• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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    • 专利摘要:
    A three-dimensional structural member (100) comprising a first cover layer (102) made of a metallic material, a second cover layer (104) made at least partially of a metallic material, and a core layer (106) made of a foam material and is arranged between the first cover layer (102) and the second cover layer (104).
    公开号:AT15680U1
    申请号:TGM50240/2016U
    申请日:2014-05-23
    公开日:2018-04-15
    发明作者:Pichler Michael；Hafellner Reinhard
    申请人:4A Mfg Gmbh；
    IPC主号:
    专利说明:

    description
    THREE-DIMENSIONAL STRUCTURAL COMPONENT MADE BY MEANS OF A SANDWICH STRUCTURE WITH FOAM CORE BETWEEN METALLIC LAYERS
    The invention relates to three-dimensionally formed structural components. Furthermore, the invention relates to an apparatus for producing a three-dimensionally formed structural component.
    Moreover, the invention relates to methods for producing a three-dimensionally shaped structural component.
    Automobile construction uses steel, for example, for the bodywork and other three-dimensionally formed structural components, because it has excellent mechanical properties. However, steel is relatively heavy. An alternative used instead of steel is aluminum, which is lighter but more expensive. It has also been proposed to use composite materials, such as metal-plastic-metal sandwich structures. However, such conventional sandwich structures suffer from a relatively high weight.
    DE 10 257 396 discloses composite elements containing 0.05 to 2 mm of metal, 0.1 to 2 mm polyisocyanate polyaddition products with DIN EN ISO 6721 storage modulus 60 - 350 MPa at -20 to + 80 ° C and / or at least 1.7 MPa at +160 to + 220 ° C, and 0.05 to 2 mm metal. DE 10 257 396 further discloses the production of body parts for automobiles, heavy goods vehicles or aircraft by shaping these layers in a press.
    DE 103 40 541 discloses composite components having the following layered structure: (i) between 0.05 mm and 2 mm of metal; (ii) between 0.1 mm and 2 mm polyisocyanate polyaddition products which are in support; (iii) between 0.05 mm and 2 mm of metal.
    However, it is still difficult to provide a three-dimensionally shaped structural member which is tough, lightweight, and freely designable with a desired shape.
    It is an object of the invention to provide a three-dimensionally formed structural member which is robust, lightweight and freely formable into a desired shape.
    In order to achieve the above-defined object, there are provided three-dimensionally shaped structural components, an apparatus for manufacturing a three-dimensionally shaped structural component, and methods for producing a three-dimensionally shaped structural component according to the independent claims.
    According to an exemplary embodiment of the invention, a three-dimensional (in particular, a three-dimensionally curved, that is not planar) structural component is provided, which is a first cover layer made of a metallic material (which may be made of one or more metals). a second cover layer made of a metallic material (which may be made of one or more metals) and a core layer partially or wholly made of a foam material (especially a solid state foam material) and between the first cover layer and the first cover layer second cover layer is arranged.
    According to another exemplary embodiment of the invention, there is provided an apparatus for manufacturing a three-dimensional (or molded) structural member, the apparatus comprising a first layer supply unit configured to supply a first cover layer made of a metallic material a second layer supply unit configured to supply a second cover layer made of a metallic material, a foam supply unit adapted to supply a material (such as a foam material or a foam precursor material) between the first cover layer and the first cover layer second cover layer is formed, which forms a core layer which is made partially or completely of foam material and is connected between the first cover layer and the second cover layer (directly, that is physically connected, or indirectly, that is via at least one intermediate structure such as an adhesive
    Layer) to form a cohesive (for example, integral) layer sequence, and comprising a shaping unit (in particular a molding unit or a plastically deforming unit) configured for three-dimensional shaping (in particular molding or plastic deformation) of the resulting (in particular planar) layer sequence (that is, the layer sequence obtained by interposing the core layer between the cover layers and directly or indirectly bonding the core layer to the cover layers) to thereby form the structural member (which is transformed or reshaped compared to the planar layer sequence).
    According to yet another exemplary embodiment of the invention, there is provided a method of manufacturing a three-dimensionally shaped structural member, the method comprising providing a first cover layer made of a metallic material, providing a second cover layer made of a metallic material arranging a core layer made wholly or partly of a foam material between the first cover layer and the second cover layer to thereby form a cohesive (or continuous) layer sequence and a three-dimensional shaping of the resulting (especially pre-planar) Layer sequence (in which all layers may be arranged parallel to each other), thereby forming the structural component.
    In the context of this application, the term "three-dimensionally designed structural part" (in contrast to a planar structure) in particular designate components that are curved in all three spatial directions and / or have structural features in all three spatial directions, thereby substantially These structural components are realized as sandwich components made of multiple bonded layers or sheets In such three-dimensionally shaped structural components, at least a portion of the at least three layers or sheets may have a common curvature, that is, these In addition, such three-dimensional structural components can have a constant thickness along their entire extent, whereby technically unavoidable tolerances are of course possible.
    In the context of this application, the term "cover layer" may refer in particular to a layer or a sheet which covers the core layer to shield the latter from an environment, but does not necessarily form a surface layer.
    In the context of this application, the term "core layer" may in particular refer to an embedded layer having a central position within the layer sequence forming the three-dimensionally designed structural component but will always be covered on both of their major surfaces by means of a respective one of the cover layers, as will be understood by one skilled in the art, that in one embodiment it is not excluded that there may be one or more additional ones However, in other embodiments, the core layer may directly contact the cover layers without any additional layer therebetween.
    In the context of this application, the term "rigid" may in particular denote that the respective metallic layer may be a solid which is capable of withstanding mechanical forces or stresses without losing its structural shape by forming the cladding layers of metals that are rigid materials.
    In the context of this application, the term "foam" may refer in particular to a substance formed by encapsulation of gas pockets in a solid state matrix Thus, the foam layer may be a solid state layer, however, having gas inclusions therein A distribution of solid state foams In a closed-cell foam, the gas forms discrete pockets, each of which is completely surrounded by the solid material, and in an open-cell foam, the gas pockets are bonded together The three-dimensionally formed structural component and can at the same time make a contribution to the mechanical stability.The solid state foam may have gas inclusions, which amount of at least 30%, in particular of at least 70%, more particularly of m at least 85% of the total volume of the core layer.
    According to an exemplary embodiment, a sandwich layer stack is provided which is formed of two mechanically robust metallic cover layers and the lightweight solid state foam material (such as plastic hard foam) therebetween. Such a sandwich layer sequence is both mechanically stable and lightweight, and also inexpensive to manufacture. Furthermore, most importantly, it has been found that such a sandwich layer sequence can be readily reshaped or formed by plastic deformation, even without heating, thanks to the material properties of the metallic cover layers. Therefore, there is almost no limitation to redesigning such a planar sandwich layer sequence into a structural member of any desired steric configuration.
