WO2009154326A1 - Pyramidal bulk structure and manufacturing method thereof - Google Patents

Pyramidal bulk structure and manufacturing method thereof Download PDF

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Publication number
WO2009154326A1
WO2009154326A1 PCT/KR2008/004963 KR2008004963W WO2009154326A1 WO 2009154326 A1 WO2009154326 A1 WO 2009154326A1 KR 2008004963 W KR2008004963 W KR 2008004963W WO 2009154326 A1 WO2009154326 A1 WO 2009154326A1
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WO
WIPO (PCT)
Prior art keywords
pyramidal
perforated
cores
core
guide pins
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Application number
PCT/KR2008/004963
Other languages
French (fr)
Inventor
Dong Yol Yang
Dae Yong Seong
Se Hee Lee
Original Assignee
Korea Advanced Institute Of Science And Technology
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Application filed by Korea Advanced Institute Of Science And Technology filed Critical Korea Advanced Institute Of Science And Technology
Publication of WO2009154326A1 publication Critical patent/WO2009154326A1/en

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Classifications

    • 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
    • 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 form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • B32B15/043—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 metal
    • 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 form; Layered products 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 form; Layered products 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 form; Layered products 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 form; Layered products 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 form; Layered products 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • 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
    • 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
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • 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
    • B32B2307/558—Impact strength, toughness
    • 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
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses, catheter
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/12—Ships
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft

Definitions

  • the present invention relates to a pyramidal bulk structure, and more particularly, to a pyramidal bulk structure which is formed by alternately stacking and bonding pyramidal truss cores obtained by crimping expanded metal and perforated cores and a method for manufacturing a pyramidal bulk structure in which a pyramidal bulk structure is manufactured through precisely stacking pyramidal truss cores and perforated cores using guide pins.
  • a sandwich panel is formed using PVC composite, foam, metal or nonmetal to have a three-dimensional internal shape.
  • the sandwich panel is manufactured by bonding outer boards on both upper and lower surfaces of a unit layer which defines the internal shape. Therefore, the sandwich panel has a disadvantage in that its application range is restricted to the type of boards.
  • the conventional variable sandwich panel 100 manufactured using expanded metal is composed of an internal structure 110, which is obtained by crimping expanded metal to have prominences and depressions, and a pair of outer boards 120 and 130 which are bonded to the upper and lower surfaces of the internal structure 110. While the sandwich panel 100 has excellent mechanical characteristics in terms of light weight, acoustic absorptivity, specific stiffness and impact resistance, it has a disadvantage in that, since the internal structure 110 constitutes a single unit layer, its application range is still restricted to the type of boards. Disclosure of Invention
  • an object of the present invention is to provide a pyramidal bulk structure which is formed by alternately stacking and bonding pyramidal truss cores obtained by crimping expanded metal and perforated cores to have a three-dimensional ultralight bulk construction based on a pyramidal shape, so that advantages can structurally be rendered in terms of light weight, strength, impact resistance, acoustic absorptivity and heat exchange rate due to the periodicity of pyramidal truss cores.
  • Another object of the present invention is to provide a method for manufacturing a pyramidal bulk structure in which pyramidal truss cores and perforated cores can be precisely and conveniently stacked using guide pins in such a way as to improve the productivity, and a stack height can be freely adjusted so as to have a wide application range.
  • a pyramidal bulk structure comprising pyramidal truss cores obtained by crimping rhombus shapes of expanded metal in diagonal directions to have pyramidal truss shapes; and perforated cores perforated to have quadrangular shapes, wherein the pyramidal bulk structure is manufactured by alternately stacking the pyramidal truss cores and the perforated cores and bonding contact portions thereof with each other.
  • the contact portions are bonded with each other by welding, brazing or adhesive bonding.
