WO2018046762A1

WO2018046762A1 - Structural mat and production thereof

Info

Publication number: WO2018046762A1
Application number: PCT/EP2017/072903
Authority: WO
Inventors: Johann Kreuter
Original assignee: Johann Kreuter
Priority date: 2016-09-12
Filing date: 2017-09-12
Publication date: 2018-03-15
Also published as: AT520962A5; DE102016117113B3; AT520962B1

Abstract

The invention relates to a structural mat (10) and to a device and a method for producing such a structural mat (10). The structural mat comprises: upper thin-walled node surfaces (1) on the upper side of the structural mat (10) and lower thin-walled node surfaces (2) on the underside of the structural mat (10), wherein the upper node surfaces (1) are spaced apart from each other in the thickness direction of the structural mat (10) with respect to the lower node surfaces (2), wherein each of the upper node surfaces (1) is enclosed by three side edges (4), wherein each of the upper node surfaces (1) is connected with three lower node surfaces (2) by means of three thin-walled connecting surfaces (3), wherein each of said lower node surfaces (2) is enclosed by three side edges (4), and wherein each of the lower node surfaces (2) is connected with three upper node surfaces (1) by means of three thin-walled connecting surfaces (3).

Description

STRUCTURAL MATERIAL AND ITS MANUFACTURE

The present invention relates to a structural mat and to a method and an apparatus for the production thereof. The applications for such a structural mat are many. The structural mat can particularly advantageously serve as a support core arranged between two cover layers or covering skins to form a composite structure in sandwich construction.

Composite components in a sandwich construction, for example with a supporting core of a honeycomb mat or a foamed plate, are known. EP 1 727 633 B1 shows a folded core for sandwich panels with a single curvature. The folded core is composed of several triangles and trapezoids.

US 2007/0015000 A1 describes a honeycomb-based structural mat. The structural mat comprises hexagonal surface elements each having three or six rectangular connecting webs to adjacent surface elements.

The US 2011/0283873 AI describes lattice work and other different support cores for the arrangement between an upper and a lower cover layer. WO 2005/113230 describes various support cores for sandwich structures, such. B. closed sinusoidal corrugated structures, honeycombs, a structural mat with dome-like elevations and trough-like depressions, adjacent dome-like elevations are connected to each other via saddle feet and the trough-like depressions are also connected to each other via saddle surfaces.

US 9,126,387 A discloses a core for a sandwich structure based on a plurality of juxtaposed square pyramidal stumps. US 5,543,204 shows a sandwich panel with a core having two sets of corrugated strips having planar peaks and troughs at regular intervals. The strips of the first set are arranged parallel to each other and spaced apart, their peaks and bottoms being in phase with each other so that parallel rows of troughs perpendicular to the strips are formed. The strips of the second set are arranged parallel to one another, their high and low points being in phase with each other. The strips of the second set are perpendicular to the strips of the first set, through the low points they run. The known from the prior art support cores are usually used for the production of flat, plate-shaped sandwich structural components. Some of the cores known from the prior art can be curved about a spatial axis and very limitedly about a second spatial axis for the production of shell-shaped sandwich components.

It is an object of the present invention to provide a structural mat which can be curved simultaneously around two spatial axes. The object is achieved with the structural mat having the features of claim 1. Advantageous developments are described in the dependent claims, the description and the figures. For example, the structural mat may be part of a structural mat composite set forth in dependent claims 9 and 10 or a sandwich structure as defined in dependent claim 11.

A structural mat is understood to be a body which, in terms of its areal extent (length and width), is larger, in particular significantly larger, than its thickness.

The node areas and connecting surfaces referred to herein are understood as three-dimensional bodies having a two-dimensional areal extent and a certain thickness as a third dimension. They can therefore also be referred to as node walls and connecting walls.

The term "thin walled" is to be understood as meaning that the area referred to as "thin walled" has a significantly higher areal extent in length and Width than the thickness. In other words, it means that the thickness is significantly smaller than the length and width of the surface extension.

The angular ranges or intervals specified herein include the upper and lower limits.

The structural mat comprises upper thin-walled nodal surfaces at the top of the structural mat and lower thin-walled nodal surfaces at the bottom of the structural mat. The surfaces of the upper node surfaces facing away from the structural mat form the upper side of the structural mat, and the surfaces of the lower node surfaces facing away from the structural mat form the underside of the structural mat. The upper node surfaces are spaced apart with respect to the lower node surfaces in the thickness direction of the structural mat. The thickness of the structural mat is thus greater than the thickness of the thin-walled upper and lower node surfaces.

When the structural mat is planar, the upper node surfaces are parallel to and in an upper plane of the structural mat and the lower node surfaces are parallel to and in a sublevel of the structural mat. The upper level of the structural mat and the lower level of the structural mat are preferably parallel in this case.

When the structural mat is curved or disposed about one, two, or more generally, spatial axes, the upper node surfaces may be tangent to an upper envelope and the lower node surfaces may be tangent to a lower envelope.

Each of the upper node surfaces may be bordered by three side edges and each of the lower node surfaces may be bordered by three side edges. Each of the node surfaces are thus associated with three side edges. For example, the sum of angles of the inner angles between the three side edges of each of the node surfaces may be 180 °. For example, the three side edges of each node surface may bound or border them respectively to a triangle, preferably to an equilateral or substantially equilateral triangle. This of course applies to the upper node surfaces and / or the lower node surfaces. The inside angle between the side edges of an equilateral triangle is 60 ° in each case. Each of the upper node surfaces may be connected to three lower node surfaces via three thin-walled connection surfaces. Each of the lower node surfaces may be connected with three thin-walled connection surfaces with three upper node surfaces. For example, the three thin-walled connection surfaces and three lower node surfaces may be arranged uniformly around the upper node surface, in particular with a pitch of 60 ° or approximately 60 °. For example, three thin-walled connection surfaces and three upper node surfaces can be arranged distributed uniformly around the lower node surface, in particular with a pitch of 60 ° or approximately 60 °.

The ratio of the length of the side edge to the thickness of the upper and / or lower node surface and / or the connecting surface may for example be at least 10: 1, in particular at least 15: 1 or at least 20: 1. The upper node surfaces, the lower node surfaces and the connection surfaces preferably have the same thickness.

For example, each of the connection surfaces at one of the side edges of the upper node surface may be connected to the upper node surface and connected to the lower node surface at one of the side edges of the lower node surface. In particular, the connection surface at the side edge may merge into the upper node surface or at the side edge into the lower node surface. In particular, the side edge forms the transition between the node surface and the connection surface.

For example, each of the connection surfaces may be angled with respect to the upper node surface and the lower node surface connected by this connection surface. The bend can be greater than 0 °, in particular greater than 10 °, and less than or equal to 90 °. That is, the angle between the node surface and the connecting surface may be greater than or equal to 90 ° and less than 180 °, preferably less than 170 °. Under a side edge is not necessarily understood a sharp edge, but in particular also rounded edges, as they result, for example, in a bending edge. The side edges are preferably straight in the plane of their node surface, the bend between the node surface and the connection surface being formed around this straight line. For example, each of the connection surfaces of two end edges extending from its associated upper node surface to the lower node surface associated with it may be limited. This means that the end edges form a structural boundary, as formed by a cutting edge, for example. This causes the terminal edges or connecting surfaces at their terminal edges to be unconnected to the other of the connecting surfaces and / or the lower and upper node surfaces that are not associated with the respective connecting surface. This allows the structural mat an even better deformability in particular by one or two mutually transverse spatial axes.

For example, for each of the connection surfaces, the side edges of the upper and lower node surfaces connected via one of the mentioned connection surfaces are substantially parallel to one another. For example, each upper node surface has six adjacent upper node surfaces, each of the three lower node surfaces being connected via two thin-walled connection surfaces to each of two of the six upper adjacent node surfaces, one side edge each having a side edge of two of the six adjacent upper node surfaces on a first axis is located, in each case one side edge, each having a side edge of two of the six adjacent upper Knotenfiächen on a second axis and each have a side edge, each having a side edge of two of the six adjacent upper node surfaces on a third axis. These axes are arranged at an angle of 60 ° or substantially 60 ° to each other. The same may apply mutatis mutandis to the lower node areas, namely that each lower node area has six adjacent lower node areas, each of the three upper node areas being connected via thin-walled or two thin-walled connection areas to two of the six lower adjacent node areas, one side edge each of the lower node area each having a side edge of two of the six adjacent lower node faces on a fourth axis, one side edge of the lower node face each having a side edge of two of the six lower node faces on a fifth axis and one side edge of the lower node face each having a side edge of two of the six lower nodes lie on a sixth axis. These axes can be arranged at an angle of 60 ° or substantially 60 ° to each other. The first and fourth axes may be parallel to each other, the second and fifth axes may be parallel to each other, and the third and sixth axes may be parallel to each other. The structural mat may have a plurality of recesses, which may be designed in particular as apertures, wherein over the circumference of each recess, three upper node surfaces and three lower node surfaces are arranged distributed in an alternating sequence, in particular with a pitch of 60 °. Through each recess extends a first, second, third, fourth, fifth and sixth axis. In the special case that the Verbindungsfiächen are angled with respect to the upper and lower Knotenfiächen by 90 °, the recess is a extending in the thickness direction of the structural mat line. At this line, six connecting surfaces or one end edge thereof may meet or abut one another. However, these six end edges are unconnected to the line recess.