    In the following, further exemplary embodiments of the three-dimensionally shaped structural components, the apparatus for producing a three-dimensional structural component, and the method for producing a three-dimensional structural component will be described.
    In one embodiment, it is particularly advantageous if the structural component is formed so that it is temperature-resistant at a temperature of at least 180 ° C. Such material selection allows the structural member to withstand, in particular, a painting procedure that is often performed in modern applications at temperatures of about 180 ° C. Further, the ability of the structural member to withstand temperatures of 180 ° C is also highly advantageous when the structural member is configured as an electro-mechanical component, as modern electro-mechanical components are operated at higher and higher power levels at which a significant amount of heat can be dissipated , Furthermore, such electromechanical components can be placed close to other electronic components that also generate heat. Therefore, it is advantageous that the materials of the structural component are selected to be temperature resistant up to at least 180 ° C.
    In one embodiment, one or both of the metallic cover layers may be made of an alloy, in particular of a sufficiently soft alloy. For example, a steel type or an aluminum type suitable for cold forming may be used. The implemented metallic material should not have a pronounced elastic limit or yield strength. The implemented metallic material should have a sufficiently high elongation at break, in particular greater than 20%, more particularly greater than 30%.
    Steel materials that meet the above requirements are soft steels for cold forming according to DIN EN 10130 (DC01, DC03, DC04, DC05, DC06, DC07). Such steel materials may preferably be zinc coated. It is also possible to use steel made by cold rolling according to DIN EN 10202 (TS230, TS245, TS260, TS275, TS290). Stainless steel suitable for deep drawing can also be used (for example 1.4301).
    It is also possible to implement malleable aluminum alloys according to DIN EN 573 (alloys of the 2000 series, alloys of the 5000 series, alloys of the 6000 series, AlMgSi 0.5, AlMgSi 1, AI 99.5).
    In one embodiment, the core layer consists exclusively of foam material, in particular of solid-state foam material. Therefore, it is sufficient that the core layer is made of only one material, that is, the foam. Thus, no support structure (such as a solid block or full body) is required to support or support the foam material in addition to the cover layers. This has significant advantages in terms of the ability of reshaping the sandwich layer stack to alter and adjust its three-dimensional shape or appearance, as well as the lightweight properties of the sandwich layer stack.
    In one embodiment, at least one of the first metallic cover layer and the second metallic cover layer is made of aluminum or steel. Steel has the particular advantage of having a high mechanical robustness, while also being favorable. Aluminum has the significant advantage of being very lightweight so that the lightweight property of the entire sandwich layer stack is further promoted by the selection of aluminum. Both steel and aluminum exhibit high rigidity and can be easily reshaped, making them particularly suitable for structural components according to embodiments of the invention.
    In one embodiment, the core layer is made of a plastic foam, that is a foam of a plastic material. Experiments by the present inventors have shown that a wide range of plastic foam materials are suitable for bonding between two metal topcoats.
    In particular, the plastic foam may be polystyrene foam. Polystyrene foam is very cheap, highly suitable for reshaping and has a low density. In particular, EPS foam (expanded polystyrene) or expanded mixtures of polystyrene offer a wide range of physical properties to meet the challenges of core layers for 3D structural components. These capabilities, combined with appropriate engineering design considerations, provide the design flexibility required to create truly lightweight and cost-efficient bridging of two facings. In one embodiment, the polystyrene foam may be provided with one or more additives to adjust the desired mechanical properties. Expanded polystyrene (EPS) is a versatile, lightweight, rigid plastic foam insulation material that can be made from solid particles of polystyrene, which end product can be made from fine spherical cells that have a large amount of air, for example 90 to 98 vol. % Air.
    Specifically, the plastic foam can be made from one or more thermoplastic polyesters, especially polyethylene terephthalate (PET) foam. PET has the particular advantage of being able to withstand high temperatures of 180 ° C and more, thereby enabling painting procedures to be carried out after completing the molding or forming of the three-dimensional structural component. This is particularly advantageous in connection with the formation of automotive components in which painting of external surfaces of certain structural components is advantageous.
    In particular, the plastic foam may be polymethacrylimide (PMI) foam. PMI is also high temperature resistant so as to be compatible with painting procedures after fabrication of the 3D structural member as just described.
    In particular, the plastic foam may be polyisocyanate-based foam. Polyurethane is also resistant to high temperatures, and polyurethane also has a very good chemical resistance. In one embodiment, the core layer has a density in a range between about 35 kg / m 3 and about 750 kg / m 3, in particular in a range between about 75 kg / m 3 and 200 kg / m 3. The ranges given are particularly suitable in view of the following technical considerations. If the density becomes too small, the quality of the sandwich structure produced is deteriorated and the ruggedness of the structural component suffers. However, if the density becomes too large, the structural component becomes too heavy and too expensive.
    In one embodiment, the structural component on adhesive material which adheres the foam material with the first cover layer and / or adheres the foam material with the second cover layer. Accordingly, the manufacturing apparatus may include an adhesive material supply unit that may be configured to deliver adhesive material between the foam material and the first cover layer and / or between the foam material and the second cover layer to thereby adhere the foam material to the first cover layer and / or or to adhere the foam material to the second cover layer. Adhesion of the foam material to at least one of the cover layers further enhances the mechanical robustness of the structural component.
    In one embodiment, the adhesive material is a hot melt adhesive. Hot melt adhesive or hot glue is a form of (for example, thermoplastic) adhesive that is sticky when hot and quickly solidifies on cooling. Hot melt adhesives can be applied by dipping or spraying, as a continuous layer or in the form of particles such as granules. Hot melt adhesive has the advantage of thermal stability and structural flexibility, which is a significant advantage during the reshaping procedure.
    In one embodiment, the adhesive material has a first adhesive layer between the first cover layer and the core layer and / or has a second adhesive layer between the second cover layer and the core layer. Therefore, ready-made adhesive layers can be sandwiched between the foam core layer and the two cover layers. This has the advantage that a continuous bonding performance can be achieved, and that the procedure can also be easily applied on an industrial scale. Alternatively, the adhesive material may be supplied between the material of the foam layer and the material of the cover layers as granules, powder or even in liquid form.
    In one embodiment, the adhesive material has a melting point above about 80 ° C, especially above about 100 ° C. Therefore, the adhesive material is solid at structural component operating temperatures (that is, fixed at maximum temperatures during normal structural component use), typically below 70 ° C. At the same time, even a moderate heating of the adhesive material allows it to stick between the foam material and the cover layers.
