US20070114269A1 - Formed metal core sandwich structure and method and system for making same - Google Patents

Formed metal core sandwich structure and method and system for making same Download PDF

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Publication number
US20070114269A1
US20070114269A1 US11/285,096 US28509605A US2007114269A1 US 20070114269 A1 US20070114269 A1 US 20070114269A1 US 28509605 A US28509605 A US 28509605A US 2007114269 A1 US2007114269 A1 US 2007114269A1
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US
United States
Prior art keywords
metal core
micro
abrasions
cells
bonding
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.)
Abandoned
Application number
US11/285,096
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English (en)
Inventor
George Straza
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.)
Celltech Metals Inc
Original Assignee
Celltech Metals Inc
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 Celltech Metals Inc filed Critical Celltech Metals Inc
Priority to US11/285,096 priority Critical patent/US20070114269A1/en
Assigned to CELLTECH METALS, INC. reassignment CELLTECH METALS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: STRAZA, GEORGE C.P.
Priority to JP2008542417A priority patent/JP2009516594A/ja
Priority to PCT/US2006/045102 priority patent/WO2007062061A2/en
Priority to EP06844479A priority patent/EP1954437A2/en
Priority to EA200801409A priority patent/EA013285B1/ru
Priority to CNA2006800433887A priority patent/CN101312825A/zh
Priority to US11/702,884 priority patent/US20070243408A1/en
Publication of US20070114269A1 publication Critical patent/US20070114269A1/en
Priority to US12/180,466 priority patent/US7753254B2/en
Priority to US12/180,459 priority patent/US7648058B2/en
Priority to US12/249,097 priority patent/US7757931B2/en
Priority to US12/249,095 priority patent/US20090123709A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/02—Honeycomb structures
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/1234—Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]

