WO2007073571A1 - Panneau composite - Google Patents

Panneau composite Download PDF

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Publication number
WO2007073571A1
WO2007073571A1 PCT/ZA2006/000147 ZA2006000147W WO2007073571A1 WO 2007073571 A1 WO2007073571 A1 WO 2007073571A1 ZA 2006000147 W ZA2006000147 W ZA 2006000147W WO 2007073571 A1 WO2007073571 A1 WO 2007073571A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheets
panel
dividers
support members
zones
Prior art date
Application number
PCT/ZA2006/000147
Other languages
English (en)
Other versions
WO2007073571B1 (fr
Inventor
Johannes Jacobus Fourie
Michael John Parker
Original Assignee
Johannes Jacobus Fourie
Michael John Parker
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 Johannes Jacobus Fourie, Michael John Parker filed Critical Johannes Jacobus Fourie
Publication of WO2007073571A1 publication Critical patent/WO2007073571A1/fr
Publication of WO2007073571B1 publication Critical patent/WO2007073571B1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H01Q15/16—Reflecting surfaces; Equivalent structures curved in two dimensions, e.g. paraboloidal
    • H01Q15/165—Reflecting surfaces; Equivalent structures curved in two dimensions, e.g. paraboloidal composed of a plurality of rigid panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/542—Shear strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability

Definitions

  • This invention relates to a composite panel and, more specifically, to a composite panel having a relatively light weight whilst displaying desirable mechanical properties, in particular flexibility and resistance to shear forces so that such panels exhibit long term dimensional stability.
  • Composite panels for use in constructing, for example, a dish for a radio telescope typically include two fibreglass sheets that are separated by an intermediate layer made up of honeycomb-shaped units.
  • the intermediate layer is manufactured from a synthetic plastics material or from aluminium.
  • a problem associated with such composite panels is that the intermediate layer is subjected to shear forces once the panel forms part of a telescope dish due to the curvature of the panel as well as external forces acting on the dish.
  • the intermediate layer can become distorted, as a result of which it no longer provides the desired support to the fibreglass sheets.
  • composite panels as described above are costly as well as time- consuming to manufacture, as well as being relatively heavy, making them difficult to handle.
  • a composite panel including:- first and second spaced apart sheets, which sheets are manufactured from a metal or metal alloy; dividers located between and attached to the first and second sheets, which dividers are sufficiently flexible to accommodate a desired curvature of the sheets and which form a grid to divide the area between the sheets into a plurality of zones; and - flexible support members for supporting the sheets, the members being configured and dimensioned to fit snugly into the zones; wherein the dividers retain the support members in place and inhibit distortion of the members under the influence of shear forces.
  • the sheets may be linear when viewed in side elevation or they may be curved.
  • the maximum curvature of each sheet may vary between about 37 and 42 degrees and is typically 38,5 degrees, or 40,3 degrees, or 41 ,6 degrees.
  • the spacing between the sheets may be about 20 mm and is dictated by the desired stiffness of the panel.
  • the sheets may be generally in the form of a sector of a circle when viewed in plan having two linear sides extending between first and second arcuate sides.
  • the length of each linear side may be between about 2000 and 3000 mm.
  • the radius of an arc defining the first arcuate side may be between about 700 mm and 5300 mm, depending on the maximum curvature of the sheets.
  • the radius of an arc defining the second arcuate side may be between about 2800 mm and 7600 mm, again depending on the maximum curvature of the sheets.
  • the lengths of the radii of the first and second arcuate sides may be proportional to the maximum curvature that the sheets are able to adopt.
  • each sheet may be about 0,5 mm and the sheets may be manufactured from steel.
  • the dividers may be in the form of elongate strips folded to form a zig-zag shape in plan view.
  • the strips may be provided with flanges along their edges that in use abut on the first and second sheets to facilitate attachment of the strips to the sheets.
  • the flanges of the strips Prior to attachment to the sheets, the flanges of the strips may be positioned at an angle of between 91 and 93 degrees relative to the strips. This ensures that the flanges make good contact with the first and second sheets during assembly of the composite panel.
  • the dividers may be attached to the first and second sheets by applying an adhesive to the flange surfaces exposed to the sheets.
  • the adhesive may be applied to the surfaces of the sheets that will be in contact with the flanges.
  • the adhesive may be an industrial strength adhesive such as, for example, Araldite 420 A/D two component epoxy adhesive. Slots may be defined in each strip in predetermined intervals along the length of the strip. The slots may extend about midway into the width of the strip.
  • the slots may be defined every 100 mm along the length of each strip and may be about 11 mm deep, depending upon the width of the strips, which is typically about 20 mm. It is to be appreciated, that the spacing between the slots may be varied in accordance with the desired dimensions of the zones.
  • the dividers may be arranged in a grid to define the zones. Slots of dividers that cross each other may be aligned so that the dividers may be slotted into each other to form the grid. The zones formed when the slots are spaced apart 100 mm are therefore square with a side length of 100 mm.
  • the strips may be manufactured from a metal or metal alloy, typically steel, and may be between 0,3 mm and 0,5 mm thick.
  • the flexible support members may be in the form of blocks having a honeycomb structure when viewed in plan.
  • the honeycomb structure allows for the effective distribution of forces acting on the panel whilst providing a lightweight support for the sheets.
  • honeycomb blocks are commercially available in sheet form, for example, from NIDA-Core.
  • the honeycomb blocks may manufactured from PVC, nylon, aluminium, or polypropylene. In order to minimise the cost and weight of the panel, aluminium is rarely used.
  • the blocks may be solid and may be manufactured from any suitable lightweight material such as a foam or polystyrene.
  • the thickness of each block may be about 20 mm and the dimensions of each block may be 100 mm by 100 mm so as to fit snugly into the zones.
  • Each block may be provided with a sheet or layer on either side thereof to facilitate attachment of the blocks to the first and second sheets.
  • the blocks may be attached to the first and second sheets by applying an adhesive to the surfaces exposed to the sheets.
  • the adhesive may be an industrial strength adhesive such as, for example, Araldite 420 A/D two component epoxy adhesive.
  • the thickness of the support members and accordingly, the width of strips and the spacing between the first and second sheets, is selected according to the desired stiffness of panel.
  • a plurality of composite panels as described above may be arranged to form a dish of a radio telescope.
  • the invention extends to a method of manufacturing a composite panel in accordance with the present invention, as will be described in more detail below.
  • Figure 1 shows an elevation view of a portion of a composite panel in accordance with the present invention
  • Figures 2 a to c show plan, perspective and side elevation views of a sheet of a composite panel having a first size and curvature in accordance with the present invention
  • Figures 3 a to c show plan, perspective and side elevation views of a sheet of a composite panel having a second size and curvature in accordance with the present invention
  • Figures 4 a to c show plan, perspective and side elevation views of a sheet of a composite panel having a third size and curvature in accordance with the present invention
  • Figure 5 shows a plan view of a section of a divider in accordance with the present invention
  • Figure 6 shows a side elevation view of the divider of Figure 5;
  • Figure 7 shows an enlarged view of area A in Figure 6;
  • Figure 8 shows a perspective view of a portion of a first sheet, dividers and flexible support members in an assembled condition
  • Figure 9 shows a plan view of Figure 8.