  • a method for manufacturing the pyramidal bulk structure comprising the steps of arranging a perforated core; stacking a pyramidal truss core on the perforated core such that lower contact points of the pyramidal truss core and contact points of the perforated core correspond to each other; stacking another perforated core on the pyramidal truss core such that upper contact points of the pyramidal truss core and contact points of another perforated core correspond to each other; stacking another pyramidal truss core on another perforated core such that lower contact points of another pyramidal truss core and the contact points of another perforated core correspond to each other; and bonding contact portions of the perforated cores and the pyramidal truss cores after a desired height is obtained by repeating the above steps.
  • a method for manufacturing the pyramidal bulk structure comprising the steps of arranging a lower mold which has a plurality of sets of guide pins vertically installed on a surface thereof; stacking a perforated core on the surface of the lower mold along the plurality of sets of guide pins; stacking a pyramidal truss core on the perforated core along the plurality of sets of guide pins; stacking another perforated core on the pyramidal truss core along the plurality of sets of guide pins; stacking another pyramidal truss core on another perforated core along the plurality of sets of guide pins; stacking perforated cores and pyramidal truss cores to a desired height by repeating the above steps; applying pressure to the stacked perforated cores and pyramidal truss cores using an upper mold having a plurality of through-holes through which the plurality of sets of guide pins pass, and bonding contact portions
  • each of the guide pins has a triangular transverse sectional shape
  • each set of guide pins is constituted by four guide pins which are positioned to face in two directions, and longitudinal and transverse surfaces of selected guide pins among the sets of guide pins guide the perforated cores and oblique surfaces thereof guide the pyramidal truss cores.
  • the pyramidal bulk structure can be applied as a new structural metal element to various industrial fields such as ships, aircrafts, automobiles, artificial bones, and the likes.
  • the productivity can be secured, and by changing the shapes of the guide pins depending upon an internal construction, it is possible to manufacture pyramidal bulk structures having various internal constructions.
  • the present invention has a benefit of reducing the cost of manufaturing structure since it uses the general perforated cores.
  • FIG. 1 is a schematic view illustrating the construction of a sandwich panel according to the conventional art
  • FIG. 2 is a schematic view illustrating component parts which constitute a pyramidal bulk structure in accordance with one embodiment of the present invention
  • FIG. 3 is a perspective view illustrating the pyramidal bulk structure in accordance with one embodiment of the present invention
  • FIG. 4 is a partial side view of the pyramidal bulk structure shown in FIG. 3;
  • FIG. 5 is views illustrating a procedure of stacking component parts to manufacture the pyramidal bulk structure according to the present invention
  • FIG. 6 is a perspective view and a plan view illustrating the configuration of a lower mold which is used to manufacture the pyramidal bulk structure according to the present invention.
  • FIG. 7 is views illustrating a method for manufacturing a pyramidal bulk structure in accordance with another embodiment of the present invention. Best Mode for Carrying Out the Invention
  • FIG. 2 is a schematic view illustrating component parts which constitute a pyramidal bulk structure in accordance with one embodiment of the present invention
  • FIG. 3 is a perspective view illustrating the pyramidal bulk structure in accordance with one embodiment of the present invention
  • FIG. 4 is a partial side view of the pyramidal bulk structure shown in FIG. 3.
  • a pyramidal bulk structure 200 is manufactured using pyramidal truss cores 210 and general perforated cores 220. That is to say, by alternately stacking and then bonding the pyramidal truss cores 210 and the perforated cores 220, the pyramidal bulk structure 200, in which pyramidal trusses are periodically formed, is manufactured.
  • the pyramidal truss cores 210 are formed by crimping expanded metal to have prominences and depressions as disclosed in Korean Unexamined Patent Publication No. 2005-0116445, they have a pyramidal truss construction by crimping the rhombus shapes of the expanded metal in diagonal directions. Namely, the pyramidal truss cores 210 have a plurality of unit pyramidal trusses.
  • the perforated cores 220 have quadrangular perforated shapes and possess regularity in that regular tetrahedrons are regularly repeated.