Definitions

  • the present invention relates to metal sandwich sheet structures and, more particularly, to formable metal core sandwich sheet structures and methods and systems for manufacturing same.
  • Metal core sandwich structures are known in the art.
  • U.S. Pat. No. 3,525,663 to Hale and U.S. Pat. No. 4,035,536 to Morrison both disclose metal sandwich structures having a formed metal core brazed to two outer metal sheets.
  • Hale and Morrison, and other similar conventional formed metal core sandwich structures cannot be easily formed into compound curves and other complex shapes without delaminating, wrinkling and/or otherwise losing its structural integrity. Therefore, prior metal core sandwich structures are not well-suited for applications that require formation of compound curves, for example, without delaminating or wrinkling during the forming process.
  • honeycomb sandwich structures Other types of metal core sandwich structures, such as honeycomb sandwich structures, are described in U.S. Pat. No. 6,544,623 to Straza, for example. Although this honeycomb core sandwich structure provides improved formability when compared to other metal core sandwich structures, it is relatively expensive to manufacture and, therefore, not well-suited for many commercial, cost-sensitive applications (e.g., automobile bodies).
  • the invention addresses the above and other needs by providing an improved metal sandwich sheet structure that includes a formed metal core that is brazed or bonded to two outer flat metal sheets.
  • This improved metal sandwich structure is capable of being formed into complex shapes while retaining its structural integrity.
  • This improved metal sandwich structure is also easier and more economical to manufacture than prior honeycomb core sandwich structures, while providing similar strengths and characteristics as the honeycomb core structures.
  • a method of producing a metal core sandwich structure includes providing a formed metal core that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves that curve in two or more directions simultaneously, for example.
  • a metal core sheet is rolled, stamped or pressed into a corrugated shape having a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core sheet.
  • a plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing process.
  • the improved brazing joints provide better bonds so the resulting multi-layer sheet structure will not fracture or delaminate during forming.
  • the resulting sandwich structure is easier to form into complex curves and shapes while maintaining its structural integrity.
  • the improved metal sandwich structure is well suited for various applications where formability and structural integrity are important (e.g., automotive body applications).
  • an apparatus for forming an improved core metal sheet includes a press or mold that presses (via stretching and/or gathering) the core metal sheet to form a desired corrugated core structure.
  • micro-protrusions and/or micro-ridges and/or micro-lines extend outwardly from the press surfaces so that during forming of the core metal sheet, micro-abrasions and/or micro-grooves and/or micro-channels (collectively referred to herein as “micro-abrasions”) are formed to extend inwardly on desired surface areas of the formed metal core.
  • micro-abrasions allow for improved brazing between the formed metal core and the two outer metal sheets through improved capillary action by the metal core during brazing.
  • the outer layer sheets are electro-tacked to the formed core prior to brazing or bonding, which allows for improved subsequent brazing and an improved quality sandwich structure.
  • the invention provides a novel electro-tacking apparatus for tack welding the formed core to the outer metal sheets prior to brazing.
  • various cell shapes and geometries such as hexagonal, square, octagonal or other shape may be formed in the core sheet as well as different cell sizes in accordance with desired formability, stiffness and crush characteristics.
  • the sandwich structure (or at least designated areas of the sandwich structure) can be designed to be more easily crushed which may help avoid automobile impact injuries while other areas of the automobile body (e.g., roofs) will be stiffer, allowing for more protection from metal crushing into passenger compartments.
  • FIG. 1 illustrates a perspective view of a metal core sheet after it has been formed, in accordance with one embodiment of the invention.
  • FIG. 2A illustrates a top view of the formed metal core sheet of FIG. 1 .
  • FIG. 2B illustrates a cross-sectional side view of the formed metal sheet of FIGS. 1 and 2 A, taken along a cross-section indicated by lines 2 B- 2 B of FIG. 2A .
  • FIG. 3A illustrates a top view of a metal core sheet formed in a corrugated checker-board pattern, in accordance with another embodiment of the invention.
  • FIG. 3B illustrates a cross-section side view of the formed metal core of FIG. 3A taken along lines 3 B- 3 B of FIG. 3A .
  • FIG. 4 illustrates a side view of a metal core sheet being formed between two press plates or molds, in accordance with one embodiment of the invention.
  • FIG. 5 illustrates an exploded side view of a metal core sandwich structure prior to brazing, in accordance with one embodiment of the invention.
  • FIG. 6 illustrates the metal core sandwich structure of FIG. 4 after brazing.
  • FIG. 7 illustrates a perspective view of an electro-tack welding apparatus used to tack weld the metal core sandwich structure prior to brazing, in accordance with a further embodiment of the invention.
  • FIG. 1 illustrates a perspective view of a formed metal core 10 made in accordance with one embodiment of the invention.
  • the metal core 10 is formed in a corrugated pattern having a plurality of cells 12 comprising alternating front and rear projections extending outwardly in front of and behind a median plane 14 , with each projection having a bonding surface area or land 16 configured to be brazed or bonded with corresponding external metal sheets (not shown) on both sides of the median plane 14 .