  • a composite panel 10 according to the invention includes first and second spaced apart curved sheets 12 and 14, which sheets 12, 14 are manufactured from steel.
  • Dividers 16 are located between and attached to the first and second sheets 12 and 14 and form a grid dividing the area between the sheets 12,14 into a plurality of zones 18.
  • the dividers 16 are sufficiently flexible to accommodate the curvature of the sheets 12, 14.
  • Flexible support members 20 for supporting the sheets 12, 14 are provided in dimensions that permit the members 20 to fit snugly into the zones 18 (see Figures 8 and 9) so that the dividers 16 inhibit the support members 20 from becoming distorted under the influence of shear forces, whilst retaining them in place.
  • the spacing between the sheets 12, 14 is about 20 mm and is dictated by the desired stiffness of the panel 10.
  • the sheets 12, 14 are generally in the form of a sector of a circle when viewed in plan and have two linear sides 22.1 and 22.2 extending between first and second arcuate sides 24 and 26.
  • each linear side 22.1 and 22.2 of the sheet 12 is 2239mm, whilst it is 2235 mm and 2983 mm respectively in Figures 3 and 4.
  • the radius R 1 of an arc defining the first arcuate side 24 is 5227 mm whilst it is 2988 mm and 749 mm respectively in Figures 3 and 4.
  • the radius R 2 of an arc defining the second arcuate side 26 is 7467 mm whilst it is 5226 mm and 2983 mm respectively in Figures 3 and 4.
  • the radii of the first and second arcuate sides 24 and 26 are thus proportional to the maximum curvature that the sheets 12, 14 are able to adopt.
  • the thickness of the sheet 12, 14 is about 0,5 mm and it is manufactured from steel.
  • the dividers 16 are in the form of elongate strips 28 folded to form a zig-zag shape in plan view as can be seen in Figure 5.
  • the strips 28 are provided with flanges 30 along their edges that abut on the first and second sheets 12 and 14 to facilitate attachment of the strips 28 to the sheets 12, 14.
  • the flanges 30 are positioned at and angle of between 91 and 93 degrees relative to the strips 28. This ensures that the flanges 30 make good contact with the first and second sheets 12 and 14 during assembly of the composite panel 10.
  • the dividers 16 are attached to the first and second sheets 12 and 14 by applying an adhesive to the flange surfaces exposed to the sheets 12, 14 or to the sheets 12, 14 themselves.
  • the adhesive is an industrial strength adhesive such as, for example, Araldite 420 A/D two component epoxy adhesive.
  • Slots 32 are defined in each strip 28 in predetermined intervals along the length of the strip 28.
  • the slots 32 extend about midway into the width of the strip 28 as shown in Figure 7. In the embodiment shown, the slots 32 are defined every 100 mm along the length of the strip 28 and are about 11 long.
  • the dividers 16 are arranged in a grid to define the zones 18 as shown in Figures 8 and 9. Slots 32 of dividers 16 that cross each other are aligned so that the dividers 16 can be slotted into each other to form the grid.
  • the zones 18 formed in the embodiment shown are square with a side length of 100 mm.
  • the strips 28 are manufactured from steel and are between 0,3 mm and 0,5 mm thick.
  • the flexible support members 20 are in the form of blocks 34 having a honeycomb structure when viewed in plan as can be seen in Figures 8 and 9.
  • the honeycomb structure allows for the effective distribution of forces acting on the panel 10 whilst providing a lightweight support for the sheets 12, 14.
  • honeycomb blocks 34 are commercially available in sheet form, for example, from NIDA-Core.
  • the honeycomb blocks 34 are manufactured from PVC, nylon, aluminium, or polypropylene. In order to minimise the cost and weight of the panel 10, aluminium is rarely used.
  • each block 34 is about 20 mm and the dimensions of each block 34 are about 100 mm by 100 mm so as to fit snugly into the zones 18.
  • the composite panels 10 are manufactured according to a method as set out below:
  • Moulds for receiving the first and second sheets 12 and 14 respectively therein having a desired curvature are prepared.
  • the moulds are installed in a light force press, with one of the moulds being fixed and the other mould being displaceable.
  • the displaceable mould is coated with a resilient material, for example 3mm neoprene rubber, to ensure that an even pressure is applied to the panel during assembly.
  • the sheets 12 and 14 are cut to a desired size either by a laser (for low volumes) or by blanking (for high volumes).
  • the dividers 16 are arranged to form a grid as described above and the support members 20 or blocks 34 are inserted into the zones 18 formed by the dividers 16. The edges of the divider-support member arrangement are trimmed so that the arrangement is approximately 10-15mm smaller than the sheets 12, 14.
  • edges are covered by a channel-shaped sheet metal.
  • the edges will most likely be welded at the four comers of the divider-support member arrangement.
  • the sheets 12,14 and the divider-support member arrangement are cleaned using a suitable cleaning agent such as, for example, acetone whereafter these are only handled by users wearing suitable gloves to avoid contamination.
  • a suitable cleaning agent such as, for example, acetone
  • the time between cleaning and final bonding should be limited and is typically not more than 30 minutes.
  • ARALDITE 420 A/D two component epoxy adhesive is prepared and applied to inner surfaces of the sheets 12, 14.
  • the thickness of the applied adhesive is about 0.1mm.
  • the first sheet 12 is then placed into the fixed mould with the adhesive-covered surface facing upwards.
  • the divider-support member arrangement is placed onto the adhesive whereafter the displaceable mould containing the second sheet 14 is lowered onto it.
  • the pressure exerted by the displaceable mould is the minimum pressure required to form the panel 10 into the mould profile.
  • the pressure is applied for the required curing time of the adhesive.
  • the moulds can optionally be heated accelerate the curing cycle. Heating the moulds can reduce the curing time by a factor of ten.
  • the panel 10 is removed from the moulds and allowed to cool after which excess adhesive is removed from the panel edges.
  • Panel support and alignment target mechanisms can now be glued into the drilled holes, after appropriate cleaning. Heat is applied locally if require to accelerate curing.
  • the panel 10 is then cleaned for painting after which a suitable primer and high reflectance top coat are applied.
  • the panel 10 can be packaged for transport.
  • Advantages of the present invention include that due to the first and second sheet being manufactured from metal instead of fibreglass, the curing time required for the adhesive bonding the support members to the sheets is significantly reduced. The curing time can be further reduced by the application of heat during curing.
  • the inclusion of the dividers inhibit distortion of the support members due to shear forces acting on said members, which could otherwise lead to distortion of the first and second sheets.
  • the panels thus have a good dimensional stability that is maintained during long-term use.
  • the use of metal sheets in combination with non-metallic support members significantly reduces the cost of the composite panel when compared to presently available panels.