  • the perforated cores 220 are commercial products, have various shapes and sizes, and serve as a structural element having high economy and productivity.
  • the perforated cores 220 have the shape of a quadrangle, whereas the bottom of the unit pyramidal truss has the shape of a rhombus.
  • the center portions (lower contact points) of the sides of the unit pyramidal truss are positioned on the corner portions (contact points) of the quadrangles of the perforated core 220. Due to this fact, the pyramidal truss cores 210 and the perforated cores 220 can be easily bonded and have structural stability. As a consequence, a construction is attained, in which pyramidal trusses are periodically formed in the pyramidal bulk structure 200. When bonding the pyramidal truss cores 210 and the perforated cores 220, welding, brazing, adhesive bonding, etc. can be employed.
  • the pyramidal bulk structure 200 according to the present embodiment can be used in various industrial fields such as ships, automobiles, aircrafts and other products which require light weight, due to the high specific stiffness thereof, and can be utilized as a new structural element for metal products, due to the advantages rendered in terms of economy, acoustic absorptivity, impact resistance, heat exchange, electromagnetic shielding.
  • FIG. 5 is views illustrating a procedure of stacking component parts to manufacture the pyramidal bulk structure according to the present invention.
  • a perforated core 220 having a desired area is first arranged (First step). Then, a pyramidal truss core 210 is stacked on the perforated core 220 such that the lower contact points of the pyramidal truss core 210 and the contact points of the perforated core 220 correspond to each other (Second step). Next, another perforated core 220 is stacked on the pyramidal truss core 210 such that the upper contact points of the pyramidal truss core 210 and the contact points of another perforated core 220 correspond to each other (Third step).
  • another pyramidal truss core 210 is stacked on another perforated core 220 such that the lower contact points of another pyramidal truss core 210 and the contact points of another perforated core 220 correspond to each other (Fourth step).
  • a desired height is obtained by repeating the first through fourth steps, by bonding the pyramidal truss cores 210 and the perforated cores 220 which are brought into contact with each other, the manufacture of the pyramidal bulk structure 200 according to the present embodiment is completed.
  • FIG. 6 is a perspective view and a plan view illustrating the configuration of a lower mold which is used to manufacture the pyramidal bulk structure according to the present invention.
  • a lower mold 300 has a plurality of sets of guide pins 310 vertically installed on the surface thereof.
  • each of the guide pins 310 is a component part which is extruded to have a triangular transverse sectional shape.
  • Four guide pins 310 which are positioned to face in two directions, constitute one set.
  • the longitudinal and transverse surfaces of selected guide pins 310 guide the perforated cores 220, and the oblique surfaces thereof guide the pyramidal truss cores 210.
  • FIG. 7 is views illustrating a method for manufacturing a pyramidal bulk structure in accordance with another embodiment of the present invention.
  • the perforated cores 220 and the pyramidal truss cores 210 are alternately stacked to a desired height in accordance with the steps shown in FIG. 5 along the guide pins 310 of the lower mold 300 configured as shown in FIG. 6 (see FIG. 7 (a)). Then, pressure is applied to the stacked perforated cores 220 and pyramidal truss cores 210 using an upper mold 320 having a plurality of through-holes through which the plurality of sets of guide pins can pass, such that the pressure is enough to perform a bonding process such as welding, brazing and adhesive bonding (see FIG. 7(b)).
  • a bonding process such as welding, brazing and adhesive bonding
  • the contact portions of the perforated cores 220 and the pyramidal truss cores 210 are integrally boned with each other through welding, brazing, adhesion, etc.
  • the manufacture of the pyramidal bulk structure 200 is completed.
  • the present invention can be applied as defining a new structural metal element to various industrial fields such as ships, aircrafts, automobiles, artificial bones, and the likes.

Abstract

A pyramidal bulk structure includes pyramidal truss cores obtained by crimping rhombus shapes of expanded metal in diagonal directions to have pyramidal truss shapes, and perforated cores perforated to have quadrangular shapes. The pyramidal bulk structure is manufactured by alternately stacking the pyramidal truss cores and the perforated cores and bonding contact portions thereof with each other.