The upper node surfaces and the lower node surfaces may be triangles, in particular equilateral triangles, wherein the connecting surfaces may be quadrilaterals. For the connecting surfaces connecting the upper and lower node surfaces, two of the four corners coincide with two corners of the upper node surface and the other two of the four corners coincide with two corners of the lower node surface.

The upper and / or lower node surfaces may be closed surfaces or in part or in each case at least one recess, an opening, a knob or a depression. This is advantageous, for example, when the structural mat is used as the core of a sandwich structure. Already the substantially closed upper node surface and / or lower node surface allows a better bonding of an upper cover layer and a lower cover layer with the structural mat. Compared to z. As a honeycomb core, which has only touches along lines with the cover layers and thus is not optimal for bonding, form the Knotenfiächen relatively large-scale editions for bonding with the upper and lower cover layer. The bond can be further improved by said recesses, knobs, apertures or depressions. Alternatively or additionally, the upper and / or lower cover layer and / or an intermediate layer, as described below, be perforated, in particular perforated uniformly, or have recesses, apertures, knobs or depressions. One advantage of this is that the textured mat composite, in particular the sandwich structure, thereby obtains an improved sound damping property. A further advantage of this is that the joining of the cover layer or the intermediate layer to the structural mat can be improved.

With the structural mat according to the invention, for example, a textured mat composite can be provided, which has a first structural mat, which is formed according to the invention, and a second structural mat, which is designed according to the invention. The first structural mat and the second structural mat can be arranged one above the other in the thickness direction of the structural mat. For example, a plurality of upper node surfaces of the first structural mat and a plurality of upper or lower node surfaces of the second structural mat be joined together, in particular glued together. The adjoining nodal surfaces can, for. B. be connected directly to each other with an adhesive layer. For example, the node surfaces of the upper and lower structural mat joined together may be congruent to each other and, in particular, be the same size. In alternative embodiments, the node surfaces joined together may vary in size.

Alternatively, between the first structural mat and the second structural mat, an intermediate layer, such. As a membrane or a film or a skin or a plate or a shell body, be arranged, wherein a plurality of upper node surfaces joined to the intermediate layer, in particular glued, and several upper or lower node surfaces of the second structural mat also joined to the intermediate layer, in particular glued , are. In this case, the node surfaces joined to the intermediate layer can congruently oppose the upper and the lower structural mat and, in particular, be of the same size. Through the intermediate layer, the nodal surfaces of the upper and lower structural mat can be arranged differently sized and offset with respect to each other.

In embodiments in which the connecting surfaces are arranged with respect to the upper or under nodal surfaces with an angle greater than 90 °, can on the structural mat, in particular the upper or lower node surfaces or an upper or lower surface layer applied to the structural mat normal forces cause the structural mat - elastic or plastic - is deformed in their areal extent. For example, the structural mat formed from a rather rigid material can distribute normal forces over the angled connecting surfaces in the cover layer and / or intermediate layer, which are typically resistant to tension, for example. If, for example, no intermediate layer or cover layer is provided, the structural mat can be deformed flat due to the normal forces, ie widening, in particular with regard to its length and width, whereas the thickness of the structural mat is reduced. If a cover layer or intermediate layer, such as a cover or intermediate membrane of an elastic, in particular elastomeric material or material is provided, to which the upper or lower node surfaces are attached and which connects the upper or lower node surfaces, a force exerted on the structural mat Normal force cause an areal, in particular elastic deformation of the cover or intermediate layer. In this way, the elasticity and / or the vibration relevant advantageous properties of the structural mat or the composite thereof can be achieved. For example, a single structural mat can be provided with such an elastic cover layer or a composite of two or at least two superimposed structural mats between which such an elastic intermediate layer is arranged can be provided. Optionally, in addition to such an elastic intermediate layer, an upper and / or lower cover layer may be provided which, for example, but not necessarily, may be formed from an elastomeric or elastic material. For example, one or the cover layers may be formed from a material having a substantially higher modulus of elasticity than the intermediate layer. Optionally, for example, the elastic cover or intermediate layer may comprise an electromechanical transducer, for example a strain sensor or an electromechanical transducer material, in particular an electroactive polymer (EAP). As a result, the deformation or expansion of the cover or intermediate layer can be detected. Stretching can advantageously be used to determine the normal forces acting on the structural mat or the structural mat composite. In further developments, a plurality of expansion sensors can be distributed over the cover or intermediate layer, in particular distributed in matrix form. As a result, spatially resolved touches, ie the location or locations can be determined at which a normal force acts on the structural mat or the textured mat composite. For example, the intermediate layer can be elastic, ie have a significantly lower modulus of elasticity than the web material. The elongation of the intermediate layer may be fixed by means of at least one sensor, for example a strain sensor adhered to the elastic intermediate layer or contained in the elastic intermediate layer, or by means of an electromagnetic transducer material, for example an electroactive polymer (EAP) attached to or in the intermediate layer contained or from which the intermediate layer is formed, determined or measured.

The structural mat can be or consist of a metal material, a plastic, paper or cardboard, or a composite material, or comprise at least one such material. A metal material is understood to mean both pure metals and metal alloys. For example, the metal material can be or are based on: aluminum, magnesium, iron, steel, titanium, nickel, chromium, etc. A composite material can be, for example, a material combination of metal and plastic, for example metal polymer hybrid material or steel polymer hybrid material, which is also known as LITECOR These include a sandwich structure with a polymer core (eg 0.1 to 1.0 mm thickness) encased in two steel cover sheets (eg 0.2 to 0.3 mm thick each), is understood. In general and with regard to the manufacturing method mentioned below, such materials are suitable for the structural mat, which are sufficiently rigid, but plastically deformable, if the structural mat is to be produced by forming and not by primary molding. In general, the materials for the cover and intermediate layers are suitable for the structural mat. Depending on the desired application, certain material combinations may be provided for the structural mat and the cover and intermediate layers or layers. This combination can determine whether a structural composite is shock-absorbing (energy-dissipating or energy-dissipating), or shear-compression-resistant and rigid or an elastic surface spring. By way of example but not exhaustively, the following combinations are indicated:

The material of the structural mat has a high modulus of elasticity (modulus of elasticity) and the material of the cover and / or intermediate layer or layers has a low or low modulus of elasticity. This results in an elastically resilient Behavior, whereby the structure composite is suitable for example as a mattress insert or as an area sensor.

The material of the structural mat has a high modulus of elasticity and the material of the cover and / or intermediate layer or layers has a high or the same modulus of elasticity. As a result, the structural composite can be used particularly advantageously as a dimensionally stable sandwich panel or sandwich shell structure.

The material of the structural mat has a high modulus of elasticity, while the cover and / or intermediate layer or -läge is plastically easily deformed. As a result, the structural composite is suitable as a shock absorber, since the energy acting on the structural composite is absorbed or dissipated via the plastic deformation work.

The invention also relates to a sandwich structure which has an upper cover layer, a lower cover layer and at least one structural mat according to the invention or a textured mat composite according to the invention. The structural mat or the structural mat composite is enclosed between the upper cover layer and the lower cover layer, wherein the upper cover layer and the lower cover layer are joined to the structural mat or the structural mat composite, in particular adhesively bonded. The upper cover layer, the intermediate layer and / or the lower cover layer, for example, of metal, a metal alloy, plastic, such as. As fiber-reinforced, in particular aramid, carbon fiber and / or glass fiber reinforced plastic or natural fiber reinforced plastic, wood, paper, textile fabric (eg erosion control mat), ceramic or ceramic paper (for example, for use in a temperature-resistant catalyst) or another known for this purpose material be.