  • a plurality of micro-abrasions or indentations 18 are formed on the bonding lands 16 .
  • the micro-abrasions 18 provide stronger brazing joints to be formed between the metal core 10 and the external metal sheets by facilitating improved capillary action by the metal core 10 during the brazing process.
  • FIG. 2A illustrates a top view of the formed metal core 10 of FIG. 1 .
  • the metal core 10 includes a plurality of upwardly projecting cells 12 A and a plurality of downwardly projecting cells 12 B.
  • the bonding lands 16 of the upwardly projecting cells 12 A are also shown while the bonding lands 16 of the downwardly projecting cells 12 B are located on the opposite side of the core 10 and, hence, not shown in FIG. 2A .
  • a plurality of micro abrasions or indentions 18 are formed on the bonding lands 16 of each cell 12 A and 12 B to facilitate improved capillary action of the metal core 10 during brazing.
  • FIG. 2B illustrates a cross-sectional side view of the metal core 10 taken along perspective lines 2 B- 2 B of FIG. 2A .
  • each cell 12 A and 12 B is formed in the shape of an octagon.
  • the invention is not limited to any particular shape, size and/or configuration of the cells 12 A, 12 B. Any desired shape, size and configuration of cells may be utilized to achieve various desired physical characteristics of the resulting metal core sandwich structure, in accordance with the present invention.
  • FIG. 3A illustrates a top view of an alternative, exemplary formed metal core 30 having a plurality of square-shaped cells 32 A and 32 B in a checkerboard configuration.
  • the cells 32 A represent upwardly projecting cells and the cells 32 B represent downwardly projecting cells.
  • Each cell 32 A and 32 B has a corresponding bonding land 34 and a plurality of micro-abrasions 36 on the surface of each bonding land 34 .
  • FIG. 3B illustrates a cross-sectional side view of the formed metal core 30 of FIG. 3A , taken along lines 3 B- 3 B of that figure.
  • FIG. 4 illustrates a cross-sectional side view of the metal core 30 as it is formed between two presses 42 and 44 having corresponding molded patterns and configurations to form the metal core 30 into a desired shape and configuration.
  • a flat sheet of metal material 30 is placed between the top and bottom presses 42 and 44 , respectively.
  • the metal core 30 is formed via stretching and/or gathering of the metal sheet material 30 to form the cells 32 A and 32 B in a checkerboard configuration.
  • presses 42 and 44 are exemplary only and that presses having other desired molded patterns and configurations may be utilized to form a metal core having cells of various shapes (e.g., octagons, hexagons, pentagons, squares, triangles, etc.), and sizes, and configurations.
  • the micro-abrasions 36 illustrated in FIG. 3A are formed during pressing of the metal core 30 .
  • a plurality of micro-protrusions, ridges and/or lines are provided on selected surfaces 46 and 48 of top and bottom presses 42 and 44 , respectively.
  • the micro-protrusions form the plurality of micro-abrasions 36 on the bonding lands 34 of the cells 32 A, 32 B of the formed metal core 30 .
  • the micro-protrusions are formed on the surfaces of the presses 42 and 44 corresponding to the bonding lands 34 of the formed metal core 30 .
  • the micro-protrusions are formed on the corresponding press surfaces by fine etching of press surfaces using known means and techniques (e.g., electrical metal etching, chemical etching, sand blasting, grit blasting, etc.).
  • the micro-protrusions are formed so as to provide micro-abrasions 36 having a depth and/or width of 0.0005 inches to 0.002 inches and cover approximately 50-80% of the surface area of the bonding lands 34 .
  • the abrasions 36 may be substantially parallel channels, criss-cross configuratons, or channels traveling in random directions and/or curved channels.
  • the micro-abrasions may be formed by electronic discharge machining (EDM) processes, which are well-known in the art.
  • EDM electronic discharge machining
  • the micro-abrasions 36 may be formed on the bonding lands 34 of the metal core 30 after the metal core 30 has been pressed and formed. It is appreciated, however, that providing presses 42 and 44 with preformed micro-protrusions that automatically form micro-abrasions 36 on the metal core 30 during pressing can save substantial time and work when compared to forming the micro-abrasions 36 manually or individually for each metal core 30 subsequent to pressing.
  • the metal core 10 , 30 may be formed after a brazing material has been placed on each side of the core 10 , 30 .
  • the metal core sheet, plus brazing material on each side of the metal core sheets, are pressed and formed together by the presses 42 and 44 .
  • the brazing material can be placed onto the surface of the metal core 10 , 30 prior to forming the core 10 , 30 by spraying a brazing powder onto the core sheet to be formed or by placing sheets of brazing material 50 on either side of the core sheet to be formed. With the proper amount of pressure during forming, the brazing material will be embedded into the core sheet. This facilitates the subsequent brazing process by evenly distributing the braze material across the surface of the core sheet to be formed.
  • the micro-abrasions 18 , 36 are formed and pass through the brazing material onto the bonding lands 16 , 34 of the formed metal core 10 , 30 . Thereafter, the formed metal core 10 , 30 plus formed brazing material sheets are sandwiched between two external metal sheets and brazed at high temperature (e.g., 670 to 730 degrees Celsius) in a reduced-atmosphere or vacuum furnace to produce a metal core sandwich structure in accordance with the present invention.
  • high temperature e.g., 670 to 730 degrees Celsius
  • FIG. 5 illustrates an exploded cross-sectional side view of an exemplary formed metal core 10 ( FIG. 1 ) sandwiched between two sheets of brazing material 50 , which are in turn sandwiched between two external metal sheets 60 .