    In one embodiment, the adhesive material has a melting point above about 180 ° C, especially above about 200 ° C, more particularly above about 250 ° C. Therefore, the adhesive material is strong even at temperatures that usually apply a varnish. Therefore, compatibility with a painting process and mechanical robustness of the composite material can be combined.
    Examples of useful hot melt adhesives are polyethylene (PE), polypropylene (PP), copolyester, copolyamide or polyurethane (PU) based materials.
    In one embodiment, the thickness of the structural member is in a range between about 0.2 mm and about 10 mm, in particular in a range between about 0.5 mm and about 8 mm. For example, the total thickness over the entire extension of the structural component may be between 1 mm and 6 mm. If the thickness becomes much smaller, the mechanical ruggedness of the structural member may be insufficient for automotive applications or the like. When the thickness becomes too large, it becomes difficult to reshape the sandwich layer stack into a three-dimensionally shaped structural member because the internal stress of the bonded layers becomes too large. The ranges indicated have proven to be an appropriate balance between these technical considerations.
    In one embodiment, the thickness of at least one of the first cover layer and the second cover layer is in a range between about 0.01 mm and about 1.5 mm, in particular in a range between about 0.08 mm and about 0.8 mm. Therefore, relatively small thicknesses of the cover layers, which are usually made of metallic material forth, sufficient to provide sufficient mechanical stability. However, the thickness of the metallic layers can be kept so small that the total density of the sandwich composite structure is sufficiently small. The structural component can therefore be formed by means of a lightweight construction.
    In one embodiment, the thickness of the core layer of solid state foam is in a range between about 0.15 mm and about 8 mm. For many applications, it is advantageous that the core layer has a greater thickness than the cover layers.
    In one embodiment, the structural component has a lacquer layer on the upper side of at least one of the first cover layer and the second cover layer. The option of painting surface layers is important for structural components used as cover panels for automotive applications or the like. However, painting procedures usually involve heating to temperatures of about 180 ° C, typically for a period of 30 minutes. The resizable sandwich layer sequence according to exemplary embodiments of the invention meets the requirements of such painting procedures.
    In one embodiment, at least one of the first cover layer and the second cover layer is a surface layer of the three-dimensionally shaped structural component. In particular, the term "surface layer" may refer to the highest or lowest area of the layer sequence or structural component that is directly exposed to the environment, such as the atmosphere.
    In one embodiment, at least one of the first cover layer and the second cover layer is a rigid layer. In particular, it may have a metallic rigidity, that is stiffness properties of metals. The corresponding rigid layer may be unable to be bent or flexibly or elastically deformed during normal use.
    In one embodiment, the structural member is configured as one of a group consisting of an automotive structural member, an aircraft structural member, a railroad structural member, and a marine structural member. It may therefore be a part of a cover panel or of a housing or a reinforcing element of an automobile, an aircraft or a train. However, other applications are possible.
    In one embodiment, the shaping is performed by cold forming, in particular by deep drawing. In particular, cold working may refer to redesigning a planar sandwich layer sequence into the three-dimensionally designed structural component without the application of additional heat. Applicable cold forming techniques include pressing, crimping, bending, drawing and shearing. Drawing can be referred to as a metal processing method that uses tensile forces to stretch metal. Deep drawing may be a conversion process for a sheet in which a sheet formed by the sandwich structure described above is drawn in a mold by the mechanical action of a punch or the like. It is therefore a form transformation process with material preservation. Deep drawing may in particular result in a structural component in which the depth of the drawn part exceeds its diameter.
    In one embodiment, the manufacturing method further comprises pressing the core layer (and optionally adhesive material to adhere the core layer to one or both of the cover layers) between the first cover layer and the second cover layer by means of heatable (eg, heated by a temperature adjustment unit) compacts , in particular rollers or rollers or drums (which can be moved longitudinally with respect to the layers and and / or which can be rotated). In this context, the individual layers (or precursors thereof, for example a granulate which later forms such a layer) are fed to rolls or similar compacts which are at an elevated temperature compared to the ambient temperature. A combination of the mechanical pressing force and the thermal energy bonding effect converts the individual layers into an inseparable sandwich layer sequence.
    In one embodiment, the foam material is supplied to the compacts as already finished cut mold layer. For example, the foam may be provided as a three-dimensional block. Using a cutting tool, such as a knife or the like, the block can be cut into individual layers or slices of foam material (for example having a thickness in a range between 1 mm and 8 mm, with a surface area of a major surface of the foam layer facing the foam) Example, in the range between 1 dm2 and 10 dm2 can be). Such a cut foam layer may then be interposed directly between the cover layers to thereby form the composite structure. This procedure can ensure that the foam layer has a continuously consistent quality and is free from voids or the like.
    In an alternative embodiment, the foam material is supplied to the compacts as a foam precursor, in particular as one of the group consisting of a precursor of granules, a precursor of powder and a liquid precursor, which is converted into a foam layer by means of the heated compacts , In such an embodiment, the foam or foam layer is formed only while the heated compacts act on the precursor web material. This embodiment is particularly suitable for the production of structural components on an industrial scale, because the precursor pulp material (such as a granulate) can be supplied continuously from a large container or via a conveyor belt.
    In one embodiment, the method may further comprise adhering the foam material to the first cover layer and / or adhering the foam material to the second cover layer by means of an adhesive material. Although the use of adhesive material is optional, this allows a particularly robust structural component to be formed because the adhesive strength is increased by the separate provision of adhesive material as a bonding agent.
    In one embodiment, the adhesive material is supplied to the compacts as a ready-formed adhesive layer. Such a continuous adhesive layer allows the provision of an adhesion force of a continuous constant quality free of voids or the like.
    In one embodiment, the adhesive material is supplied to the compacts as adhesive particles, in particular as adhesive powder or granules, which is converted by means of the heated compacts in the adhesive layer. In such an embodiment, the adhesive layer is formed only during the actual layer connection procedure. This embodiment is particularly suitable for the production of the structural components on an industrial scale, since the adhesive substance can be supplied continuously from a large container or via a conveyor belt.
    In one embodiment, the compacts are heated to a temperature in a range between about 100 ° C and about 250 ° C, more preferably in a range between about 130 ° C and about 180 ° C. It has been found that these temperatures are suitable for efficiently promoting the bonding process while minimizing the thermal impact on the sandwich layer sequence.