It is a further object of the present invention to provide a method and an apparatus for the production of a structural mat, in particular the structural mat described herein. The object is achieved by the method according to claim 12 and the device according to claim 20. Advantageous developments are described in the dependent claims, the description and the figures. The method for producing a textured mat, in particular a structural mat mentioned herein, initially assumes that a thin-walled, in particular continuous or homogeneously thin-walled flat material, in particular a sheet-like flat material or material web, is provided. The web has a plurality of holes forming a uniform pattern of holes. The material web can for example already be provided wound with the hole pattern, for example on rolls, or the hole pattern can be introduced in the web-shaped sheet in the context of the inventive method prior to processing, as they are mentioned below, such. B. by punching or in general a separation process. The hole pattern is preferably a hexagonal hole pattern, ie, six further holes of the hole pattern can be arranged around each hole, in particular with an equal pitch and an equal spacing. The hole pattern can basically be defined by the centroids of three adjacent holes forming an equilateral triangle. For example, the quotient s / r from side length s of the isosceles triangle and hole radius r (radius of the circular hole or distance r corner to centroid of the hexagonal hole) may be greater than or equal to 2.2. Alternatively or additionally, the quotient s / t of side length s of the isosceles triangle and thickness t of the web material may be, for example, greater than or equal to 10. The holes of the hole pattern can z. B. have a circular shape or a hexagonal or hexagonal, in particular isosceles hexagonal shape.

The flat material or the material web is conveyed through a first forming station, with the first forming station bending, in particular folding, the flat material at a multiplicity of first and fourth bending lines parallel to a first bending axis. This can take place alternately around a first bending line and fourth bending line along the transport direction of the material web, resulting in a zigzag folding. The second forming station can bend the flat material or the material web formed in the first forming station at a plurality of second and fifth bending lines parallel to a second bending axis, in particular fold them. In particular, the material web can be alternately bent around a second and fifth bending line in the transport direction, so that a zigzag folding results.

The formed in the second forming station flat material is bent at a plurality of parallel to a third bending axis third bending lines and sixth bending lines, especially folded. This can take place in particular along the transport direction of the material web along a third bending line and sixth bending line alternately, so that a zigzag folding is produced. The first bending axis, the second bending axis and the third bending axis are mutually angularly offset, in particular arranged at 60 ° to each other angularly offset. Through each hole of the hole pattern runs a first, second, third, fourth, fifth and sixth bending line. This results in the structural mat according to the invention, such. The structural mat according to claim 1. The edges resulting from the bending around the bending lines correspond to the side edges of the upper and lower node surfaces. Thus, the side edges of the node surfaces may be bending or folding edges. Generally, the forming around the bending lines is a plastic forming. For example, the bending or folding around the bend lines can take place at an angle of greater than 0 ° up to and including 90 °.

In preferred embodiments, the hole pattern is such that the centroid of each hole of the hole pattern and the centroids of two holes of the hole pattern adjacent to this hole form the corners of an equilateral triangle. In other words, the respective centroids of three adjacent holes of the hole pattern may form the corners of an equilateral triangle. This results in the hexagonal arrangement of the holes of the hole pattern.

In exemplary embodiments, the holes of the hole pattern may have a circular shape, wherein the first and fourth bending lines are spaced from each other by a distance corresponding to the amount of the radius of the circular shape. For example, the first and fourth bending lines may each be spaced by half the radius from the center of the circular shape. Alternatively or additionally, the second and fifth bending lines can be spaced from each other by a distance corresponding to the amount of the radius of the circular shape. For example, the second bendline and the fifth bendline may each be spaced at half the radius from the center of the circular shape. Alternatively or additionally, the third and sixth bending lines may be spaced from each other by a distance corresponding to the amount of the radius of the circular shape. For example, the third bendline and the sixth bendline may each be spaced by half the radius from the center of the circular shape. In exemplary embodiments, in which the holes of the hole pattern have a hexagonal shape, in particular an isosceles hexagonal shape, the first bend line may pass through two corners of the hexagon and the fourth bend line through two other corners of the hexagon. Alternatively or additionally, the second bend line may pass through two corners of the hexagon and the fifth bend line through two other corners of the hexagon. Alternatively or additionally, the third bend line may pass through two corners of the hexagon and the sixth bend line through two other corners of the hexagon. This results in the two end edges of each connection surface, which extend from the upper node surfaces to the lower node surfaces and laterally delimit the connection surfaces, in particular as a structural boundary. In addition, defined bends can be made through the corners of the hexagon.

For example, to improve the formability of the web material around the bend lines, each hexagon may have recesses at the corners of the hexagon. The same applies to a circular hole, wherein six recesses may be provided evenly distributed over the circumference of the hole.

The bending edge or bending line or material in the area of the bending lines can optionally be weakened by means of a perforation, an embossing line or a film-hinge-like reduction of the thickness, which is arranged along the intended bending lines, in order to form the bend around the bending line to facilitate. Accordingly, several or all of the bendlines can be weakened in this way.

Generally, preferably, the sheet is reversely bent at the fourth bend line than at the first bend line. Alternatively or additionally, the flat material can be bent opposite to the fifth bending line opposite than at the second bending line. Alternatively or additionally, the flat material may be reversed at the sixth bending line opposite than at the third bending line. These opposite bends result in zigzag folding.

The hole pattern of the section of the material web entering the first forming station may preferably have a row of holes which is arranged perpendicular to the transport direction of the incoming section and / or parallel to one of the bending axes, such as z. B. the first or second bending axis. Due to this arrangement can be achieved that the tools of the forming stations need to be made less complex.

Preferably, the material web in the first forming station, the second forming station and / or the third forming station can be formed simultaneously over its entire width, in particular parallel to a row of holes, in particular around the corresponding bending axes or bending lines. By the simultaneous forming over the entire width of the material web can be advantageous to avoid uneven folding or wrinkling of the web during forming. Particularly advantageously, the full bend around the bend line can be performed in one step. In the case of folding core production methods known in the prior art, the bending takes place in several small steps because of the multi-axial shortening during bending.

The device for producing a structural mat, in particular the structural mat described herein, such. As the structural mat according to claim 1 is suitable for carrying out the method described herein for producing a structural mat. The device is designed for producing a structural mat by forming a material web by means of a plurality of forming stations. The apparatus comprises a first forming station, a second forming station and a third forming station arranged and configured to pass through the web in sequence. For example, a transport path may be provided, which is designed to supply the material web to the first forming station and / or to lead from the first forming station to the second forming station and / or to lead from the second forming station to the third forming station.

The first forming station can have at least one forming tool which is adapted to plastically bend or fold the material web passing through the first forming station parallel to a first bending axis in the web running direction alternately about a first bending line and a fourth bending line to obtain a first zigzag folding.

The second forming station may comprise at least one forming tool adapted to alternately pass the web of material passing through the second forming station parallel to a second bending axis which is inclined, in particular at an angle of substantially 60 ° to the first bending axis, in the web running direction second bendline and plastically angling, in particular folding, a fifth bending line to obtain a second zigzag folding.

The third forming station may comprise at least one forming tool which is adapted to pass the material web passing through the third forming station parallel to a third bending axis, which is arranged obliquely, in particular at an angle of substantially 60 ° to the first and second bending axis Web direction alternately by a third bending line and a sixth bending line to obtain a third zigzag folding plastically, in particular to fold.

For example, the at least one forming tool of the first and / or second and / or third forming station may comprise a pair of toothed rollers arranged in parallel with respect to their axes of rotation, in particular intermeshing. Between the intermeshing toothed rollers, the web is carried out, whereby the teeth of the intermeshing toothed rollers can act on the material web. With the teeth of the intermeshing toothed rollers, the corresponding zigzag folding around the bending lines can be generated. In order to prevent the incoming web from being displaced in parallel by the intermeshing toothed rollers whose axes of rotation are oblique to the web running direction, the intermeshing rollers may comprise toothed racks forming the teeth of the toothed rollers, the parts of rods, strips slidable in grooves parallel to the axes of rotation or are generally body and during the contact with the material web to carry out a compensation movement along the roll axis of rotation and relative to the roll main body. In an exemplary embodiment in which the tools can be constructed with less complexity, the angle between the normal of one of the axes of rotation of the toothed rollers of the first forming station and the transport direction of the section of the material web entering the first forming station, in particular in the projection onto the material web 60 ° or in about 60 °.

The angle between the normal of one of the axes of rotation of the toothed rollers of the second forming station and the transport direction of the section of the material web entering the second forming station may be between 15 ° and 35 ° in particular in the projection onto the material web. The angle between the normal of one of the axes of rotation of the toothed rollers of the third forming station and the transport direction of the section of the material web entering the third forming station can be between 26 ° and 43 ° in particular when projecting onto the material web.