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un panneau composite (10) comprenant une première et une seconde tôle courbe non jointive (12, 14), lesdites tôles (12, 14) étant fabriquées en acier. Des séparateurs (16) se trouvent entre les deux tôles (12, 14) et sont fixés à celles-ci, ces séparateurs formant une grille qui divise la partie entre les tôles (12, 14) en une pluralité de zones (18). Les séparateurs (16) s’avèrent suffisamment souples pour s’adapter à la courbure des tôles (12, 14). Des éléments de support souples (20) destinés à soutenir les tôles (12, 14) présentent des dimensions leur permettant de s’ajuster parfaitement aux zones (18) afin que les séparateurs (16) empêchent les éléments de support (20) de se tordre sous l’effet d’efforts longitudinaux, tout en les maintenant en place.
PCT/ZA2006/000147 2005-12-22 2006-12-18 Panneau composite WO2007073571A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA2005/10409 2005-12-22
ZA200510409 2005-12-22

Publications (2)

Publication Number Publication Date
WO2007073571A1 true WO2007073571A1 (fr) 2007-06-28
WO2007073571B1 WO2007073571B1 (fr) 2007-08-09

Family

ID=37865699

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/ZA2006/000147 WO2007073571A1 (fr) 2005-12-22 2006-12-18 Panneau composite

Country Status (1)

Country Link
WO (1) WO2007073571A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB535161A (en) * 1940-02-09 1941-03-31 Jicwood Ltd A method of producing curved "sandwich" material
US3196533A (en) * 1963-07-10 1965-07-27 Martin Marietta Corp Method for forming honeycomb materials
NL6502135A (fr) * 1964-02-19 1965-08-20
WO1981003640A1 (fr) * 1980-06-10 1981-12-24 Staff Entrepriser As Procede de fabrication de coques de bateau, de carrosseries de vehicule, de containers et de structures de coque semblables, et treillis de tubes utilise dans la fabrication de ces structures
US4453367A (en) * 1981-07-10 1984-06-12 General Electric Company Honeycomb core material and sandwich construction structural building materials incorporating same
JPH1134192A (ja) * 1997-07-18 1999-02-09 Showa Aircraft Ind Co Ltd ハニカムパネル

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB535161A (en) * 1940-02-09 1941-03-31 Jicwood Ltd A method of producing curved "sandwich" material
US3196533A (en) * 1963-07-10 1965-07-27 Martin Marietta Corp Method for forming honeycomb materials
NL6502135A (fr) * 1964-02-19 1965-08-20
WO1981003640A1 (fr) * 1980-06-10 1981-12-24 Staff Entrepriser As Procede de fabrication de coques de bateau, de carrosseries de vehicule, de containers et de structures de coque semblables, et treillis de tubes utilise dans la fabrication de ces structures
US4453367A (en) * 1981-07-10 1984-06-12 General Electric Company Honeycomb core material and sandwich construction structural building materials incorporating same
JPH1134192A (ja) * 1997-07-18 1999-02-09 Showa Aircraft Ind Co Ltd ハニカムパネル

Also Published As

Publication number Publication date
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