  • the brazing material sheets 50 have not been pressed and formed with the metal core 10 , as described above.
  • FIG. 6 illustrates a cross-section side view of the resulting metal core sandwich structure 70 after brazing of the metal core 10 to the external metal sheets 60 has been completed.
  • the micro-abrasions 18 FIG. 2A
  • micro-abrasions 18 produce a stronger metal core sandwich structure 70 that can be formed into compound curves, and other shapes and forms, more easily without delaminating, wrinkling or otherwise losing its structural integrity.
  • micro-abrasions may also be formed on the interior surface of the external metal sheets 60 in order to improve the capillary effect of the external metal sheets 60 during brazing.
  • all of the layers of the metal sandwich structure 70 comprising a formed metal core 10 , brazing material sheets 50 and two outer metal sheets 60 , are electro-tack-welded together so as to secure the multiple layers to one another and prevent relative movements during the brazing process. This further improves the strength of the braze joints formed between the bonding lands 16 of the core 10 and the external metal sheets 60 to provide a higher quality finished product.
  • FIG. 7 illustrates a perspective view of a novel tack welding apparatus 100 that may be used in conjunction with the present invention.
  • the apparatus 100 includes a computer and/or electronically controlled actuator box 102 that contains standard electronics and mechanical components (e.g., gears, switches, power supply, etc.) to control movement of an actuator arm 104 that controls movement of a top plate 106 .
  • the metal core sandwich structure 70 ( FIGS. 5 and 6 ) is positioned between the top plate 106 and a bottom ground plate 108 .
  • the top tack-welding plate 106 comprises a plurality of subsections 110 that are electrically insulated from each other.
  • the subsections 110 can be made from copper or copper-alloy and are insulated from one another by an insulating material (e.g., ceramic). Each of the subsections 110 are electrically coupled to a corresponding conductive wire 112 via corresponding contacts 114 .
  • the conductive wires 112 are coupled to a power switch box 116 that controls when electrical current is supplied to each individual wire 112 .
  • the power switch box 116 can be controlled by a computer or processor (not shown).
  • a high energy, low voltage current is sequentially applied to each subsection 110 to tack-weld a corresponding portion of the metal core sandwich structure 70 located between the corresponding subsection 10 and the bottom ground plate 108 .
  • the top and bottom plates 106 and 108 respectively, apply an even pressure throughout the sandwich structure 70 .
  • a sequence of tack welds are rapidly performed in different areas of the sandwich structure 70 by sequentially applying an electrical current to each subsection 110 of the top plate 106 .
  • portions of the sandwich structure 70 following tack-welding are allowed to cool while other portions are being tack-welded.
  • This cooling process provides better tack-welds and the resulting sandwich structure 70 has a lower tendency to delaminate at individual tack welds.
  • letting the structure 70 heat up and cool in different areas as it is being tack welded helps prevent individual tack welds from separating.
  • the metal core sandwich structure 70 may incorporate any type of metal and/or metal alloys as the formed core 10 , 30 and the external metal sheets 60 , such as A1 or D2 steel, for example. It is understood that any metals, metal alloys, or combinations thereof, that are suitable for brazing are contemplated to be within the scope of the present invention (e.g., copper, aluminum, titanium, etc.). Additionally, any type of known brazing material in the form of sheets, foils, sprays, powders, paste or slurries, for example, may be utilized in accordance with the present invention. Furthermore, it is contemplated that some embodiments of the invention may utilize non-metal core materials and non-metal external sheets.
  • known synthetic and/or polymer materials may be used to form an injection-molded core and thereafter bonded (e.g., sonically welded and/or vibration welded) to synthetic and/or polymer outer sheets.
  • Micro-abrasions are formed on the bonding lands of the non-metal core which facilitate gripping between the core and the external sheets during and after welding.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
US11/285,096 2005-11-22 2005-11-22 Formed metal core sandwich structure and method and system for making same Abandoned US20070114269A1 (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
US11/285,096 US20070114269A1 (en) 2005-11-22 2005-11-22 Formed metal core sandwich structure and method and system for making same
CNA2006800433887A CN101312825A (zh) 2005-11-22 2006-11-21 成形金属芯夹心结构及其制造方法和系统
EA200801409A EA013285B1 (ru) 2005-11-22 2006-11-21 Слоистая структура с формованным металлическим сердечником и способ, и система для её изготовления
PCT/US2006/045102 WO2007062061A2 (en) 2005-11-22 2006-11-21 Formed metal core sandwich structure and method and system for making same
EP06844479A EP1954437A2 (en) 2005-11-22 2006-11-21 Formed metal core sandwich structure and method and system for making same
JP2008542417A JP2009516594A (ja) 2005-11-22 2006-11-21 成形金属コアサンドイッチ構造およびそれを製造するための方法およびシステム
US11/702,884 US20070243408A1 (en) 2005-11-22 2007-02-05 Formed core sandwich structure and method and system for making same
US12/180,466 US7753254B2 (en) 2005-11-22 2008-07-25 Formed core sandwich structure and method and system for making same
US12/180,459 US7648058B2 (en) 2005-11-22 2008-07-25 Formed metal core sandwich structure and method and system for making same
US12/249,097 US7757931B2 (en) 2005-11-22 2008-10-10 Formed core sandwich structure and method and system for making same
US12/249,095 US20090123709A1 (en) 2005-11-22 2008-10-10 Formed core sandwich structure and method and system for making same