In general, the angular position of the axes of rotation of the tools to the incoming material web of the second and third forming station with the desired bending angle by which the material web is bent around the bending lines, vary. Therefore, the angles at which the material web runs out of the first and second forming station also vary.

For example, the angle between the normal of one of the axes of rotation of the toothed rollers of the first forming station and the transport direction of the portion of the material web leaving the first forming station, in particular in a projection onto the material web, can be between 63 ° and 80 °.

The angle between the normal of one of the axes of rotation of the toothed rollers of the second forming station and the transport direction of the portion of the material web leaving the second forming station can be between 25 ° and 45 °, especially in the projection onto the material web.

The angle between the normal of one of the axes of rotation of the toothed rollers of the third forming station and the transport direction of the portion of the material web leaving the third forming station can be 60 ° or approximately 60 °, in particular when projecting onto the material web.

In general, the transport direction of the section of the material web which enters the first forming station can be parallel offset relative to the transport direction of the section of the material web which leaves the third forming station. By way of example, the at least one forming tool of the first and / or second and / or third forming station may comprise a die and a punch that can be put on and set down with respect to the die, between which the material web is carried out or can be carried out. The die and the punch each have a Umformstruktur, wherein the Umformstrukturen of the die and the punch interlock when the Stamp is made with respect to the die, that is moved to the die, and the forming structures of the die and the punch do not interlock when the punch is placed in relation to the die, that is removed from the die to the transport of the web relative to the punch and die. The corresponding zigzag folding around the bend lines can be created by setting the punch in relation to the die. By way of example, the forming tool of the first forming station may comprise the die and the punch which can be put on and removed with respect to the die, wherein the forming tools of the second and third forming stations may comprise intermeshing toothed rollers as described herein. Other combinations of punch, die and toothed rollers are possible. For example, the forming tool may be a rotary bending machine whose structure and function are known to those skilled in the art.

applications

In addition to the suitability of the structural mat described herein as the core for a layered composite material, in particular a sandwich structure, the structural mat is also suitable for a large number of other applications. The areas of application of the structural mat are in the area of the automotive industry, railway engineering, construction, furniture construction and aviation. Further fields of application include shipbuilding, container and plant construction, the chemical industry, container and transport container construction, energy generation and electrochemical energy storage and catalysts. Further areas of application are toolmaking, interior design, robotics, optics and lighting and medical technology applications.

Applications can be: use as a spacer material for the installation of photovoltaic panels on roofs, as a leveling for interior fitting, (the adjustable thickness profile of the structural mat can compensate for floor or wall bumps), as curved lightweight panels with continuous thickness profile in the aerospace industry ,

Other applications use, for example:

(a) the large internal surfaces and continuous cavities (b) the ability to react elastically and forcefully to compressive loads.

Applications, in particular in connection with (a):

In an application in connection with a heat exchanger, the latter may have the structure composite according to the invention, wherein the intermediate layer or layers comprise a metal sheet, in particular made of copper, aluminum or an aluminum or copper alloy, and the first and second structural mat, between which the intermediate layer is arranged, of metal, in particular copper, aluminum or an aluminum or copper alloy may be. The intermediate layer separates first and second chambers from one another and in particular forms a common chamber wall of the first and second chambers, the first structural mat being in the first chamber and the second structural mat being in the second chamber. The intermediate layer can be bonded to the first and second structural mat in a materially bonded manner, in particular adhesively bonded, soldered or welded. For example, the upper cover layer can form a chamber wall of the first chamber and / or the lower cover layer can form a chamber wall of the second chamber. In particular, the first structural mat can be joined to the upper cover layer in a material-bonded manner and / or the second structural mat can be joined to the lower cover layer in a material-bonded manner, in particular adhesively bonded, soldered or welded. The upper and / or lower cover layer may be made of metal or plastic, for example.

In an application in connection with a soundproofing panel, it may be configured as a composite or sandwich structure according to the invention. For this purpose, the cover layers or cover layers, ie the upper and / or the lower cover layer, between which at least one structural mat according to the invention or a textured mat composite is optionally enclosed with an intermediate layer arranged between two structural mats, can be perforated, in particular have a uniform hole structure. If present, the intermediate layer can also be perforated, in particular have a uniform hole structure. The perforation allows sound waves to reach the region between the upper and lower cover layers and be absorbed, in particular dissipated, there. The cavities enclosed by the cells of the structural mat, wherein the cell is understood as meaning in each case an upper node surface with the three connecting surfaces projecting therefrom or a lower node surface with the three connecting surfaces protruding from it be filled with bulk material, in particular granules, ie granular to powdery solid, resulting in even better sound-absorbing properties. Alternatively, the cavities enclosed by the cells could be filled with foam. In an application in the field of medicine, for example in orthopedics, dentistry or regenerative medicine, the structural mat or a textured mat composite, for example, without cover and intermediate layers, an open-pore skeleton structure, for example, as a carrier for human or animal body cells or cell cultures. The surfaces of the structural mat or of the structured mat composite can be coated, for example, with one or more medical active substances or medicaments, for example in order to promote cell colonization of the structural mat. The structural mat or the structural mat composite, which may comprise a plurality of structural mats stacked one on top of another, can for example be rolled up or curved in any other desired shape, which is made possible by the advantageous deformability of the structural mat according to the invention.

In an application in connection with a catalyst device, for example in chemistry or motor vehicle technology, the latter may have a structural mat according to the invention or a structural mat composite according to the invention for forming an open-pored framework structure as a carrier for catalyst materials. The surfaces of the structural mat (s) may, for example, be provided or coated with a catalytically active substance (according to the desired application), for example platinum. Alternatively, the structural mat itself may be formed of the catalytically active substance. Due to the large surfaces provided by the cells of the structural mat, the applied catalytically active substance can better develop its effect. Through the structural mat, the catalyst device can be divided into several chambers.

In an application in the context of thermal insulation or thermal insulation, a structural mat composite according to the invention, in particular a sandwich composite comprising an upper and lower cover layer, can have one or more structural mats according to the invention arranged between the upper and lower cover layers. The cavities enclosed by the cells of the structural mat or any cavity enclosed by a cell may be filled with a heat-insulating solid, in particular a bulk material, for example granules, or it may be foamed. In an electronic equipment application, the structural mat or structural mat composite may form a flexible housing or flexible scaffolding for electronic components. For this purpose, the structural mat can be made more robust, wherein the cavities enclosed by the cells can accommodate electronic components and / or flexible printed circuit boards. For example, an intermediate layer can be accommodated between two adjacent structural mats, which has or is a flexible printed circuit board.

In an application in connection with a preferably flexible battery or a rechargeable battery, its or its structural mats may be formed of an electrically conductive material. Prior to joining or stacking the conductive pattern mats, the cavities enclosed by the cells between two adjacent pattern mats are filled with a ply mat. The insert mat has a multiplicity of random packings, with one (central) random pack arranged in the cavity of one cell and connected to the three adjacent packings via connecting webs of the insert mat. Between each of the three adjacent packing and the central packing such a connecting web is arranged. The insert mat is loosely bordered by the adjacent structural mats. The structural mat may e.g. form the anode of a battery while the conductive pattern mat acts as a cathode, or vice versa.

The structural mat according to the invention and the structural mat composite according to the invention can be used as a filter or sieve. The structured mat composite can have two or more layers of the inventive structural mats arranged one above the other or stacked and joined together, in particular without cover layers and intermediate layers. The textured mat composite can rest on a grid. For example, adjacent superposed structural mats may be arranged twisted relative to one another and optionally joined such that the mutually facing node surfaces of the two structural mats are rotated relative to one another by 60 ° relative to the congruent position of the mutually facing node surfaces.

In an application in connection with a soil erosion protection mat, for example, for slope or embankment attachment, this may comprise the structural mat or the textured mat composite or be formed therefrom, in particular without cover and Liners. The at least one structural mat can be made of a decomposable or degradable material, in particular textile material.

Applications, in particular in connection with (b):

In an application of the structural mat according to the invention or the structural mat composite according to the invention as a surface spring, this can serve, for example, as an insert in a mattress. The web material for the structural composite has a high modulus of elasticity, wherein the cover and intermediate layers may be absent, for example. As a result, the structural mat has a certain elasticity with respect to normal forces and it can widen reversibly flat under load.

