• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a method for manufacturing a sandwich material part comprising at least two sheets (2a, 2b) of a thermoplastic synthetic material separated by a core (3) of at least one layer of a reinforcing material. This method is characterized in that by thermoforming the two sheets (2a, 2b), preparing a flexible core (3) comprising at least one layer of reinforcing material, positioning a first sheet (2a) on a mold (9) having a shape complementary to the first sheet (2a), the core (3) is positioned on this first sheet, the second sheet (2b) is positioned on the core (3), and then a force determined and homogeneously distributed on the second sheet (2b) to achieve a mechanical deformation and shaping of the reinforcing material core. The invention also relates to a piece of sandwich material made according to such a method.
    公开号:FR3014013A1
    申请号:FR1302787
    申请日:2013-11-29
    公开日:2015-06-05
    发明作者:Didier Lucas；Gwenael Picaut
    申请人:EURO SHELTER；
    IPC主号:
    专利说明:

    [0001] The technical field of the invention is that of pieces made of sandwich material (or sandwich pieces) combining at least two sheets of a thermoplastic material separated by a core. reinforcing material as well as methods of making such parts. Patent WO2011 / 058514 discloses a method for manufacturing non-planar parts for aeronautics (aircraft portholes) which are formed of two skins of thermoplastic material separated by a reinforcing core, also of thermoplastic material. These parts are shaped hot and vacuum between a mold and a mold against. The materials used are softened by the temperature. The compression which is ensured by the mold and the vacuum makes it possible to obtain the desired shaping. This process is particularly interesting but it is however limited to the production of parts made entirely of thermoplastic materials (skins and heart).
    [0002] Moreover, this process is complex and expensive. The mold is associated with a counter mold, both controlled both in temperature and vacuum level. It is also known to achieve by thermo-blow parts in thermoplastic materials to achieve for example cowlings or body parts of vehicles. These parts have a thickness of 5 to 8 mm they are relatively heavy while having a limited mechanical strength.
    [0003] There is now a need to produce inexpensive sandwich pieces for automobiles or land, air or sea vehicles. These parts must also be light and have interesting mechanical characteristics. It is the object of the invention to provide a particularly simple and easy process to implement allowing the manufacture of sandwich material parts that are lighter and stronger than existing thermoplastic parts. The invention also makes it possible to produce sandwich material parts having a more or less complex three-dimensional profile. Thus, the subject of the invention is a method for manufacturing a sandwich material part comprising at least two sheets of a thermoplastic synthetic material separated by a core of at least one layer of reinforcing material, a process characterized by the following steps: two sheets of thermoplastic material reinforced or not and having substantially the same profile are made by thermoforming, - a flexible core comprising at least one layer of a reinforcing material is also prepared, - a first sheet is positioned on a mold having a shape complementary to the first sheet, - the first sheet and / or one face of the reinforcing material core is glued, - the reinforcing material core is positioned on the first sheet placed on the mold, the second sheet and / or another face of the web of reinforcing material is adhered to, the second sheet is positioned on the web of reinforcing material, a force of determined and homogeneously distributed on the second sheet to effect mechanical deformation and shaping of the reinforcing material core, - this force is maintained until the adhesive is polymerized, - the piece of material is disassembled sandwich. According to a particular embodiment, the second sheet may be fixed on a counter-mold having a shape complementary to the second sheet. The second sheet may be secured to the counter-mold by suction means. According to another embodiment, the second sheet may be applied against the core by a pocket in which the vacuum will be made. Advantageously, the sheets may be made by thermoforming-blowing. It is also an object of the invention to provide a piece of sandwich material at once very light and very resistant and achievable at a lower cost. The sandwich material part according to the invention comprises two sheets of a thermo-plastic synthetic material separated by a core comprising at least one layer of reinforcing material, this part being characterized in that the core is a flexible core comprising at least one layer of one of the following materials: plastic or metallic honeycomb, grooved foam, grooved cork, grooved balsa, pegs bonded to a flexible support. According to a particular embodiment, each sheet may include a peripheral rim, the edge of a sheet fitting into the rim of the other sheet so as to form a border for the part. The core may have a thickness of between 3 mm and 60 mm.