    In one embodiment, at least one of the first cover layer and the second cover layer is provided by unrolling (ie, unrolling) thereof from a feed roll or swell roll. The cover layers, which are preferably made of thin metal sheets, can be provided with such a small thickness that they can be rolled up on the roll. Therefore, a continuous procedure can be performed which allows the production of the sandwich layer sequence quickly and at a low cost.
    In one embodiment, the method comprises applying a lacquer layer on top of at least one of the first cover layer and the second cover layer. By means of a suitable selection of the materials of the cover layers and the core layer (and optionally of adhesive material therebetween), the high temperature requirements of painting an outer surface of the three-dimensionally shaped structural component can be achieved.
    In one embodiment, the lacquer layer is applied to an exposed surface of the finished reshaped sandwich layer sequence at a temperature in the range between about 120 ° and about 250 ° C, more preferably in the range between about 170 ° C and about 200 ° C. A typical temperature of such a painting procedure involves the application of 180 ° C for 30 minutes.
    Within the context of this application, three-dimensionally designed structural components are disclosed. It should be noted, however, that the entire disclosure of this application can be applied to any structural components in other embodiments of the invention, regardless of whether they are three-dimensional or planar. Therefore, the following aspects of the invention are also disclosed: 1. Aspect: A structural component (which may be planar), comprising: a first cover layer made of a metallic material; a second cover layer made of a metallic material; A core layer made of a foam material and disposed between the first cover layer and the second cover layer.
    2. Aspect: The structural component of aspect 1, wherein the core layer consists exclusively of the foam material.
    3. Aspect: The structural component of aspect 1 or 2, wherein at least one of the first cover layer and the second cover layer is made of aluminum or steel.
    4. Aspect: The structural component of any one of aspects 1 to 3, wherein the core layer is made of a plastic foam.
    5. Aspect: The structural component of aspect 4, wherein the plastic foam comprises polystyrene or polystyrene mixtures.
    6. Aspect: The structural component of aspect 4, wherein the plastic foam is a thermoplastic polyester, in particular polyethylene terephthalate foam.
    7. Aspect: The structural component of aspect 4, wherein the plastic foam is polymethacrylic-lime foam.
    8. Aspect: The structural component of aspect 4, wherein the plastic foam is a polyiso-cyanate-based foam, in particular polyurethane.
    9. Aspect: The structural member of any of Aspects 1 to 8, wherein the core layer has a density in a range between 35 kg / m 3 and 750 kg / m 3, in particular in a range between 75 kg / m 3 and 200 kg / m 3 Has.
    10. Aspect: The structural member of any one of aspects 1 to 9, comprising adhesive material that bonds the foam material to the first cover layer and / or bonds the foam material to the second cover layer.
    11. Aspect: The structural component of aspect 10, wherein the adhesive material is a hot melt adhesive.
    12. Aspect: The structural component of aspect 10 or 11, wherein the adhesive material comprises a first adhesive layer between the first cover layer and the core layer and / or has a second adhesive layer between the second cover layer and the core layer.
    13. Aspect: The structural member of any one of aspects 10 to 12, wherein the adhesive material has a melting point above 80 ° C, especially above 100 ° C.
    14. Aspect: The structural member of any of Aspects 1 to 13, wherein the thickness of the structural member is in a range between 0.2 mm and 10 mm, in particular in a range between 0.5 mm and 8 mm, more particularly in a range between 1 mm and 6 mm.
    15. Aspect: The structural member of any of Aspects 1 to 14, wherein the thickness of at least one of the first cover layer and the second cover layer is in a range between 0.01 mm and 1.5 mm, in particular in a range between 0 , 08 mm and 0.8 mm, is.
    16. Aspect: The structural member of any one of aspects 1 to 15, comprising a resist layer, in particular forming a surface layer, on top of at least one of the first cover layer and the second cover layer.
    17. Aspect: The structural member of any one of Aspects 1 to 16, wherein at least one of the first cover layer and the second cover layer is a surface layer.
    18. Aspect: The structural component of any one of aspects 1 to 17, wherein at least one of the first cover layer and the second cover layer is a rigid layer.
    19. Aspect: The structural member of any one of Aspects 1 to 18 configured as one of the group consisting of an automotive structural member, an aircraft structural member, a railroad structural member and a ship structural member.
    20. Aspect: An apparatus for manufacturing a structural component, the apparatus comprising: a first layer supply unit configured to supply a first cover layer made of a metallic material; A second layer supply unit configured to supply a second cover layer made of a metallic material; A foam delivery unit configured to supply a material between the first cover layer and the second cover layer that forms a core layer that is at least partially made of a foam material and that is bonded between the first cover layer and the second cover layer to form a cohesive layer sequence.
    21. Aspect: The apparatus of aspect 20, comprising an adhesive material delivery unit configured to supply adhesive material between the foam material and the first cover layer and between the foam material and the second cover layer to thereby transfer the foam material to the first cover layer Adhere cover layer and stick the foam material to the second cover layer.
    22. Aspect: A method of manufacturing a structural component, the method comprising: providing a first cover layer made of a metallic material; Providing a second cover layer made of a metallic material; Arranging a core layer at least partially made of a foam material between the first cover layer and the second cover layer to thereby form a cohesive layer sequence.
    23. Aspect: The method of aspect 22, wherein the method further comprises pressing the core layer, and optionally adhesive material, between the first cover layer and the second cover layer by means of heated compacts, in particular rollers.
    24. Aspect: The method of aspect 23, wherein the foam material is supplied to the compacts as a finished cut solid state foam layer.
    25. Aspect: The method of aspect 23, wherein the foam material is supplied to the compacts as foam precursor material, in particular granules or powder, which is converted into a foam layer by means of the heated compacts.
    26. Aspect: The method of any one of aspects 22 to 25, further comprising adhering the foam material to the first cover layer and adhering the foam material to the second cover layer by means of adhesive material.
    [0089] 27. Aspect: The method of Aspects 23 and 26, wherein the adhesive material is supplied to the compacts as a finished formed adhesive layer.
    28. Aspect: The method of aspect 26 or 27, wherein the adhesive material is supplied to the compacts as adhesive particles, in particular as adhesive powder or granules, which are converted into the adhesive layer by means of the heated compacts.
    29. Aspect: The method of any one of aspects 23 to 28, wherein the compacts are heated to a temperature in a range between 100 ° C and 250 ° C, especially in a range between 130 ° C and 180 ° C ,
    30. Aspect: The method of any one of aspects 22 to 29, wherein at least one of the first cover layer and the second cover layer is provided by unrolling from a roll.
    31. Aspect: The method of any one of aspects 22 to 30, comprising applying a lacquer layer on an upper side of at least one of the first cover layer and the second cover layer, in particular after the three-dimensional shaping.