In an application of the structural mat according to the invention or the structural mat composite according to the invention as a vibration damping mat (eg for machine tools), this can have at least two stacked structural mats, in particular with a high modulus of elasticity, in particular of steel or metal, between which an intermediate layer is arranged and the between an upper cover layer and a lower cover layer are bordered. At least the intermediate layer may be made of a material with low or low modulus of elasticity, for example an elastomeric material, such as rubber or silicone, in order to allow the elastic compensation strain in the surface. As a result, a vibrating excitation, which is normal to the structural mat, be damped. The upper and lower cover layer is preferably made of a material which has a low modulus of elasticity or is not zugsteif. Application as shock-absorbing surface elements: The energy of shock-like loads can be well absorbed by the structural mat or the layered composite material. For this purpose, a coordinated material combination of the web material (pressure / bending resistant) and the cover and intermediate layers (these are energy-absorbing of plastically deformable materials) is selected.

Application as a planar weight or force sensor: The structure is the same as with the vibration-damping structural mat, except that in addition one or more strain sensors (eg DMS strips) can be used to measure the elongation of the elastic membrane. Application as an active vibration damper: The structure, like the two-dimensional weight or force sensor, only allows the elasticity of the elastomer membrane to be controlled electrically (eg by being made of an electromechanical transducer material, such as an electroactive polymer or piezoelectric material). By stretching and shortening the elastic membrane, a force normal to the surface of the structural mat is generated. This way, vibrations can be controlled or generated not only passively but also actively.

Application in container construction: means for closing the edges of the structural mat to closed surfaces such. B. tubes by z. As an overlapping impact or in particular by overlapping deposits that anchor themselves in the inner cavities. This also makes it possible to line up in the surface for the areal enlargement of the structural mats, without noticeable discontinuities in the material properties or without noticeable enlargement with regard to the thickness of the structural mat.

In general, a surface referred to as "thin-walled" may have a ratio of length and / or width to thickness of at least 10: 1, more preferably at least 15: 1, or at least 20: 1. The invention has been described with reference to several embodiments and developments. In the following the invention will be described with reference to figures. The disclosed features form the subject of the invention individually and advantageously in any combination of features. 1 shows a perspective view of a structural mat according to the invention,

FIG. 2 shows a perspective view of a further embodiment of a structural mat according to the invention,

FIG. 3 shows a plan view of a structural mat according to the invention,

FIG. 4 shows a structural mat composite of structural mats according to the invention, which is curved around a plurality of mutually transverse spatial axes,

FIG. 5 a shows a device for producing a structural mat,

FIG. 5b shows another device for producing a structural mat,

Figure 6 is a plan view of a starting material, from which the structural mat by

Forming is made, FIG. 7 shows a first forming step,

FIG. 8 shows a second forming step,

FIG. 9 shows a third forming step,

FIG. 10 shows a sandwich structure with a core made from a core according to the invention

Matt structural composite,

Figure 11 is a plan view of a starting material for the production of

Structure mat

Figure 12 is a plan view of an alternative starting material for the manufacture of

Structure mat

Figure 13 is a perspective view of a composite body with an intermediate layer or -läge between two structural mats and

Figure 14 is a perspective view of a composite body comprising two structural mats for use in a battery or accumulator.

The structural mats of Figures 1 and 2 differ essentially only by the angle by which the thin-walled Verbindungsfiächen 3 are angled with respect to the upper thin-walled node surfaces 1 and the lower thin-walled Knotenfiächen 2. Figures 1 and 2 are therefore described in context. The embodiments of a structural mat 10 shown in FIGS. 1, 2, 3 and 4 may be made of a material web, for example by primary shaping, in particular casting or injection molding, or preferably by reshaping, in particular bending or folding, in several steps (FIGS. 7, 8 and 9) 20 with a uniform hole pattern - various suitable uniform hole patterns are shown by way of example in FIGS. 6, 11 and 12 - are produced. A plurality of structural mats 10 may or may be assembled to form a structural mat composite (Figures 4 and 10) to form, for example, the core of a sandwich structure (Figure 10).

The finished ur- or deformed structural mat 10 (Figures 1 to 4) has upper thin-walled nodal surfaces 1 at the top of the structural mat 10 and lower thin-walled Knotenfiächen 2 on the underside of the structural mat 10. The surfaces of the upper node faces 1 facing away from the structural mat 10 form the upper side of the structural mat 10, and the surfaces of the lower node faces 2 pointing away from the structural mat 10 form the underside of the structural mat 10. The upper node faces 1 are with respect to the lower node surfaces 2 in the thickness direction of the pattern mat 10 spaced. The thickness of the structural mat 10 results from the distance from the upper side to the underside of the structural mat 10. Preferably, the areal extent of the structural mat 10, ie the length and the width of the structural mat 10, is greater or significantly greater than the thickness of the structural mat 10.

Each of the upper nodes 1 is bordered by three side edges 4. Further, each of the lower node surfaces 2 is also bordered by three side edges 4. The three side edges 4 of each node surface 1, 2 are preferably equally long and arranged at 60 ° angles to each other and may be straight. The side edges 4 of each node surface 1, 2 bound the node surface 1, 2 to a substantially equilateral triangle. The corners of the triangles may optionally be formed by recesses 8a (FIGS. 11 and 12). The recesses 8a are particularly in the production by forming, such. As folding or bending, since they simplify the bending or folding and / or avoid accumulation of material at the corners due to bending or folding.

Each of the upper node surfaces 1 is connected to three lower node surfaces 2 via three thin-walled connection surfaces 3. The same applies to the lower node surfaces 2. That is, each of the lower node surfaces 2 is connected via three thin-walled connection surfaces 3 with three upper node surfaces 1. Each of the upper node surfaces 1, the lower node surfaces 2 and the connection surfaces 3 is the same thickness. Each of the connection surfaces 3 is connected to the upper node surface 1 at one of the side edges 4 of the upper node surface 1 and connected to the lower node surface 2 at one of the side edges 4 of the lower node surface 2. Each of the connection surfaces 3 is angled with respect to the upper node surface 1 and the lower node surface 2, which are connected by this connection surface 3. The angle between the upper node surface 1 and the connection surface 3 and / or between the lower node surface 2 and the connection surface 3 may be, for example, 90 ° (FIG. 2) or greater than 90 ° and less than 180 °, in particular less than 170 ° (Figures 1, 3 and 4). The side edges 4 of the upper and lower node surfaces 1, 2, which are connected via a connecting surface 3, are parallel or substantially parallel to one another. The angle between the connection surface 3 and the upper node surface 1 connected to it can correspond in terms of magnitude to the angle between this connection surface 3 and the lower node surface 2 connected to it. As is shown by way of example on an upper node surface 1 in FIG. 1, in particular each of the upper and / or lower node faces 1, 2 can have a bead 4a which extends into the bonding surface 3 and interrupts the side edge 4. As a result, the elasticity or deformability between the node surface 1, 2 and the connecting surface 3 can be reduced or the stability can be increased.

Three upper node surfaces 1 and three lower node surfaces 2 are arranged alternately over the circumference of a recess 8 or a hole 8. Each of the connection surfaces 3 has two end edges 3a, each forming a portion of the enclosure of the hole 8. The end edges 3 a thus form a structural boundary for the connection surfaces 3. The end edges 3 a of the connection surfaces 3 extend from the upper node surface 1 to the lower node surface 2. The end edges 3 adjoin the hole 8 and thus are unconnected Structural mat 10 particularly advantageous around two or more spatial axes, d. H. be curved twice or more, without being damaged or excessively distorted (Figure 4). The terminal edges 3a of each bonding surface 3 may be parallel to each other when formed by a hexagonal hole 8 (Fig. 12), or to waist the bonding surface 3 when defining circular holes 8 (Fig. 11).

As already mentioned, the upper node faces 1 and the lower node faces 2 may be triangles or equilateral triangles, the connecting faces 3 being quadrilaterals. For the connecting surfaces 3 connecting an upper node surface 1 and lower node surface 2, two of the four corners having two corners of the upper node surface 1 and the other two of the four corners having two corners of the lower node surface 2 coincide or coincide.

By facing away from the structural mat surfaces of the upper node surfaces 1 and the lower Knotenfiächen 2 are compared to a honeycomb honeycomb relatively large surfaces for a joint between an upper cover layer and the upper Knotenfiächen 1 and between a lower cover layer and the lower Node areas 2 available. This opens up a multiplicity of possibilities for joining connections between the covering layer 11, 12 and the node surface 1, 2. Examples for this are solvable, such. As magnetic compounds and Velcro, and non-releasable compounds such. B. welding, soldering and riveting.