    [0004] The sheets may have a thickness of between 0.2 mm and 3 mm. According to particular embodiments, the profile of the sheets may not be flat. The invention will be better understood on reading the following description of particular embodiments, a description given with reference to the accompanying drawings, in which: FIGS. 1a and 1b respectively show a cross section AA and a view from above of a sandwich part according to the invention, the trace of the cutting plane AA is marked in Figure lb; FIGS. 2a and 2b show a first example of a core that can be used for the sandwich piece according to the invention; FIGS. 3a and 3b show a second example of a core that can be used for the sandwich piece according to the invention; Figures 4a and 4b show a third example of a usable core for the sandwich part according to the invention; FIG. 5 schematizes the various steps of the method according to one embodiment of the invention; FIG. 6 schematizes other steps of the method according to another embodiment of the invention; Figure 7a schematically shows in cross section another sandwich piece according to the invention, a piece having a border; - Figure 7b shows only and in section the second sheet of the sandwich piece according to Figure 7a; - Figure 8a shows in cross section a sandwich piece according to the invention bordered and having a planar profile; and - Figure 8b shows the components of the part according to Figure 8a before assembly. Referring to Figures 1a and 1b, a sandwich piece 1 according to an embodiment of the invention is here a non-planar piece. The sandwich form of the piece 1 extends along the three dimensions of the space. There is shown here a bowl-shaped piece 1 substantially square and rounded, both on its four vertices la and at its bottom lb.
    [0005] This is an example that is not limiting and that can explain both the different possible structures for the part according to the invention and the different steps of the method according to the invention. The piece 1 is a sandwich piece which comprises two sheets 2a and 2b of a thermoplastic material, sheets which are separated by a core 3 of a reinforcing material. Thermoplastic synthetic materials are materials that can soften above a certain temperature and harden upon cooling. This phenomenon is reversible and the material is recyclable. Examples of thermoplastic materials that may be chosen are polycarbonate, polyethylene, polyamide, polyester, polystyrene and acrylonitrile butadiene styrene (or ABS). In particular, it will be possible to use the polycarbonate which will be shaped by the thermoforming-blowing technique.
    [0006] This technique is well known to those skilled in the art and it is not necessary to describe it in detail. It allows to make thin pieces of very different shapes while maintaining a sheet thickness that remains homogeneous throughout the room. Other techniques such as molding could of course be used. The sheets used may have a reduced thickness of between 0.2 mm and 3 mm. It is indeed not necessary with the invention to implement very thick sheets because the thermoplastic material is associated with a core 3 which will give rigidity to the sandwich piece produced. As an alternative, sheets 2a and 2b may be made of reinforced thermoplastic material, for example glass or carbon fibers. The core 3 is glued between the two sheets 2a and 2b and has a profile that follows all the curvatures of the sheets 2a, 2b. The core may have a thickness of between 3 mm and 60 mm depending on the desired rigidity for the part. The soul will have a relative flexibility allowing it to marry after deformation the curved profiles of the leaves. One of the advantages of the invention is that the core 3 can be made of very diverse materials and which are not themselves thermoplastics. Figures 2a and 2b show for example a core 3 made of honeycomb. The honeycomb can be formed as represented by hexagonal cells. It could also be formed by cylindrical tubes held between two thin skins. The honeycomb of the core 3 may be aluminum or a plastic material (such as polycarbonate or polypropylene). The honeycomb has sufficient flexibility to allow it to follow the curved profiles of the sheets 2a, 2b. FIGS. 3a and 3b show another example of a material that can be used to make the core 3 of