Description

Description
PYRAMIDAL BULK STRUCTURE AND MANUFACTURING
METHOD THEREOF
Technical Field
[1] The present invention relates to a pyramidal bulk structure, and more particularly, to a pyramidal bulk structure which is formed by alternately stacking and bonding pyramidal truss cores obtained by crimping expanded metal and perforated cores and a method for manufacturing a pyramidal bulk structure in which a pyramidal bulk structure is manufactured through precisely stacking pyramidal truss cores and perforated cores using guide pins. Background Art
[2] In general, a sandwich panel is formed using PVC composite, foam, metal or nonmetal to have a three-dimensional internal shape. The sandwich panel is manufactured by bonding outer boards on both upper and lower surfaces of a unit layer which defines the internal shape. Therefore, the sandwich panel has a disadvantage in that its application range is restricted to the type of boards.
[3] A variable sandwich panel manufactured using expanded metal has been disclosed in
Korean Unexamined Patent Publication No. 2005-0116445. Referring to FIG. 1, the conventional variable sandwich panel 100 manufactured using expanded metal is composed of an internal structure 110, which is obtained by crimping expanded metal to have prominences and depressions, and a pair of outer boards 120 and 130 which are bonded to the upper and lower surfaces of the internal structure 110. While the sandwich panel 100 has excellent mechanical characteristics in terms of light weight, acoustic absorptivity, specific stiffness and impact resistance, it has a disadvantage in that, since the internal structure 110 constitutes a single unit layer, its application range is still restricted to the type of boards. Disclosure of Invention
Technical Problem
[4] Accordingly, the present invention has been made in an effort to solve the problems occurring in the related art, and an object of the present invention is to provide a pyramidal bulk structure which is formed by alternately stacking and bonding pyramidal truss cores obtained by crimping expanded metal and perforated cores to have a three-dimensional ultralight bulk construction based on a pyramidal shape, so that advantages can structurally be rendered in terms of light weight, strength, impact resistance, acoustic absorptivity and heat exchange rate due to the periodicity of pyramidal truss cores. [5] Another object of the present invention is to provide a method for manufacturing a pyramidal bulk structure in which pyramidal truss cores and perforated cores can be precisely and conveniently stacked using guide pins in such a way as to improve the productivity, and a stack height can be freely adjusted so as to have a wide application range. Technical Solution
[6] In order to achieve the first object, according to one aspect of the present invention, there is provided a pyramidal bulk structure comprising pyramidal truss cores obtained by crimping rhombus shapes of expanded metal in diagonal directions to have pyramidal truss shapes; and perforated cores perforated to have quadrangular shapes, wherein the pyramidal bulk structure is manufactured by alternately stacking the pyramidal truss cores and the perforated cores and bonding contact portions thereof with each other.
[7] According to another aspect of the present invention, the contact portions are bonded with each other by welding, brazing or adhesive bonding.
[8] In order to achieve the second object, according to another aspect of the present invention, there is provided a method for manufacturing the pyramidal bulk structure, comprising the steps of arranging a perforated core; stacking a pyramidal truss core on the perforated core such that lower contact points of the pyramidal truss core and contact points of the perforated core correspond to each other; stacking another perforated core on the pyramidal truss core such that upper contact points of the pyramidal truss core and contact points of another perforated core correspond to each other; stacking another pyramidal truss core on another perforated core such that lower contact points of another pyramidal truss core and the contact points of another perforated core correspond to each other; and bonding contact portions of the perforated cores and the pyramidal truss cores after a desired height is obtained by repeating the above steps.