To improve, for example, an adhesive bond with the cover layer 11, 12, each of the upper node faces 1 and / or the lower node faces 2 may have a recess or opening 9 (FIGS. 11 and 12). For example, the opening 9, which can be configured as a hole, located in the centroid of the node surface 1, 2 and the node surface 1, 2 penetrate in the thickness direction. Furthermore, structural mats 10 can be joined to form a structural mat composite 14 (FIGS. 4 and 10). For this purpose, a first structural mat 10 and a second structural mat 10 are superimposed, wherein the mutually facing node surfaces 1, such. B. upper Knotenfiächen 1 of the first structural mat 10 and upper node surfaces 1 of the second structural mat 10 are congruent with each other and joined together, in particular glued, are or will. Alternatively, the congruently juxtaposed nodal surfaces 1 may be joined together with another joining method described herein or known to those skilled in the art.

As an alternative to a direct connection of the nodal surfaces 1, 2 of the first and second structural mat 10, an intermediate layer or intermediate layer (FIG. 13) may be arranged between the first and second structural mat 10, comprising a plurality of upper node surfaces 1 of the first and second structural mat 10 and the regions between spans this node surfaces 1. Node surfaces 1, 2 of the first structural mat 10 and node surfaces 1, 2 of the second structural mat 10 can each be joined to the intermediate layer, such as. B. be glued or be, for example, with an adhesive layer, which is arranged between the intermediate layer and to be joined with the intermediate layer node surface 1, 2.

The structural mat 10 or the structural mat composite 14 are particularly advantageous for producing a sandwich structure which has an upper cover layer 11, a lower cover layer 12 and at least one structural mat 10 or a structural mat composite 14. The structural mat 10 or the structural mat composite 14 is enclosed between the upper cover layer 11 and the lower cover layer 12. The upper cover layer 11 and the lower cover layer 12 are joined to the structural mat 10 or the structural mat composite 14, in particular with its or their node surfaces 1 or 2, in particular adhesively bonded. The upper and lower, designed with, for example, flexible or inflexible or rigid deformation properties cover layers 11, 12 may, for example, plate-shaped or cup-shaped, such. B. be curved around a spatial axis or about two or more spatial axes.

In the figure 5 is a schematic diagram of a device 30 for producing a structural mat 10, as shown in the figures, by reshaping a material web 20, preferably of constant thickness, by means of a plurality of forming stations 31, 32, 33 shown. The first forming station 31, the second forming station 32 and the third forming station 33 are arranged so as to be traversed by the web 20 in sequence. The device 30 is adapted for the forming of thin material webs with respect to the surface, which have a hole pattern which is shown in different embodiments in FIGS. 6, 7, 11 and 13. The holes 8 of the hole pattern are arranged in staggered rows. To each hole 8 of the hole pattern 6 further holes 8 of the hole pattern are arranged at an equal distance and a same pitch. The centroids of three adjacent holes 8 form the corners of an equilateral triangle. Thus, a regular hole structure over the length and width of the web 20 is generated. The first forming station 31 has at least one forming tool which is adapted to plastically bend the material web 20 passing through the first forming station 31 parallel to a first bending axis 5 in the web running direction alternately about a first bending line 5a and a fourth bending line 5b to obtain a first zigzag folding or to fold. The first forming station 31 bends or folds the sheet 20 at a plurality of first and fourth bending lines 5a, 5b parallel to the first bending axis 5. This forming process is shown by way of example for a number of the holes 8 in FIG. Through the arranged in a row holes 8 a first bending line 5 a extends and thereby cuts two corners of the hexagonal holes 8. Further, through the arranged in a row holes 8, the fourth bending line 5 b, where it intersects two corners of the hexagonal holes 8. The first bending line 5a and the fourth bending line 5b are parallel to each other. The first forming station 31 angles the material web 20 consisting of a flat material about the first bending line 5a in one direction and around the fourth bending line 5b in an opposite direction, in particular at an angle of less than or equal to 90 °. This is done at all the first forming station 31 continuous rows of holes. The second forming station 32 has at least one forming tool, which is adapted to pass through the second forming station 32, formed by the first forming station 31 material web 20 parallel to a second bending axis 6, obliquely, in particular at an angle of substantially 60 °, is arranged to the first bending axis 5, in the web running direction alternately by a second bending line 6a and a fifth bending line 6b for obtaining a second zigzag folding plastically bend or fold. The second forming station 32 bends or folds the flat material formed in the first forming station 31 at a plurality of second and fifth bending lines 6a, 6b parallel to the second bending axis 6. FIG. 8 shows a section of the material web 20 which has been reshaped in the first forming station 31. Due to the zigzag folding from the first forming station 31, the second bending line 6a and the fifth bending line 6b are divided into bending line sections, which are arranged offset parallel to each other and extend from a hole 8 to an adjacent hole 8 of a row of holes. If the web material 20 shown in FIG. 8 were folded flat, the bending line 6a, 6b would look like that shown in FIGS. 11 and 12.

The third forming station 33 has at least one forming tool which is adapted to the material web 20 passing through the third forming station 33 parallel to a third bending axis 7, each obliquely, in particular at an angle of substantially 60 °, to the first and second bending axis 5, 6 is alternately bent or folded in the web running direction by a third bending line 7a and a sixth bending line 7b to obtain a third zigzag folding. The third forming station 33 bends or folds the flat material 20 formed in the second forming station 32 on a multiplicity of third and sixth bending lines 7a, 7b parallel to a third bending axis 7. FIG. 9 shows a detail of a material web 20 formed by the second forming station 32, in which the third bending axis 7 and a third bending line 7a and a sixth bending line 7b are shown, around which the material web 20 is formed in the third forming station 33. After the material web 20 has passed through the third forming station 33, it has the shape of the structural mat 10, as shown in Figures 1 to 4, on.

The hole pattern can be introduced in principle in any orientation in the web 20, in which case only the orientations of the forming stations 31, 32, 33 would have to be adjusted. However, it is preferred that the hole pattern of the material web 20 is aligned such that a row of holes is arranged transversely, in particular perpendicular to the transport direction of the portion of the material web 20, which is arranged upstream of the first forming station 31. As a result, the forming stations 31, 32, 33 or their tools can be constructed less complex or simpler.

For example, the forming tool at least one of first, second and third forming station 31, 32, 33 comprise a pair of parallel with respect to their axes of rotation, intermeshing toothed rollers between which the web 20 is feasible or performed with their teeth the corresponding zigzag folding around the bending lines 5a, 5b; 6a, 6b; 7a, 7b can be generated or generated.

In the device of FIG. 5 a, the angle a between the normal n of one of the axes of rotation of the toothed rollers of the first forming station 31 and the transport direction of the section of the material web 20 entering the first forming station 31 can be 60 ° or approximately 60 °. The angle a 'between the normal n of one of the axes of rotation of the toothed rollers of the first forming station 31 and the transport direction of the expiring from the first forming station 31 portion of the web 20 may be between 63 ° and 80 °. The angle b between the normal n of one of the axes of rotation of the toothed rollers of the second forming station 32 and the transport direction of the section of the material web 20 entering the second forming station 32 may be between 15 ° and 35 °. The angle b 'between the normal n one of the axes of rotation of the toothed rollers of the second forming station 32 and the transport direction of the expiring from the second forming station 32 portion of the web 20 may be between 25 ° and 45 °. The angle c between the normal n of one of the axes of rotation of the toothed rollers of the third forming station 33 and the transport direction of the section of the material web 20 entering the third forming station 33 may be between 26 ° and 43 °. The angle c 'between the normal n one of the axes of rotation of the toothed rollers of the third forming station 33 and the transport direction of the expiring from the third forming station 33 portion of the web 20 may be 60 ° or approximately 60 °. In particular, the transport directions of the section entering the first forming station 31 and the section leaving the third forming station 33 may be offset parallel to one another. As an alternative to the device of FIG. 5 a, in the device of FIG. 5 b the angle a between the normal n of one of the axes of rotation of the toothed rollers of the first forming station 31 and the transport direction of the section of the material web 20 entering the first forming station 31 can be 0 ° or approximately 0 ° ° amount. Accordingly, the angle a 'between the normal n of one of the axes of rotation of the toothed rollers of the first forming station 31 and the transport direction of the expiring from the first forming station 31 portion of the web 20 is also 0 ° or approximately 0 °. The angle b between the normal n of one of the axes of rotation of the toothed rollers of the second forming station 32 and the transport direction of the section of the material web 20 entering the second forming station 32 may be between 35 ° and 50 °. The angle b 'between the normal n of one of the axes of rotation of the toothed rollers of the second forming station 32 and the transport direction of the expiring from the second forming station 32 portion of the web 20 may be between 55 ° and 75 °. The angle c between the normal n of one of the axes of rotation of the toothed rollers of the third forming station 33 and the transport direction of the section of the material web 20 entering the third forming station 33 can be between 25 ° and 45 °. The angle c 'between the normal n one of the axes of rotation of the toothed rollers of the third forming station 33 and the transport direction of the expiring from the third forming station 33 portion of the web 20 may be 60 ° or approximately 60 °. In particular, the transport directions of the section entering the first forming station 31 and the section leaving the third forming station 33 may be offset parallel to one another.