    32. Aspect: The method of aspect 31, wherein the lacquer layer is applied at a temperature in the range between 120 ° C and 250 ° C, especially in the range between 170 ° C and 200 ° C.
    According to any of aspects 1 to 32, the structural member may be temperature resistant at a temperature of 180 ° C.
    The aspects defined above and further aspects of the invention will be described with reference to FIGS
    Embodiments will become apparent, which are to be described below, and under
    Reference to these embodiments will be explained.
    The invention will be described in further detail below with reference to embodiments to which the invention is not limited.
    FIG. 1 shows a cross-sectional view of a three-dimensionally designed one
    Structural component according to an exemplary embodiment of the invention.
    FIG. 2 illustrates a first part of an apparatus for manufacturing a three-dimensionally shaped structural component according to an exemplary embodiment of the invention in which an integral planar sandwich layer stack is formed.
    Figure 3 illustrates a second part of an apparatus for manufacturing a three-dimensionally shaped structural component according to an exemplary embodiment of the invention, in which the finished integral planar sandwich layer stack is reshaped or formed by deep drawing.
    FIG. 4 shows the composition of a sandwich layer stack as a semifinished product for a three-dimensional structural component according to an exemplary embodiment of the invention.
    FIG. 5 illustrates a thermoforming mold for reshaping a flat two-dimensional sandwich layer stack into a three-dimensional structural component according to an exemplary embodiment of the invention.
    FIG. 6 shows a structural component according to an exemplary embodiment of the invention, which is formed by means of the deep-drawing mold of FIG. 5.
    Figure 7 and Figure 8 show schematically parts of apparatus for the manufacture of
    Structural components according to exemplary embodiments of the invention.
    FIG. 9 shows a car as well as two three-dimensionally designed structural components thereof manufactured according to exemplary embodiments of the invention.
    FIG. 10 shows various three-dimensional structural components that may be manufactured according to exemplary embodiments of the invention.
    FIG. 11 shows a rear wall of an automobile as an example of a three-dimensional structural component according to an exemplary embodiment of the invention.
    FIG. 12 is a graph illustrating advantages in terms of weight and manufacturing cost of structural components according to exemplary embodiments of the invention as compared to conventional technologies.
    The illustrations in the drawings are schematic. In different drawings, similar or identical elements are given the same reference numerals.
    FIG. 1 illustrates a cross-sectional view of a three-dimensional structural component 100 according to an exemplary embodiment of the invention.
    The three-dimensional structural member 100 has a first cover layer 102 made of a 0.1 mm thick steel sheet as a rigid material, a second cover layer 104 made of a 0.1 mm thick steel sheet as a rigid material and a bottom surface layer, and a core layer 106 made of a 6 mm-thick solid state polystyrene foam material having a density of 150 kg / m 3 and disposed between the first cover layer 102 and the second cover layer 104. Further, a first adhesive layer 108 of hot melt adhesive is sandwiched between the first cover layer 102 and the core layer 106 to thereby bond the first cover layer 102 to the core layer 106. Likewise, a second adhesive layer 110 of hot melt adhesive is sandwiched between the second cap layer 104 and the core layer 106 to thereby bond the second cap layer 104 to the core layer 106. On top of the first cover layer 102, a resist layer 112 is applied to form a second surface layer of the integral three-dimensional reformed layer sequence 112, 102, 108, 106, 110, 104.
    In order to obtain the three-dimensionally formed structural member 100, the originally planar layer sequence 102, 108, 106, 110, 104 has been sterically deformed by means of a deep-drawing die or the like to thereby form the stereoscopic or three-dimensionally shaped structural member 100. Advantageously, the lacquer layer 112 is applied directly to the first cover layer 102 after the conversion procedure to ensure that the lacquer layer 112 is not adversely affected by the remodeling process.
    The metallic cover layers 102, 104 are substantially undeformable (under normal conditions) and rigid and provide the structural member 100 with mechanical stability. On the other hand, the core layer 106 made of the low-density polystyrene foam in the solid state (for example, 150 kg / m 3) provides the structural member 100 with the required thickness and required volume, while keeping the structural member 100 lightweight. The material of the core layer 106 is also favorable and has, in combination with the cover layers 102, 104, suitable properties to accept substantially all types of desired structural transformations of the semifinished product in the form of the previously planar layer sequence 102, 108, 106, 110, 104 allow. At the same time, a high degree of rigidity as well as pronounced damping properties can be obtained with the structural member 100. The three-dimensional shape of the structural member 100 can be freely adjusted to correspond to its technical function, for example, for its use as a panel for automotive applications. As can be seen from Figure 1, the redesign procedure maintains substantially the entire thickness d of the structural member 100 relatively constant, as well as the relative thicknesses of the individual layers 102, 108, 106, 110, 104 thereof. Further, the structural component 100 meets safety requirements, for example, for applications related to aerospace technology and rail transport. Furthermore, the structural component 100 is also temperature-resistant over a wide range.
    Figure 2 illustrates a first part 200 of an apparatus for manufacturing a three-dimensionally shaped structural component 100 according to an exemplary embodiment of the invention, such as that shown in Figure 1, in which an integral planar sandwich layer stack 102, 108, 106, 110, 104 is formed.
    As can be seen from Figure 2, the multiple components constituting the structural member 100 are supplied in different shapes in an input stage 260 of the first part 200 of the manufacturing apparatus.
    A first layer supply unit 202 is shown only schematically in FIG. 2 and is configured to supply a first metal sheet as the first cover layer 102. Although not shown in FIG. 2, the first cover layer 102 may be unrolled from a feed roll to thereby enable continuous production of structural components. In view of the small thickness of the first cover layer 102 of, for example, 0.1 mm, the metal sheet material can be stored in a compact manner on the roll. A second layer feed unit 204 is also shown schematically in FIG. 2 and configured to feed a second metal sheet as the second cover layer 104. Similarly, the second cover layer 104 may be unrolled from another feed roll to thereby permit continuous production of structural components. In view of the small thickness of the second cover layer 104 of, for example, 0.1 mm, this metal sheet material can also be stored in a compact manner on the other feed roller.
    Between the first layer supply unit 202 and the second layer supply unit 204, a foam precursor supply unit is arranged to supply a granule 262 of a foam precursor along the production line of FIG. More specifically, a feed unit 206 shown schematically conveys the granules 262 toward a tapered well 208. The granules 262 are configured so that when between the first cover layer 102 and the second cover layer 104 at an elevated temperature of, for example, 120 ° C and at an elevated pressure of, for example, a few bars, it is converted into a continuous foam layer, i.e., foam core layer 106. Also, the described supply of granules 262 and its conversion to a continuous foam layer is a continuous process involving the continuous production of Structural components with a high yield and efficiency allows.