[9] In order to achieve the second object, according to still another aspect of the present invention, there is provided a method for manufacturing the pyramidal bulk structure, comprising the steps of arranging a lower mold which has a plurality of sets of guide pins vertically installed on a surface thereof; stacking a perforated core on the surface of the lower mold along the plurality of sets of guide pins; stacking a pyramidal truss core on the perforated core along the plurality of sets of guide pins; stacking another perforated core on the pyramidal truss core along the plurality of sets of guide pins; stacking another pyramidal truss core on another perforated core along the plurality of sets of guide pins; stacking perforated cores and pyramidal truss cores to a desired height by repeating the above steps; applying pressure to the stacked perforated cores and pyramidal truss cores using an upper mold having a plurality of through-holes through which the plurality of sets of guide pins pass, and bonding contact portions of the perforated cores and the pyramidal truss cores with each other; and removing a resultant integrated pyramidal bulk structure from the upper and lower molds. [10] According to a still further aspect of the present invention, each of the guide pins has a triangular transverse sectional shape, each set of guide pins is constituted by four guide pins which are positioned to face in two directions, and longitudinal and transverse surfaces of selected guide pins among the sets of guide pins guide the perforated cores and oblique surfaces thereof guide the pyramidal truss cores.
Advantageous Effects
[11] Thanks to the above features, in the present invention, by stacking and bonding pyramidal truss cores which can be mass-produced and can be applied to various fields and general perforated cores, the unit layer of the pyramidal bulk structure can be easily manufactured.
[12] Also, in the present invention, by using guide pins and molds when alternately stacking the pyramidal truss cores and the perforated cores, the precise control of bonding positions becomes possible. Further, in the present invention, since pyramidal trusses are periodically formed in the pyramidal bulk structure, advantages are provided in terms of light weight, impact resistance, acoustic absorptivity, and heat exchange. Thus, the pyramidal bulk structure can be applied as a new structural metal element to various industrial fields such as ships, aircrafts, automobiles, artificial bones, and the likes.
[13] Moreover, in the present invention, due to the fact that the pyramidal truss cores and the perforated cores are stacked using the guide pins, the productivity can be secured, and by changing the shapes of the guide pins depending upon an internal construction, it is possible to manufacture pyramidal bulk structures having various internal constructions.
[14] Further, the present invention has a benefit of reducing the cost of manufaturing structure since it uses the general perforated cores. Brief Description of the Drawings
[15] The above objects, and other features and advantages of the present invention will become more apparent after a reading of the following detailed description taken in conjunction with the drawings, in which:
[16] FIG. 1 is a schematic view illustrating the construction of a sandwich panel according to the conventional art;
[17] FIG. 2 is a schematic view illustrating component parts which constitute a pyramidal bulk structure in accordance with one embodiment of the present invention; [18] FIG. 3 is a perspective view illustrating the pyramidal bulk structure in accordance with one embodiment of the present invention;
[19] FIG. 4 is a partial side view of the pyramidal bulk structure shown in FIG. 3;
[20] FIG. 5 is views illustrating a procedure of stacking component parts to manufacture the pyramidal bulk structure according to the present invention;
[21] FIG. 6 is a perspective view and a plan view illustrating the configuration of a lower mold which is used to manufacture the pyramidal bulk structure according to the present invention; and
[22] FIG. 7 is views illustrating a method for manufacturing a pyramidal bulk structure in accordance with another embodiment of the present invention. Best Mode for Carrying Out the Invention
[23] Reference will now be made in greater detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
[24] FIG. 2 is a schematic view illustrating component parts which constitute a pyramidal bulk structure in accordance with one embodiment of the present invention, FIG. 3 is a perspective view illustrating the pyramidal bulk structure in accordance with one embodiment of the present invention, and FIG. 4 is a partial side view of the pyramidal bulk structure shown in FIG. 3.
[25] Referring to FIGs. 2 through 4, a pyramidal bulk structure 200 according to the present embodiment is manufactured using pyramidal truss cores 210 and general perforated cores 220. That is to say, by alternately stacking and then bonding the pyramidal truss cores 210 and the perforated cores 220, the pyramidal bulk structure 200, in which pyramidal trusses are periodically formed, is manufactured.