As an alternative to a forming station with a forming tool comprising a pair of intermeshing toothed rollers, the at least one forming tool of at least one of first, second and third forming stations 31, 32, 33 can have a die and a die which can be put on and set off with respect to the die include (not shown). Between the die and the stamp, the web 20 is performed. The die and the punch each have a forming structure, wherein the forming structure of the die and the punch engage with each other when the punch is made with respect to the die, and the forming structure of the die and the punch do not interlock when the punch relative to the Die is turned off. Thereby, the transport of the material web 20 relative to the punch and the die can be made possible and the corresponding zigzag folding about the bending lines 5 a, 5 b; 6a, 6b; 7a, 7b by hiring of the punch or moving the punch to the die. For example, the feed of the material web 20 may be clocked or continuous.

The intermediate layer 13 of the structural mat composite 14 from FIG. 13 has at least one sensor 13 a, which is adapted to determine the deformation of the intermediate layer 13 along the length and / or width of the intermediate layer 13. The sensor 13a can be configured as a strain gauge sensor or strip. If the intermediate layer 13 has a plurality of sensors 13a, the point at which the deformation takes place can be determined. As a result, it can be determined, for example, at which point a normal force acts on the textured mat composite. The sensor or sensors 13a may be integral with the intermediate layer 13 or attached to the intermediate layer 13, such as adhered to the intermediate layer 13, for example.

The structural mat composite 14 of FIG. 14 has two structural mats 10 stacked one above the other, whose lower nodal surfaces 2 congruently abut one another and are joined together, in particular by a joint connection described herein. The fact that the lower node surfaces 2 congruently abut each other, the mutually facing cavities, which are each bordered by a cell, which is formed by the upper node surface 1 and the three protruding therefrom connecting surfaces 3, congruent to each other, creating a variety of common Cavities are formed. In several or each of the common cavities, a filler 15 is arranged or inserted. To each filling body 15 three packing 15 are arranged evenly distributed, which are each connected to a connecting web 16 with the packing 15 around which the three packing 15 are arranged. The filling body 15 and the connecting webs 15 connecting the filling members 15 form a laying mat which is loosely inserted and / or enclosed between the adjacent and connected structural mats 10. The insert mat can serve, for example, to connect structural mats 10 or structural mat composites 14 arranged next to one another in order to increase the areal extent of the structural mat 10 or of the structural mat composite 14. The two adjacent webs 15 connecting connecting webs 16 are annular in this example, but could also have other shapes.

The filler 15 and the connecting webs 16 may for example be formed of an electrically conductive material, such as metal. The structural mats 10 can be made an electrically conductive material, such as metal may be formed, for example, is nobler or less noble than the metal of the insert mat. If an electrolyte is present between the structural mats 10 and the filling bodies 15, for example by immersing the arrangement from FIG. 14 in an electrolyte, or an electrolyte is enclosed between an upper covering layer 11 and a lower covering layer 12 (for example FIG galvanic cell, in particular primary or secondary cell are formed. This can be a battery or a rechargeable battery.

LIST OF REFERENCE NUMBERS

1 upper thin-walled nodal surface

2 lower thin-walled nodal surface

3 interface

3 a end edge

4 side edge

4a bead

5 first bending axis

5 a first bending line

5b fourth bend line

6 second bending axis

6a second bend line

6b fifth bend line

7 third bending axis

7a third bend line

7b sixth bendline

8 holes

8a recess

9 recess / recess / hole / knob / projection

10 structural mat

11 upper cover layer / cover layer

12 lower cover layer / cover layer

13 intermediate layer / intermediate layer

13a sensor / strain sensor

14 textured mat composite

15 packings

16 connecting bridge

20 material web / flat material

30 device

31 first forming station

32 second forming station

33 third forming station n normal / vertical

Claims

claims

A structural mat (10) comprising:

- Upper thin-walled Knotenfiächen (1) at the top of the pattern mat (10) and lower thin-walled nodal surfaces (2) on the underside of the structural mat (10), wherein the upper node surfaces (1) with respect to the lower node surfaces (2) in the thickness direction of Structural mat (10) are spaced,

- Wherein each of the upper node surfaces (1) of three side edges (4) is bordered

- wherein each of the upper node surfaces (1) via three thin-walled connecting surfaces (3) with three lower node surfaces (2) is connected,

- Wherein each of the lower node surfaces (2) of three side edges (4) is bordered and

- Each of the lower node surfaces (2) via three thin-walled connecting surfaces (3) with three upper node surfaces (1) is connected.

Structure mat (10) according to claim 1, characterized in that the side edges (4) of each upper node surface (1) bound each to a substantially equilateral triangle and / or that the side edges (4) of each lower node surface (2) this to each limit a substantially equilateral triangle.

Structural mat (10) according to claim 1 or 2, characterized in that each of the connecting surfaces (3) on one of the side edges (4) of the upper node surface (1) is connected to the upper node surface (1) and on one of the side edges (4). the lower node surface (2) is connected to the lower node surface (2).

Structure mat (10) according to one of the preceding claims, characterized in that each of the connecting surfaces (3) of two end edges (3a) extending from its associated upper node surface (1) to its associated lower node surface (2) is limited in which the terminal edges (3a) or the connecting surfaces (3) are unconnected at their terminal edges (3a) to the other of the connecting surfaces (3) and / or the lower and upper node surfaces (1, 2) facing the respective connecting surface (3a). 3) are not assigned. Structure mat (10) according to one of the preceding claims, characterized in that each of the connecting surfaces (3) is angled relative to the upper node surface (1) and the lower node surface (2) which connects this connecting surface (3).

Structure mat (10) according to one of the preceding claims, characterized in that the side edges (4) of the upper and lower node surface (1, 2) connected via a connecting surface (3) are substantially parallel to each other.

Structural mat (10) according to one of the preceding claims, characterized in that the upper node surfaces (1) and the lower node surfaces (2) triangles and the connecting surfaces (3) are quadrilaterals, wherein for the one upper node surface (1) and lower node surface ( 2) connecting connecting surfaces (3) is true that two of the four corners with two corners of the upper node surface (1) and the other two of the four corners with two corners of the lower node surface (2) match.

Structure mat (10) according to one of the preceding claims, characterized in that at least one upper node surface (1) and / or at least one lower node surface (2) has a recess or an opening (9).

A structural mat composite (14), comprising a first structural mat (10) according to one of the preceding claims, and a second structural mat (10), which is designed according to one of the preceding claims, wherein a plurality of upper node surfaces (1) of the first structural mat (FIG. 10) and a plurality of upper node surfaces (1) of the second structural mat (10) joined together, in particular glued.

A structural mat composite (14) comprising a first structural mat (10) formed according to any one of the preceding claims and a second structural mat (10) formed according to any one of the preceding claims, wherein between the first structural mat (10) and the second Structural mat (10) is arranged a plurality of upper node surfaces (1) of the first and second structural mat (10) and the areas between these node surfaces (1) spanning intermediate layer (13), with the the upper or lower node surfaces (1, 2) of the first structural mat (10) and the upper or lower node surfaces (1, 2) of the second structural mat (10) joined, in particular glued. Sandwich structure comprising an upper cover layer (11), a lower cover layer (12) and at least one structural mat (10) according to any one of claims 1 to 8 or a structural mat composite (14) according to claim 9 or 10, wherein the structural mat (10) or the structured mat composite (14) between the upper cover layer (11) and the lower cover layer (12) edged and the upper cover layer (11) and the lower cover layer (12) with the structural mat (10) or the structural mat composite (14) are joined.

12. A method for producing a structural mat (10), in particular a structural mat (10) according to any one of claims 1 to 8, wherein a thin-walled, in particular sheet-like flat material (20) is provided which has a plurality of holes (8), the form a uniform hole pattern, wherein the flat material (20) by a first forming station (31) is conveyed, wherein the first forming station (31) the flat material (20) on a plurality of to a first bending axis (5) parallel first and fourth bending lines (5a 5b), a second forming station (32) bends the flat material (20) formed in the first forming station (31) at a plurality of second and fifth bending lines (6a, 6b) parallel to a second bending axis (6) and a third forming station (33) the sheet (20) formed in the second forming station (32) bends over a plurality of third and sixth bending lines (7a, 7b) parallel to a third bending axis (7) the first bending axis (5), the second bending axis (6) and the third bending axis (7) are mutually angularly offset, in particular angularly offset by 60 ° to each other, and wherein through each hole (8) a first, second, third, fourth, fifth and sixth bend line extends (5a, 5b; 6a, 6b; 7a, 7b). The method according to claim 12, characterized in that the centroid of each hole (8) of the hole pattern and the centroids of two holes (8) of the hole pattern adjacent to this hole (8) form the corners of an equilateral triangle.