    In order to additionally promote the adhesion between the core layer 106 and the metallic cover layers 102, 104, two adhesive layers 108, 110 are supplied by means of appropriate adhesive material supply units 210, 212. Since the adhesive layers 108, 110 in the present embodiments are made of hot melt adhesive (other adhesive materials may be used as well), they may also be rolled up on a roll. The adhesive layers 108, 110 may optionally be provided with a non-adhesive film to avoid adhesion between different portions of the respective adhesive layers 108, 110 while still being rolled up on the rollers (not shown). The first adhesive layer 108 is fed between the first cover layer 102 and the foam material, whereas the second adhesive layer 110 is fed between the foam material and the second cover layer 104. The provision of adhesive material is optional, but further increases the mechanical strength of the formed three-dimensional structural component 100.
    The hot melt adhesive becomes tacky when heated to an elevated temperature T> in an intermediate stage 270 downstream of the first stage 260 in a process flow. Here, the layers 102, 108, 106, 110, 104 are compressed and glued together between heated rollers 220, 222 of the intermediate stage 270. The heated rollers 220, 222 perform some tasks simultaneously. First, they convert the granules 262 into a continuous foam core layer 106. Second, they heat the hot melt adhesive to a temperature where it becomes tacky and sticks to the adjacent layers. Third, this compresses the layers 102, 108, 106, 110, 104 to thereby form a uniform integrally formed layer sequence with individual layers substantially inseparable from each other.
    At an output stage 280 of the first part 200 downstream of the intermediate stage 270 in the process flow, the planar layer sequence 102, 108, 106, 110, 104 is cooled down and can be further processed, for example cut into pieces of desired shape and size, before being fed to a second part 300 of the manufacturing apparatus, as shown in FIG. At the end of the treatment by means of the first part 200, an integral five-layer sandwich layer stack 150 is obtained.
    FIG. 3 illustrates the second part 300 of the apparatus for producing a three-dimensional structural component 100 according to an exemplary embodiment of the invention, in which the planar sandwich layer stack 102, 108, 106, 110, 104 formed is remodulated by means of deep drawing.
    FIG. 3 therefore shows a thermoforming apparatus as the second part 300. A cut piece 320 of the planar layer sequence 102, 108, 106, 110, 104, as produced according to FIG. 2, is introduced into a housing 302 of the thermoforming apparatus. A first thermoforming tool 304 is disposed in the second part 300 below the part 320. The first thermoforming tool 304 has a first hold-down clamp 306 and has a first shape 308. The second thermoforming tool 310 has a first hold-down clamp 312 and has a second shape 314.
    To reshape the piece 320 into the structural member 100, the thermoforming dies 304, 310 are moved relative to each other until the hold-down clamps 306, 312 collectively engage a lateral portion of the piece 320. Therefore, the lateral portion of the piece 320 is spatially fixed by clamping before the actual redesigning procedure is performed. Without the application of heat, the clamped piece 320 is then reshaped as a result of reciprocal movement of the molds 308, 314 for further mutual advancement by deep drawing so that the planar piece 320 is redesigned according to the cooperating surface shapes of the molds 308, 314. This procedure can be performed at room temperature, that is, a cold forming or redesigning procedure.
    After completing this procedure, the remodeled piece 320 is removed from the second part 300 of the manufacturing apparatus and may be subjected to a paint application procedure (not shown). This involves applying a high temperature of, for example, 180 ° C for 30 minutes, and forms the resist layer 112 on top of the first cover layer 102. Then, the fabrication of the structural member 100 is completed.
    FIG. 4 shows the composition of the sandwich layer stack 150 as one
    Precursor material for a three-dimensional designed structural component 100 according to an exemplary embodiment of the invention.
    According to FIG. 4 and more generally in any desired embodiment of the invention, the thickness di of the foam core layer 106 may be greater than the thicknesses d2, d3 of the cover layers 102, 104. For example, the thicknesses d2, d3 of the cover layers 102, 104 may be greater than the thicknesses d4, d5 of the optional adhesive layers 108, 110.
    There is a high freedom regarding the selection of materials for the individual layers. The cover layers 102, 104 are formed of a metallic material such as steel or aluminum. The core layer 106 may be made of or based on EPS, polyphenyl ether (PPE), PET, PMI and / or polyurethane (PU) based plastic foam, provided that the density of such foams is sufficiently low, preferably less than 750 kg / m3 to meet the requirements of the structural member 100 for a light weight. Preferably, the adhesive layers 108, 110 are made from a hot melt adhesive that may be provided in the form of films, powder, granules, or the like.
    FIG. 5 illustrates a deep-drawing tool 500 for use during the redesigning of a sandwich layer stack 150 into a three-dimensionally designed structural component 100 according to an exemplary embodiment of the invention. FIG. 6 illustrates a structural component 100 according to an exemplary embodiment of the invention by means of the deep-drawing tool 500 is formed by Figure 5. It can be seen from FIG. 5 and FIG. 6 that the shape of the structural component 600 is defined by means of the shape of the mold 500.
    By applying a cold forming technique (such as deep drawing or stretch drawing), stretching by a large percentage of, for example, up to 40% or more is possible. It is also possible to form structures with small radii. Even thickness distributions can be precisely adjusted.
    FIG. 7 schematically shows a part 200 of an apparatus for producing structural components 100 according to an exemplary embodiment of the invention.
    Referring also to FIG. 2, the part 200 shown in FIG. 7 has a first swelling roll 700 as the layer supply unit 202 on which metal sheet material is rolled up as a base for the first cover layer 102 and for producing the structural components can be unrolled. Similarly, part 200 has a second swelling roll 702 as the second layer delivery unit 204, on which metal sheet material is rolled up as a base for the second cover layer 104, and can be unrolled to make the structural components. In addition, part 200 has a third swelling roll 704 as the first adhesive layer applying unit 210 on which a layer of hot melt adhesive as a base for the first adhesive layer 108 (which may or may not be applied to a backing film avoiding self-adhesion of the hot melt adhesive) is rolled up is and can be unrolled to produce the structural components. Further, part 200 has a fourth swelling roll 706 as the second adhesion layer applying unit 212 on which another layer of hot melt adhesive as a base for the second adhesive layer 110 (which may or may not be applied to a backing film to prevent self-adhesion of the hot melt adhesive) is rolled up and can be unrolled to produce the structural components.