the part. This core 3 is formed here of a plate 4 which has grooves 5 forming a grid. The grooves delimit substantially square pins 6. The depth of the grooves 5 is equal to at least 70% of the thickness of the plate 4. This results in a flexibility for the plate 4 which allows its adaptation to the curved profiles of the sheets 2a and 2b of the sandwich. The grooved plate 4 may be made of a synthetic foam, such as extruded polystyrene, polyvinyl chloride (or PVC), polyurethane ... The grooved plate 4 may also be made of cork or balsa. FIGS. 4a and 4b show another example of a material that can be used to make the core 3 of the part. This material is formed of pins 8 which are all integral with a flexible support 7 (for example by gluing). This embodiment makes it possible to obtain a core 3 having an even greater flexibility than that of the mode of FIGS. 3a, 3b. The part ensuring the integrity of the core before mounting is here constituted by the flexible support 7 which is for example a sheet of fabric or nonwoven synthetic material, or a sheet or film of polyethylene. The support 7 has a thickness that does not exceed a few tenths of a millimeter. The pins 8 may be made of balsa, thermoplastic or thermosetting plastic material. The pins may for example be formed by cylindrical tubes of PVC (polyvinyl chloride), or be constituted by a foam of a thermoplastic or thermosetting material (extruded polystyrene, PVC, polyurethane ...). In all cases the core 3 will be defined so as to have a flexibility allowing it to follow if necessary the curved profiles of the thermoplastic sheets. FIG. 5 schematizes the various steps of the method according to one embodiment of the invention. The part that is manufactured is the bowl 1 10 shown in Figures la and lb. During a first step A will be made by thermoforming two sheets 2a and 2b of a thermoplastic material, reinforced or not, and having substantially the same profile (here a non-planar profile). The sheets 2a and 2b, if they have a similar profile, have of course slightly different dimensions to take into account the final geometry of the piece 1 and in particular the thickness of the core 3. It is also prepared ( step B) a core 3 comprising at least one layer of a reinforcing material. By preparation is meant cutting the core 3 substantially to the dimensions of the part to be produced. The first sheet 2a is then positioned (step C) on a mold 9 having a shape complementary to the first sheet 2a. The mold 9 is shown in section in the figure. It comprises a cavity 10 which corresponds to the profile of the first sheet 2a. The inner face 11 of the first sheet 2a is then adhered. Then (step D) is positioned the core 3 of reinforcing material on the first sheet 2a, glued and placed in the mold 9.
    [0007] Alternatively it would be possible to glue a face of the core 3 of reinforcing material. The positioning of the core 3 on the first sheet is facilitated by the flexibility of the core 3 which is used.
    [0008] The core 3 can practically follow the profile of the first sheet. During this step, it is possible to complete the cutting of the core 3. The second sheet 2b and / or the other face of the core 3 of reinforcing material are then adhered.
    [0009] Positioning (step E) the second sheet 2b on the core 3 of reinforcing material. Lastly, (step F) a determined force is applied which is homogeneously distributed over the second sheet 2b in order to effect mechanical deformation and shaping of the core 3 of the reinforcement material. This force is maintained until polymerization of the glue. Finally dismantle the sandwich part 1 made. According to the embodiment shown in FIG. 5, the second sheet 2b is applied against the core 3 by a flexible bag 12 in which a certain level of vacuum is achieved by means of a pump 13. compression is dosed by playing on the level of vacuum achieved. The bag 12 is made integral with the mold 9 by adhesive tapes 14. FIG. 6 shows a variant of the method according to the invention in which the second sheet 2b is positioned (step G) on a counter mold 15 having a shape 16 which is complementary to the profile of the second sheet 2b. The second sheet 2b is then (step H) made integral with the counter mold 15 by a temporary connection means which will advantageously be a suction means 17,18.