[26] Here, while the pyramidal truss cores 210 are formed by crimping expanded metal to have prominences and depressions as disclosed in Korean Unexamined Patent Publication No. 2005-0116445, they have a pyramidal truss construction by crimping the rhombus shapes of the expanded metal in diagonal directions. Namely, the pyramidal truss cores 210 have a plurality of unit pyramidal trusses. The perforated cores 220 have quadrangular perforated shapes and possess regularity in that regular tetrahedrons are regularly repeated. The perforated cores 220 are commercial products, have various shapes and sizes, and serve as a structural element having high economy and productivity.
[27] The perforated cores 220 have the shape of a quadrangle, whereas the bottom of the unit pyramidal truss has the shape of a rhombus. When stacking the pyramidal truss core 210 on the perforated core 220, the center portions (lower contact points) of the sides of the unit pyramidal truss are positioned on the corner portions (contact points) of the quadrangles of the perforated core 220. Due to this fact, the pyramidal truss cores 210 and the perforated cores 220 can be easily bonded and have structural stability. As a consequence, a construction is attained, in which pyramidal trusses are periodically formed in the pyramidal bulk structure 200. When bonding the pyramidal truss cores 210 and the perforated cores 220, welding, brazing, adhesive bonding, etc. can be employed.
[28] The pyramidal bulk structure 200 according to the present embodiment can be used in various industrial fields such as ships, automobiles, aircrafts and other products which require light weight, due to the high specific stiffness thereof, and can be utilized as a new structural element for metal products, due to the advantages rendered in terms of economy, acoustic absorptivity, impact resistance, heat exchange, electromagnetic shielding.
[29] Hereafter, a method for manufacturing the pyramidal bulk structure constructed as mentioned above will be described.
[30] FIG. 5 is views illustrating a procedure of stacking component parts to manufacture the pyramidal bulk structure according to the present invention.
[31] Referring to FIGs. 3 through 5, in order to manufacture the pyramidal bulk structure
200 according to the present embodiment, a perforated core 220 having a desired area is first arranged (First step). Then, a pyramidal truss core 210 is stacked on the perforated core 220 such that the lower contact points of the pyramidal truss core 210 and the contact points of the perforated core 220 correspond to each other (Second step). Next, another perforated core 220 is stacked on the pyramidal truss core 210 such that the upper contact points of the pyramidal truss core 210 and the contact points of another perforated core 220 correspond to each other (Third step). Thereupon, another pyramidal truss core 210 is stacked on another perforated core 220 such that the lower contact points of another pyramidal truss core 210 and the contact points of another perforated core 220 correspond to each other (Fourth step). After a desired height is obtained by repeating the first through fourth steps, by bonding the pyramidal truss cores 210 and the perforated cores 220 which are brought into contact with each other, the manufacture of the pyramidal bulk structure 200 according to the present embodiment is completed.
[32] FIG. 6 is a perspective view and a plan view illustrating the configuration of a lower mold which is used to manufacture the pyramidal bulk structure according to the present invention.
[33] Referring to FIG. 6, a lower mold 300 has a plurality of sets of guide pins 310 vertically installed on the surface thereof. Here, each of the guide pins 310 is a component part which is extruded to have a triangular transverse sectional shape. Four guide pins 310, which are positioned to face in two directions, constitute one set. Here, in each set of guide pins 310, the longitudinal and transverse surfaces of selected guide pins 310 guide the perforated cores 220, and the oblique surfaces thereof guide the pyramidal truss cores 210. Thus, if the above-described lower mold 300 is used, when stacking the pyramidal truss cores 210 and the perforated cores 220, the precise control of bonding positions becomes possible.
[34] FIG. 7 is views illustrating a method for manufacturing a pyramidal bulk structure in accordance with another embodiment of the present invention.