    In addition, the embodiment of Figure 7 provides a continuous layer of a ready made plastic foam layer which serves as the core layer 106 and is rolled up and can be unrolled from a fifth swelling roll 712 to make the structural components. After completing the fabrication of the planar layer sequence 102, 108, 106, 110, 104 between the heatable rolls 220, 222, the sandwich layer sequence 150 so formed may be rolled on a sixth roll 708, which may be referred to as a target roll.
    The manufacturing method may be controlled by a central control unit 710, which may be a microprocessor or a central control unit (CPU). The control unit 710 may coordinate the cooperation of the sections 260, 270, 280.
    FIG. 8 schematically shows another first part 200 of an apparatus for manufacturing structural components 100 according to exemplary embodiments of the invention.
    The embodiment of Figure 8 differs from the embodiment of Figure 7 in that the precursors or semifinished products for forming the sandwich layer sequence 150 are respectively cut layers, as can be seen from the left side of Figure 8. The cover layers 102, 104 are provided as ready-cut rectangular metal sheets. The core foam layer 106 is a finished rectangular layer that can be cut after unrolling from a swelling roll and before feeding to the heated processing rolls 220,222. The optional but most advantageous adhesive layers 108, 110 may be continuous or discontinuous layers of hot melt adhesive cut from a swell roll. The pieces of sandwich layer sequence 150 so produced may be stored one above the other, for example on a support 800, such as a pallet.
    FIG. 9 shows a car 900 and two three-dimensional structural components 920, 940 thereof, which are manufactured according to exemplary embodiments of the invention. Structural member 920 is a fire barrier or end wall, which in the present embodiment has a thickness of 3mm and a weight of 1.6kg. The structural member 940 is a rear seatback having a thickness of 8 mm and a weight of 1.8 kg. FIG. 10 shows various three-dimensional structural components that may be manufactured according to exemplary embodiments of the invention. Among these structural components, the fire protection wall 920 and the rear seat back 940 may also be recognized.
    FIG. 11 shows an image of the rear wall 940 of an automobile as an example of a three-dimensional structural component according to an exemplary embodiment of the invention. The rear wall 940 is based on aluminum facings 1.2 mm thick. Compared with a conventional construction, the rear wall 940 has the same stiffness, the same overall thickness, but a lower weight, and can be manufactured at a lower cost. The weight can be reduced by about 30%, and the cost can be reduced by about 25%. The backplane 940 also meets electrical charge protection requirements and meets requirements for long-term usability.
    FIG. 12 shows a diagram 1200 illustrating advantages in terms of weight (plotted along an abscissa 1220) and manufacturing cost (plotted along an ordinate 1240) of structural components according to exemplary embodiments as compared to conventional technologies. As can be seen from graph 1200, the composite multilayer architecture according to exemplary embodiments of the invention results in high stiffness, low weight, good damping properties, and economical manufacturability.
    It should be noted that the term "comprising" does not exclude other elements or steps and that the "on" does not exclude a plurality.
    Also, elements described in connection with different embodiments may be combined.
    It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims.
    An implementation of the invention is not limited to the preferred embodiments shown in the figures and described above. Instead, a plurality of variants are possible using the solutions shown and the principle according to the invention, even in the case of fundamentally different embodiments.
    权利要求:
    Claims (36)
    [1]
    claims
    A three-dimensional structural member (100) comprising: a first cover layer (102) made of a metallic material; a second cover layer (104) made of a metallic material; a core layer (106) made of a foam material and disposed between the first cover layer (102) and the second cover layer (104); wherein the structural member (100) is temperature stable at a temperature of 180 ° C; wherein at least one of the first cover layer (102) and the second cover layer (104) is made of aluminum or steel; wherein the core layer (106) is made of a plastic foam; wherein the plastic foam is polymethacrylimide foam; wherein the core layer (106) has a density in a range between 35 kg / m3 and 750 kg / m3, in particular in a range between 75 kg / m3 and 200 kg / m3; wherein the thickness of the structural member (100) is in a range between 0.2 mm and 10 mm, in particular in a range between 0.5 mm and 8 mm, more particularly in a range between 1 mm and 6 mm; wherein the thickness of at least one of the first cover layer (102) and the second cover layer (104) is in a range between 0.01 mm and 1.5 mm, in particular in a range between 0.08 mm and 0.8 mm.
    [2]
    2. A three-dimensional structural member (100), comprising: a first cover layer (102) made of a metallic material; a second cover layer (104) made of a metallic material; a core layer (106) made of a foam material and disposed between the first cover layer (102) and the second cover layer (104); wherein the structural member (100) is temperature resistant at a temperature of 180 ° C.
    [3]
    The structural member (100) of claim 1 or 2, wherein the core layer (106) consists solely of the foam material.
    [4]
    The structural member (100) of claim 2 or 3, wherein at least one of the first cover layer (102) and the second cover layer (104) is made of aluminum or steel.
    [5]
    The structural member (100) of any one of claims 2 to 4, wherein the core layer (106) is made of a plastic foam.
    [6]
    The structural member (100) of claim 5, wherein the plastic foam comprises polystyrene or polystyrene blends.
    [7]
    The structural member (100) of claim 5, wherein the plastic foam is a thermoplastic polyester, especially polyethylene terephthalate foam.
    [8]
    8. The structural member (100) of claim 5, wherein the plastic foam is polymethacrylimide foam.
    [9]
    The structural member (100) of claim 5, wherein the plastic foam is a polyisocyanate-based foam, especially polyurethane.
    [10]
    The structural member (100) of any one of claims 2 to 9, wherein the core layer (106) has a density in a range between 35 kg / m 3 and 750 kg / m 3, in particular in a range between 75 kg / m 3 and 200 kg / m3 has.
    [11]
    The structural member (100) of any one of claims 1 to 10, comprising adhesive material (108, 110) that bonds the foam material to the first cover layer (102) and / or bonds the foam material to the second cover layer (104).
    [12]
    The structural member (100) of claim 11, wherein the adhesive material (108, 110) is a hot melt adhesive.
    [13]
    The structural member (100) of claim 11 or 12, wherein the adhesive material (108, 110) comprises a first adhesive layer (108) between the first cover layer (102) and the core layer (106) and / or a second adhesive layer (110) between the second cover layer (104) and the core layer (106).
    [14]
    The structural member (100) of any of claims 11 to 13, wherein the adhesive material (108, 110) has a melting point above 80 ° C, especially above 100 ° C.
    [15]
    The structural member (100) of any one of claims 2 to 14, wherein the thickness of the structural member (100) is in a range between 0.2 mm and 10 mm, more preferably in a range between 0.5 mm and 8 mm in particular in a range between 1 mm and 6 mm.