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Application Number Priority Date Filing Date Title
US11/285,096 US20070114269A1 (en) 2005-11-22 2005-11-22 Formed metal core sandwich structure and method and system for making same

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US11/702,884 Continuation-In-Part US20070243408A1 (en) 2005-11-22 2007-02-05 Formed core sandwich structure and method and system for making same
US12/180,459 Continuation US7648058B2 (en) 2005-11-22 2008-07-25 Formed metal core sandwich structure and method and system for making same

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US20070114269A1 true US20070114269A1 (en) 2007-05-24

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US11/285,096 Abandoned US20070114269A1 (en) 2005-11-22 2005-11-22 Formed metal core sandwich structure and method and system for making same
US12/180,459 Active US7648058B2 (en) 2005-11-22 2008-07-25 Formed metal core sandwich structure and method and system for making same

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US12/180,459 Active US7648058B2 (en) 2005-11-22 2008-07-25 Formed metal core sandwich structure and method and system for making same

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US (2) US20070114269A1 (ru)
EP (1) EP1954437A2 (ru)
JP (1) JP2009516594A (ru)
CN (1) CN101312825A (ru)
EA (1) EA013285B1 (ru)
WO (1) WO2007062061A2 (ru)

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CN109304901A (zh) * 2017-07-27 2019-02-05 张跃 一种钎焊夹芯复合板限位结构
CN108397680B (zh) * 2017-02-08 2021-03-23 张跃 一种夹芯金属板材
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US7648058B2 (en) 2010-01-19
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WO2007062061A3 (en) 2007-07-12
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EA200801409A1 (ru) 2008-10-30
CN101312825A (zh) 2008-11-26

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