    [0010] For this purpose the form 16 of the counter mold 15 is pierced with holes 17, regularly distributed over the entire surface of the form 16, and which are connected to a vacuum pump 18 via an internal channel 19 against the mold 15. Because of the lightness of the second sheet 2b, the depression needed to maintain it is moderate. The pump 18 can be stopped and the vacuum level will be maintained by the closing of a valve 20. Then the second sheet 2b and / or the other face of the core 3 of reinforcing material is bonded, which core is positioned beforehand in the mold 9 against the first sheet 2a (step D). The counter mold 15 is then returned by means of handling means (not shown). The upturn 15 is facilitated by the disconnection of the vacuum pump 18. The mold 15 is finally positioned (step I) against the mold 9 which has received the first sheet 2a and the reinforcement core 3. The steps A to D have therefore been conducted as in the previous embodiment. Finally, a force F is applied to the counter mold 15. This force is, by the form of the counter mold, distributed homogeneously on the second sheet 2b and makes it possible to perform the mechanical deformation and the shaping of the core. 3 of the reinforcing material. This force is maintained until the adhesive is polymerized. Finally dismantle the sandwich part 1 made. Different variants are possible without departing from the scope of the invention. It is possible first of all to produce a sandwich piece having a plane profile, delimited or not by a border. This embodiment will be described later. It is also possible to implement a core 3 formed of several layers of flexible reinforcing material.
    [0011] This variant will be useful when the shape of the sheets 2a, 2b is particularly complex. Each layer of the soul will individually have a greater flexibility than that of the complete soul. Repeatedly, step 5 D will be repeated so as to successively position each bonded reinforcement layer before placing the second sheet 2b. With the method according to the invention can achieve very varied forms combining curved parts and planar parts. It is thus possible to make 10 panels of dressing of land vehicles particularly resistant, but also internal equipment (furniture, seats ...). The invention makes it possible to take advantage of conventional thermoforming processes of thermoplastic sheets 15 which are widespread. It is thus possible to supply the sheets at a lower cost. Thanks to the use of souls formed of flexible layers, it then becomes possible with inexpensive tools to produce parts and panels that are both very light and very resistant. FIG. 7a shows a sandwich piece similar to that of FIG. 1, of which it differs only in the presence at the level of the second sheet 2b of a peripheral rim 21. During the assembly of the two sheets 2a 25 and 2b with the 3 the rim 21 covers an upper rim 24 of the first sheet 2a and thus ensures the edge of the part 1 by covering the core 3. It may be necessary to put in place after bonding a sealing bead 22 along the flange 21 which tightly closes the part 1. It may for example achieve the cord 22 with a silicone sealant.
    [0012] FIG. 7b shows, for greater precision, the second sheet 2b alone and before the assembly of the part 1. FIG. 8a shows another embodiment of a sandwich part 1 according to the invention, the part shown in section transverse and which has a parallelepipedic general profile. Figure 8b shows the different parts of this part 1 before assembly.
    [0013] Piece 1 has a planar profile here. The first sheet 2a is formed into a rectangular bowl which has a planar bottom 23 surrounded by a rectangular peripheral rim 24. The second sheet 2b also has a planar bottom 15 which is surrounded by a rectangular peripheral rim 21. The profiles of the two parts 2a and 2b are defined so as to fit the flange 24 of the first sheet 2a in the flange 21 of the second sheet 2b. Thus, the width and the length of the first sheet 2a are slightly smaller than those of the second sheet 2b. As in the embodiment previously described, the core 3 is bonded to the first sheet 2a or to the second sheet 2b before vacuum assembly of the part 1. The materials making it possible to produce the core 3 may be chosen from the materials listed previously. As for the part according to FIG. 7a, the flange 21 forms a border for the part 1. It ensures the protection of the core 3. A sealing bead 22 may be applied along the flange 21 to seal the piece 1. It may for example achieve the cord 22 with a silicone sealant.