14. The method according to any one of the two preceding claims, characterized in that the holes (8) of the hole pattern have a circular shape, wherein the first and fourth bending line (5 a, 5 b) by a distance equal to the amount of the radius of the circular shape correspond, are spaced apart from each other and / or the second and fifth bending line (6a, 6b) by a distance equal to the amount of the radius of the circular

Form correspond, spaced from each other and / or the third and sixth bending line (7 a, 7 b) by a distance corresponding to the amount of the radius of the circular shape, are spaced from each other. 15. The method according to any one of the three preceding claims, characterized in that the holes (8) of the hole pattern have a hexagonal shape, in particular an isosceles hexagonal shape, wherein the first bending line (5 a) through two corners of the hexagon and the fourth bending line (5b) through two other corners of the hexagon and / or the second bending line (6a) through two corners of the hexagon and the fifth bending line (6b) through two other corners of the hexagon and / or the third bending line (7a) through two corners of the hexagon and the sixth bend line (7b) pass through two other corners of the hexagon.

Method according to one of the four preceding claims, characterized in that the flat material (20) at the fourth bending line (5b) is bent opposite than at the first bending line (5a) and / or the flat material (20) at the fifth bending line (6b ) is oppositely bent than at the second bending line (6a) and / or the flat material (20) at the sixth bending line (7b) is bent opposite than at the third bending line (7a).

Method according to one of the five preceding claims, characterized in that the flat material (20) in the transport direction in the first forming station (31) alternately around a first and fourth bending line (5a, 5b) and / or in the second forming station (32) alternately a second and fifth bending line (6a, 6b) and / or in the third forming station (33) alternately around a third and sixth bending line (7a, 7b) is bent.

Method according to one of the six preceding claims, characterized in that the hole pattern of the section of the infeed station (31) entering the first forming station (31) Material web (20) has a row of holes which is arranged perpendicular to the transport direction of the incoming portion.

Method according to one of the seven preceding claims, characterized in that the material web (20) in at least one of first forming station (31), second forming station (32) and third forming station (33) over its entire width, in particular parallel to a row of holes, simultaneously is transformed.

Device (30) for producing a structural mat (10), in particular a structural mat (10) according to one of claims 1 to 8, by reshaping a material web (20) by means of a plurality of reshaping stations (31, 32, 33), the device comprising:

a first forming station (31), a second forming station (32) and a third forming station (33) arranged to pass through the web (20) in sequence,

wherein the first forming station (31) comprises at least one forming tool adapted to pass through the first forming station (31) web of material (20) parallel to a first bending axis (5) in the web running direction alternately about a first bending line (5 a) and a plastically bend the fourth bending line (5b) to obtain a first zigzag folding,

wherein the second forming station (32) comprises at least one forming tool adapted to pass the web of material (20) passing through the second forming station (32) parallel to a second bending axis (6) which is inclined, in particular at an angle of substantially 60 ° , is arranged to the first bending axis (5), in the web running direction alternately by a second bending line (6a) and a fifth bending line (6b) to obtain a second zigzag folding plastic, wherein the third forming station (33) has at least one forming tool adapted is, by the third forming station (33) passing material web (20) parallel to a third bending axis (7), each obliquely, in particular at an angle of substantially 60 °, to the first and second bending axis (5, 6) is to bend in the web running direction alternately by a third bending line (7a) and a sixth bending line (7b) to obtain a third zigzag folding plastically. Apparatus (30) according to claim 20, characterized in that the at least one forming tool at least one of first, second and third forming station (31, 32, 33) comprises a pair of parallel with respect to their axes of rotation, interlocking toothed rollers, between which the material web (20) is carried out, with the teeth of which the corresponding zigzag folding around the bending lines (5a, 5b, 6a, 6b, 7a, 7b) can be produced.

Device (30) according to claim 21, characterized in that

the angle (a) between the normal (n) of one of the axes of rotation of the toothed rollers of the first forming station (31) and the transport direction of the section of the material web (20) entering the first forming station (31) is 60 ° or approximately 60 °; and or

- The angle (a ') between the normal (n) one of the axes of rotation of the toothed rollers of the first forming station (31) and the transport direction of the first forming station (31) expiring portion of the web (20) is between 63 ° and 80 °; and or

- The angle (b) between the normal (n) one of the axes of rotation of the toothed rollers of the second forming station (32) and the transport direction of the second forming station (32) incoming portion of the web (20) between 15 ° and 35 °; and or

- The angle (b ') between the normal (n) of one of the axes of rotation of the toothed rollers of the second forming station (32) and the transport direction of the second forming station (32) expiring portion of the web (20) between 25 ° and 45 °; and or

the angle (c) between the normal (n) of one of the axes of rotation of the toothed rollers of the third forming station (33) and the transport direction of the section of the material web (20) entering the third forming station (33) is between 26 ° and 43 °; and or

- The angle (c ') between the normal (n) one of the axes of rotation of the toothed rollers of the third forming station (33) and the transport direction of the third forming station (33) expiring portion of the web (20) is 60 ° or approximately 60 ° ,

23. Device (30) according to claim 20, 21 or 22, characterized in that the at least one forming tool at least one of first, second and third forming station (31, 32, 33) a die and a with respect to the die and on stoppable punch, between which the material web (20) is performed, wherein the die and the punch each have a Umformstruktur, wherein the Umformstrukturen of the die and the punch engage when the punch is made with respect to the die, and the Umformstrukturen the Die and punch do not intermesh when the punch is in relation to the die so as to allow the transport of the web (20) relative to the punch and die, with the corresponding zigzag folding around the bend lines (5a, 5b; 6b, 7a, 7b) can be generated by setting the punch in relation to the die.

24. Structured mat composite (14) according to claim 10 or sandwich structure according to claim 11, characterized in that the modulus of elasticity of the material of the first and / or second structural mat (10) is higher, in particular substantially higher, than the elastic modulus of the material of the intermediate layer (13) and for example, the upper and / or lower cover layer (11, 12).

25. Structured mat composite (14) according to claim 10 or sandwich structure according to claim 11, characterized in that the intermediate layer (13) and / or the upper cover layer (11) and / or the lower cover layer (12) has one or more strain sensors (13a) wherein the at least one strain sensor (13a) is configured to measure an areal expansion of the intermediate layer (13) and / or the cover layer (11; 12).

26. Structured mat composite (14) according to claim 10 or sandwich structure according to claim 11, characterized in that the intermediate layer (13) and / or the upper cover layer (11) and / or the lower cover layer (12) an electromechanical transducer material, in particular EAP, or Includes or consists of a piezo film.

27. Structured mat composite (14) according to claim 10 or sandwich structure according to claim

11, characterized in that the material for the cover or intermediate layer (11,

12, 13) is easier plastically deformable than the material of the structural mat (10). Structural mat composite (14) according to claim 10 or sandwich structure according to claim 11, characterized in that two first structural mats (10), which are in particular butt-abutting adjacently disposed side by side, are provided, wherein a Einlagematte is provided, the gap between the two spans first structural mats (10) and thus the two first structural mats (10) connects positively.

Structured mat composite (14) or sandwich structure according to claim 28, characterized in that the insert mat comprises a multiplicity of filling bodies (15) and connecting webs (16) which connect adjacent filling bodies (15), one filling body (15) in each case being arranged in cells of the two first structural mats (10) enclosed cavities is arranged, wherein a cell in each case by an upper or lower Knotenfiäche (1, 2) and the projecting therefrom Verbindungsfiächen (3) is formed.

Structured mat composite (14) or sandwich structure according to claim 29, characterized in that in the cavities of the two first or lower structural mats (10) arranged filler (15) simultaneously in the cells of the second structural mat (10) or two second structural mats (10) enclosed cavities are arranged, wherein a cell in each case from an upper or lower node surface (1, 2) and the projecting therefrom connecting surfaces (3) is formed.

Structured mat composite (14) or sandwich structure according to claim 30, characterized in that the second structural mat (10) spans the gap between the two first structural mats (10) or the two second structural mats (10), in particular butt-abutting, are arranged side by side the gap between the two second structural mats (10) approximately coincides with the gap between the two first structural mats (10).