    [16]
    The structural member (100) of any one of claims 2 to 15, wherein the thickness of at least one of the first cover layer (102) and the second cover layer (104) is in a range between 0.01 mm and 1.5 mm, in particular in a range between 0.08 mm and 0.8 mm.
    [17]
    The structural member (100) of any one of claims 1 to 16, comprising a lacquer layer (112), particularly forming a surface layer, on an upper surface of at least one of the first cover layer (102) and the second cover layer (104).
    [18]
    18. The structural member (100) of any one of claims 1 to 17, wherein at least one of the first cover layer (102) and the second cover layer (104) is a surface layer.
    [19]
    19. The structural member (100) of any one of claims 1 to 18, wherein at least one of the first cover layer (102) and the second cover layer (104) is a rigid layer.
    [20]
    20. The structural component (100) of claim 1, configured as one of the group consisting of an automotive structural component, an aircraft structural component, a rail vehicle structural component and a structural component.
    [21]
    21. The structural member (100) of any one of claims 1 to 20, wherein the structural member (100) is configured as an electromechanical component.
    [22]
    22. An apparatus (200, 300) for manufacturing a three-dimensional structural component (100), the apparatus (200, 300) comprising: a first layer supply unit (202) configured to supply a first cover layer (102), which is made of a metallic material; a second layer supply unit (204) configured to supply a second cover layer (104) made of a metallic material; a foam supply unit (206, 208) configured to supply a material between the first cover layer (102) and the second cover layer (104) forming a core layer (106) made at least partially of a foam material the first cover layer (102) and the second cover layer (104) are joined to form a cohesive layer sequence (102, 104, 106); a shaping unit (300) configured to three-dimensionally shape the resulting layer sequence (102, 104, 106) to thereby form the structural member (100) from materials that are temperature resistant at a temperature of 180 ° C.
    [23]
    The apparatus (200, 300) of claim 22, comprising an adhesive material supply unit (210, 212) adapted to supply adhesive material (108, 110) between the foam material and the first cover layer (102) and between the foam material and the second cover layer (104) is configured to thereby adhere the foam material to the first cover layer (102) and to adhere the foam material to the second cover layer (104).
    [24]
    24. A method of making a three-dimensional structural member (100), the method comprising: providing a first cover layer (102) made of a metallic material; Providing a second cover layer (104) made of a metallic material; Arranging a core layer (106) made at least in part of a foam material between the first cover layer (102) and the second cover layer (104) to thereby form a cohesive layer sequence (102, 104, 106); three-dimensionally shaping the resulting layer sequence (102, 104, 106) thereby to make the structural member (100); wherein the structural member (100) is formed to be temperature resistant at a temperature of 180 ° C; wherein at least one of the first cover layer (102) and the second cover layer (104) is made of aluminum or steel; wherein the core layer (106) is made of a plastic foam; wherein the plastic foam is polymethacrylimide foam; wherein the core layer (106) is produced with a density in a range between 35 kg / m3 and 750 kg / m3, in particular in a range between 75 kg / m3 and 200 kg / m3; wherein the structural component (100) is produced with a thickness in a range between 0.2 mm and 10 mm, in particular in a range between 0.5 mm and 8 mm, more particularly in a range between 1 mm and 6 mm; wherein at least one of the first cover layer (102) and the second cover layer (104) is made with a thickness in a range between 0.01 mm and 1.5 mm, in particular in a range between 0.08 mm and 0.8 mm.
    [25]
    25. A method of making a three-dimensional structural member (100), the method comprising: providing a first cover layer (102) made of a metallic material; Providing a second cover layer (104) made of a metallic material; Arranging a core layer (106) made at least in part of a foam material between the first cover layer (102) and the second cover layer (104) to thereby form a cohesive layer sequence (102, 104, 106); three-dimensionally shaping the resulting layer sequence (102, 104, 106) thereby to make the structural member (100); wherein the structural member (100) is formed to be temperature resistant at a temperature of 180 ° C.
    [26]
    The method of claim 24 or 25, wherein the forming is performed by cold working, in particular by deep drawing the layer sequence (102, 104, 106).
    [27]
    27. The method of any one of claims 24 to 26, wherein the method further comprises pressing the core layer (106), and optionally adhesive material (108, 110), between the first cover layer (102) and the second cover layer (104). by means of heated compacts (220, 222), in particular rollers.
    [28]
    The method of claim 27, wherein the foam material is supplied to the compacts (220, 222) as a final cut solid state foam layer.
    [29]
    29. The method of claim 27, wherein the foam material is supplied to the compacts (220, 222) as foam precursor material, in particular granules or powder, which is converted into a foam layer by means of the heated compacts (220, 222).
    [30]
    The method of any one of claims 24 to 29, further comprising adhering the foam material to the first cover layer (102) and adhering the foam material to the second cover layer (104) by means of adhesive material (108, 110).
    [31]
    The method of claims 27 and 30, wherein the adhesive material (108, 110) is supplied to the compacts (220, 222) as a final formed adhesive layer.
    [32]
    32. The method of claim 30 or 31, wherein the adhesive material (108, 110) is supplied to the compacts (220, 222) as adhesive particles, in particular as adhesive powder or granules, by means of the heated compacts (220, 222) in the adhesive layer will be transformed.
    [33]
    33. The method of any one of claims 27 to 32, wherein the compacts (220, 222) are heated to a temperature (T>) in a range between 100 ° C and 250 ° C, especially in a range between 130 ° C and 180 ° C.
    [34]
    34. The method of any one of claims 24 to 33, wherein at least one of the first cover layer (102) and the second cover layer (104) is provided by rolling from a roll (700, 702).
    [35]
    35. The method of any of claims 24 to 34, comprising applying a lacquer layer (112) on an upper side of at least one of the first cover layer (102) and the second cover layer (104), in particular after the three-dimensional shaping.
    [36]
    36. The method of claim 35, wherein the cover layer (112) is applied at a temperature in the range between 120 ° C and 250 ° C, in particular in the range between 170 ° C and 200 ° C.
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    同族专利:
    公开号 | 公开日
    EP2999588A1|2016-03-30|
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    KR20190090846A|2016-12-06|2019-08-02|크로마틱 3디 머티리얼즈 인크.|Fabrication of 3D Objects from Thermosets|
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    申请号 | 申请日 | 专利标题
    GBGB1309323.2A|GB201309323D0|2013-05-23|2013-05-23|Three-dimensional structural member formed by a sandwich structure with foam core between metallic layers|
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