    权利要求:
    Claims (10)
    [0001]
    CLAIMS 1- A method for manufacturing a sandwich material part comprising at least two sheets (2a, 2b) of a thermoplastic synthetic material separated by a core (3) of at least one layer of a reinforcing material characterized by the following steps: - two sheets (2a, 2b) of thermoplastic material reinforced or not and having substantially the same profile are produced by thermoforming, - a flexible core (3) comprising at least one layer is also prepared; of a reinforcing material, - a first sheet (2a) is positioned on a mold (9) having a shape complementary to the first sheet (2a), - the first sheet (2a) and / or one face of the core (3) of reinforcing material, - the core (3) of reinforcement material is positioned on the first sheet (2a) placed on the mold (9), the second sheet (2b) is glued and / or another face of the core (3) of reinforcement material, - the second sheet is positioned e (2b) on the core (3) of reinforcing material, - a determined force is applied homogeneously distributed on the second sheet (2b) to achieve a mechanical deformation and shaping of the core ( 3) of reinforcing material, - this force is maintained until polymerization of the glue, 30 - the piece of sandwich material (1) is disassembled.
    [0002]
    2- A method of manufacturing a sandwich material part according to claim 1, characterized in that the second sheet (2b) is fixed on a counter-mold (15) having a shape complementary to the second sheet (2b).
    [0003]
    3- A method of manufacturing a sandwich material part according to claim 2, characterized in that the second sheet (2b) is secured to the against-mold (15) by a suction means (17,18).
    [0004]
    4. Process for manufacturing a sandwich material part according to claim 1, characterized in that the second sheet (2b) is applied against the core (3) by a pocket (12) in which a vacuum is produced.
    [0005]
    5- A method of manufacturing a sandwich material part according to one of claims 1 to 4, characterized in that the sheets (2a, 2b) are produced by thermoforming-blowing. 15
    [0006]
    6- piece sandwich material (1) made according to the method according to one of the preceding claims and comprising two sheets (2a, 2b) of a thermoplastic plastic material separated by a core (3) having at least one layer of a reinforcing material, part 20 characterized in that the core (3) is a flexible core comprising at least one layer of one of the following materials: plastic or metallic honeycomb, grooved foam, grooved cork, grooved balsa, pins linked to a flexible support. 25
    [0007]
    7- piece sandwich material according to claim 6, characterized in that each sheet (2a, 2b) comprises a peripheral flange (21,24), the edge of a sheet (24) fitting into the flange (21). from the other sheet so as to form a border for the piece (1). 30
    [0008]
    8- piece sandwich material according to one of claims 6 or 7, characterized in that the core (3) has a thickness of between 3 mm and 60 mm.
    [0009]
    9- piece sandwich material according to one of claims 6 to 8, characterized in that the sheets (2a, 2b) have a thickness of between 0.2 mm and 3 mm.
    [0010]
    10- piece sandwich material according to one of claims 6 to 9, characterized in that the profile of the sheets (2a, 2b) is not plane.
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    EP2878427B1|2018-03-07|
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    ES2667820T3|2018-05-14|
    FR3014013B1|2016-11-04|
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    法律状态:
    2015-10-23| PLFP| Fee payment|Year of fee payment: 3 |
    2016-10-24| PLFP| Fee payment|Year of fee payment: 4 |
    2017-10-20| PLFP| Fee payment|Year of fee payment: 5 |
    2018-10-24| PLFP| Fee payment|Year of fee payment: 6 |
    2020-10-16| ST| Notification of lapse|Effective date: 20200914 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1302787A|FR3014013B1|2013-11-29|2013-11-29|METHOD FOR MANUFACTURING A PIECE OF SANDWICH MATERIAL AND PART PRODUCED ACCORDING TO SUCH A METHOD|FR1302787A| FR3014013B1|2013-11-29|2013-11-29|METHOD FOR MANUFACTURING A PIECE OF SANDWICH MATERIAL AND PART PRODUCED ACCORDING TO SUCH A METHOD|
    EP14195167.3A| EP2878427B1|2013-11-29|2014-11-27|Method for manufacturing a part made of sandwich material and part manufactured according to such a method|
    ES14195167.3T| ES2667820T3|2013-11-29|2014-11-27|Manufacturing procedure of a piece of sandwich material and piece made following such a procedure|
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