[35] In order to manufacture the pyramidal bulk structure according to the present embodiment, the perforated cores 220 and the pyramidal truss cores 210 are alternately stacked to a desired height in accordance with the steps shown in FIG. 5 along the guide pins 310 of the lower mold 300 configured as shown in FIG. 6 (see FIG. 7 (a)). Then, pressure is applied to the stacked perforated cores 220 and pyramidal truss cores 210 using an upper mold 320 having a plurality of through-holes through which the plurality of sets of guide pins can pass, such that the pressure is enough to perform a bonding process such as welding, brazing and adhesive bonding (see FIG. 7(b)). In this state, the contact portions of the perforated cores 220 and the pyramidal truss cores 210 are integrally boned with each other through welding, brazing, adhesion, etc. Thereupon, by removing the integrated resultant product from the upper and lower molds 320 and 300 (see FIG. 7(c)), the manufacture of the pyramidal bulk structure 200 is completed.
[36] In the present invention, by forming the guide pins to have a different sectional shape depending upon an internal shape, a pyramidal bulk structure having a different internal shape can be manufactured. Industrial Applicability
[37] The present invention can be applied as defining a new structural metal element to various industrial fields such as ships, aircrafts, automobiles, artificial bones, and the likes.
[38] Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

Claims
[ 1 ] A pyramidal bulk structure comprising: pyramidal truss cores obtained by crimping rhombus shapes of expanded metal in diagonal directions to have pyramidal truss shapes; and perforated cores perforated to have quadrangular shapes, wherein the pyramidal bulk structure is manufactured by alternately stacking the pyramidal truss cores and the perforated cores and bonding contact portions thereof with each other.
[2] The pyramidal bulk structure according to claim 1, wherein the contact portions are bonded with each other by welding, brazing or adhesive bonding.
[3] A method for manufacturing the pyramidal bulk structure according to claim 1, comprising the steps of: arranging a perforated core; stacking a pyramidal truss core on the perforated core such that lower contact points of the pyramidal truss core and contact points of the perforated core correspond to each other; stacking another perforated core on the pyramidal truss core such that upper contact points of the pyramidal truss core and contact points of another perforated core correspond to each other; stacking another pyramidal truss core on another perforated core such that lower contact points of another pyramidal truss core and the contact points of another perforated core correspond to each other; and bonding contact portions of the perforated cores and the pyramidal truss cores after a desired height is obtained by repeating the above steps.
[4] A method for manufacturing the pyramidal bulk structure according to claim 1, comprising the steps of: arranging a lower mold which has a plurality of sets of guide pins vertically installed on a surface thereof; stacking a perforated core on the surface of the lower mold along the plurality of sets of guide pins; stacking a pyramidal truss core on the perforated core along the plurality of sets of guide pins; stacking another perforated core on the pyramidal truss core along the plurality of sets of guide pins; stacking another pyramidal truss core on another perforated core along the plurality of sets of guide pins; stacking perforated cores and pyramidal truss cores to a desired height by repeating the above steps; applying pressure to the stacked perforated cores and pyramidal truss cores using an upper mold having a plurality of through-holes through which the plurality of sets of guide pins pass, and bonding contact portions of the perforated cores and the pyramidal truss cores with each other; and removing a resultant integrated pyramidal bulk structure from the upper and lower molds.
[5] The method according to claim 4, wherein each of the guide pins has a triangular transverse sectional shape, each set of guide pins is constituted by four guide pins which are positioned to face in two directions, and longitudinal and transverse surfaces of selected guide pins among the sets of guide pins guide the perforated cores and oblique surfaces thereof guide the pyramidal truss cores.
[6] The method according to any one of claims 3 to 5, wherein the contact portions are bonded with each other by welding, brazing or adhesive bonding.
PCT/KR2008/004963 2008-06-20 2008-08-25 Pyramidal bulk structure and manufacturing method thereof WO2009154326A1 (en)

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CN104464710A (en) * 2014-11-21 2015-03-25 南京航空航天大学 Acoustic sandwich panel
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