I

Referring to Figure 1-6, a thermoplastic plastic insert unit 2 becomes I

fixed in a thermoplastic sandwich product 1 as a result of the I

present invention. The thermoplastic sandwich product 1 made I

according to the preferred form, consists of a PEI fiber-reinforced upper cover layer I

7 an in-situ foamed core 8 and a lower PEI fiber-reinforced cover layer 9. I

The thermoplastic plastic insert unit 2 is made from an I

thermoplastic plastic such as polyetherimide and can be a steel metal insert I

5 or a hole in which wire 5 is arranged, so that the insert unit is an I

attachment point in the sandwich product 1 can function. I

The plastic insert unit 2 generally has a cylindrically shaped body I

3 with a circular flange 4. The cylindrical body 3 can be inserted between the flange 4 I

and the end of the insert unit 12, locally a smaller diameter 6, see I

Figure 2. I

The above insert unit 2 can be made, for example, via the injection-molded I

process of a thermoplastic plastic reinforced with short fibers or I

20, for example, via the patented composite flow molding process with an I

continuous fiber reinforced thermoplastic plastic. I

Referring to Figure 3, in the thermoplastic sandwich product 1, an I

hole 11, with a predetermined diameter at a desired location I

applied, for example with a low speed drill. The cutting tool I

25 to manufacture the hole, a manually or automatically operated I

milling machine. After this, the thermoplastic plastic insert unit 2 becomes I

placed the hole 11. I

The dimension of the length of the cylindrical part 3 of the insert unit is I

accurately matched to the thickness of the sandwich product 1, so that an I

Fusion can take place between the flange 4 and the top cover layer 7 and of I

the bottom 12 of the insert unit 2 with the top of the lower cover layer I

9. I

The diameter of the drill 13 is slightly larger than the diameter of the cylindrical I

part 3 of the insert unit 2. I

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Or the diameter of the drill 13 is smaller, for example 2-4 mm, than the diameter of the cylindrical part 3 of the insert unit 2. In this case, the insert unit 2 can first be placed in the sandwich product 1 with pressure and / or speed. see Figure 4.

The circular flange 4 has a diameter that is larger than the diameter of the drill 13 or larger than the largest diameter of the cylindrical part 3 of the insert unit 2 and is relatively thin compared to the cylindrical part 3 of the insert unit 2.

Figure 3 and Figure 1 show the installation of an insert unit 2 via drilling and welding.

The flat or substantially flat part of the thermoplastic sandwich product is now placed on a table 14 and positioned such that the insert unit 2 comes to sit between the horn 6 and the anvil 10 of the ultrasonic device. The insert unit can also be placed on the hole. The horn 6 of the ultrasonic device, for example the 900 series from Branson Ultrasonic Corporation, is now placed just above the insert unit 2. By adding ultrasonic energy and pressure, heat is created between the interfaces of the thermoplastic plastic insert unit 2, the bottom of the flange 4 with the top of the upper cover layer 7 and simultaneously from the bottom 12 of the insert unit 2 with the top of the lower cover layer 9. If sufficient heat is generated so that the interfaces of the insert unit 2 and the cover layers become 7.9 and melt together, the addition of ultrasonic energy is stopped. After which, after cooling, the insert unit 2 is secured (welded) in the thermoplastic sandwich product 1.

If a hole 17 with a diameter smaller than the largest diameter of the body of the insert is used, see figure 4, this results in a larger adhesion surface 13, see figure 5.

Figure 5 also indicates that by adding ultrasonic energy and pressure, the core material is compressed 16.

By notching the hole 18 instead of drilling, the top cover layer can further be used to reinforce the hole, see figure 6.

The above possibilities to use the sandwich material (core and top cover layer) of the largest diameter of the body of the insert unit when applying the insert unit in a thermoplastic sandwich product can of course be combined in all kinds of ways.

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It should be clear that the dimension of the insert unit 2, body 3 and flange 4, I

is dependent on the thermoplastic sandwich product 1 used, the I

application and material selection of the insert unit. I

The present invention makes it possible to use a thermoplastic plastic I

5 insert unit 2 in less than 10 seconds in a thermoplastic I

to confirm sandwich product 1. It appears that the application of the I

The present invention provides a significant reduction in working time, costs and I

weight, in particular if insert units are used that are made I

according to the composite flow molding process. I

10 It should be clear to those skilled in the art that there are all sorts of I

variations and extensions are possible to the I described above

the present invention without departing from the scope of the I

present invention I

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20 I

25 I

30 I

35 I

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Claims (9)

1. A method of mounting a thermoplastic plastic insert unit in a thermoplastic plastic sandwich product with at least one flat or substantially flat section. Examples of thermoplastic plastic sandwich products are: a flat plate; a slightly curved product, a folded product, etc. The above-mentioned method consists of: - the use of a thermoplastic plastic insert unit with flange; 10. making a hole in the upper cover layer of the thermoplastic sandwich product with a diameter equal to or almost equal to the largest diameter of the body of the thermoplastic plastic insert unit; wherein all or substantially all of the core material is removed between the cover layers; Placing the plastic insert unit in the hole; providing an ultrasonic device comprising, inter alia, a horn and an anvil, wherein the insert unit is positioned between the horn and the anvil. applying ultrasonic energy and pressure to thereby generate heat between the bottom of the flange of the plastic insert unit and the top of the upper cover layer of the thermoplastic sandwich product; fixing the insert unit by cooling, after sufficient heat has been supplied to allow fusion to take place between the surface of the bottom of the flange of the plastic insert unit and the top of the upper cover layer of the thermoplastic sandwich product. 1024630 1. I 2. The method of claim 1, wherein the dimensions of the plastic insert unit I are chosen such that by adding ultrasonic energy and pressure, I fuses simultaneously from the bottom of the plastic insert I unit with the top of the lower cover layer and the bottom of the flange of the insert unit with the top of the top cover of the thermoplastic sandwich product. I 3. The method of claims 1 and 2, wherein the core material and / or the upper cover layer, the size of a maximum of the largest diameter of the body of the plastic insert unit, is used in securing the plastic insert I unit in the thermoplastic sandwich product. I 4. The method of claims 1, 2 and 3, wherein only a hole is provided in the upper cover layer of at most the largest diameter of the plastic insert unit and wherein at most all or substantially all of the core material is removed. I 5. The method of claims 1, 2, 3 and 4 wherein the diameter of the hole in the upper cover layer of the thermoplastic sandwich product is smaller than the diameter of the body of the insert unit and the removal of the core material is not is limited. I 6. The method of claim 1, 2, 3, 4 and 5, wherein in the upper cover layer the I cross-section of at most the largest diameter of the body of the insert is divided into at least 2 or more parts. I 7. Combinations of the methods of claim 1, 2, 3, 4, 5 and 6. I Figure 1 General cross-section of the ultrasonic welding of an insert in a thermoplastic sandwich product. Figure 2 Example of a plastic insert unit, cross section. Figure 3 Drilling a hole in a thermoplastic sandwich product Figure 4 Inserting a plastic insert unit into a hole with a smaller diameter than the largest diameter of the body of the insert unit and where not all the core material in the hole has been removed . Figure 5 The plastic insert unit welded into the thermoplastic sandwich product of Figure 4. Figure 6 An example of a notch in the upper cover layer of a thermoplastic sandwich product. 20 25 30 35 1024630