Multilayer Component and Method for the Manufacture Thereof

Abstract

The invention relates, among other things, to a component including at least one base plate, at least one cover plate arranged on the base plate, at least one damping layer arranged between the base plate and the cover plate and at least one stiffening element. The base plate is free from the cover plate and the damping layer at least in sections on the cover plate side in a connection area, and the stiffening element is connected to the base plate and the cover plate on the cover plate side in the connection area. The invention further relates to a method for the manufacture of a component and a use of a component.

Claims

1) A component, comprising at least one base plate; at least one cover plate arranged on the base plate; at least one damping layer arranged between the base plate and the cover plate; and at least one stiffening element; wherein the base plate is free from the cover plate and the damping layer on the cover plate side at least in sections in a connection area, and wherein the stiffening element is connected to the base plate and the cover plate in the connection area on the cover plate side.

2) The component according to claim 1, wherein the stiffening element is strip-shaped, in particular is designed as a Holland Profile.

3) The component according to claim 1, wherein the stiffening element is connected in a firmly bonded manner, in particular by means of welding, to the base plate and the cover plate.

4) The component according to claim 1, wherein the stiffening element has a one-sided or both-sided chamfer on the side facing the base plate.

5) The component according to claim 1, wherein the damping layer is connected to the base plate and the cover plate in a firmly bonded manner, in particular is adhered.

6) The component according to claim 1, wherein the damping layer is designed as a film, in particular with a thickness of less than 200 m, preferably less than 100 m.

7) The component according to claim 1, wherein the component has several base plates, several cover plates, and/or several stiffening elements.

8) The component according to claim 1, wherein the component comprises at least two base plates each with at least one cover plate arranged thereon, wherein adjacent base plates with the cover plates arranged thereon are connected in a butt joint.

9) component according to claim 1, wherein the component has at least one longitudinal stiffening element and transverse stiffening element as stiffening elements.

10) The component according to claim 1, wherein the stiffening element on the one side and the cover plate and the damping layer on the other are at a predefined distance from one another in the connection area.

11) The component according to claim 1, wherein the component is a supporting structural component of a ship, in particular a component of a ship's hull, a ship's wall, a ship's bulkhead, a ship's ventilation duct and/or a ship's deck.

12) Use of a component according to claim 1 in shipbuilding, in particular for a supporting ship structure, for a ship's hull, for a ship's wall, for a ship's bulkhead, for a ship's ventilation duct and/or for a ship's deck.

13 A method for the manufacture of a component, in particular according to claim 1, the method comprising: providing at least one base plate; providing at least one stiffening element; arranging at least one cover plate on the base plate, wherein a damping layer is provided between the base plate and the cover plate; connecting the stiffening element to the base plate and the cover plate on the cover plate side in a connection area of the base plate, wherein the connection area is free from the cover plate and the damping layer at least in sections.

14) The method according to claim 13, wherein the stiffening element is connected in a firmly bonded manner, in particular by means of welding, to the base plate and the cover plate.

15) The method according to claim 13, wherein the method further comprises: chamfering of the stiffening element on one side or preferably on both sides on the side of the stiffening element that faces the base plate before the connection of the stiffening element to the base plate and the cover plate.

16) The method according to claim 13, wherein the method further comprises: fixing of the stiffening element to the base plate in places, in particular before arranging the cover plate on the base plate.

17) The method according to claim 13, wherein the method further comprises: providing at least one cover plate already provided with a damping layer.

18) The method according to claim 13, wherein the cover plate is connected to the base plate in a firmly bonded manner by means of the damping layer.

19) The method according to claim 13, wherein the cover plate, the damping layer and the stiffening element are arranged relative to one another such that a predefined distance is maintained between the stiffening element on the one side and the cover plate and the damping layer on the other in the connection area.

20) The method according to claim 13, wherein the method further comprises: fixing of the cover plate on the base plate in places, in particular before connecting the stiffening element to the base plate and the cover plate on the cover plate side.

21) The method according to claim 13, wherein the method further comprises: introducing recesses into the cover plate and the damping layer before connecting to the base plate; and joining, in particular welding, the cover plate to the base plate in the region in which the recesses have been introduced.

22. The method according to claim 13, wherein several base plates are each provided with at least one cover plate arranged thereon and the method further comprises: connection of adjacent base plates with the cover plates arranged thereon to one another in a butt joint.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0077] The invention is described in greater detail below using exemplary embodiments in connection with the drawing, in which:

[0078] FIGS. 1a-1e are perspective views of schematic representations of an exemplary embodiment of a method according to the invention for the manufacture of an exemplary embodiment of a component according to the invention;

[0079] FIG. 2 is a perspective view of a schematic representation of the exemplary embodiment from FIG. 1e;

[0080] FIG. 3 is an enlarged schematic side view of the exemplary embodiment from FIG. 1e;

[0081] FIG. 4 is a schematic side view of the connection area before welding; and

[0082] FIGS. 5a and 5b are enlarged images of welded areas of an exemplary embodiment of a component according to the invention.

DETAILED DESCRIPTION

[0083] FIGS. 1a-1e are perspective views of schematic representations of an exemplary embodiment of a method according to the invention for manufacturing an exemplary embodiment of a component 1 according to the invention (see FIG. 1e). The order of the representations is merely for reasons of clarity. This means that the implementation of the method can preferably follow a different order of the method steps.

[0084] FIG. 1a firstly shows two base plates 2. The base plates are for example made of steel and have a thickness of around 3 mm. FIG. 1b shows how several cover plates 4 can be arranged on each base plate 2. The underside of the cover plates 4 are provided with a self-adhesive damping layer 10. FIG. 1c and FIG. 1d show how the cover plates 4 are arranged on the base plate 2 in a patchwork manner and are adhered to said base plate. Stiffening elements 6, 8 designed as longitudinal stiffening elements 6 and transverse stiffening elements 8 are also shown. FIG. 1e shows all stiffening elements, in other words in this case six longitudinal stiffening elements 6 and two transverse stiffening elements 8 arranged in their corresponding position, forming the component 1. FIG. 2 shows a schematic plan view of the exemplary embodiment from FIG. 1e and FIG. 3 shows an enlarged schematic side view of the exemplary embodiment from FIG. 1e.

[0085] However, the manufacture of the component 1 preferably does not occur in the order shown. This will now be described in particular with reference to the further figures.

[0086] FIG. 3 shows a connection area 12, the base plate 2 being free from the cover plate 4 and the damping layer 10 on the cover plate side at least in sections in this connection area 12 (see FIG. 4).

[0087] FIG. 4 shows a further enlarged schematic side view of this connection area 12 before welding. The stiffening element 6 can be connected to both the base plate 2 and the cover plate 4 on the cover plate side in the connection area 12. In order to do this, the stiffening elements 6, 8 are both chamfered at an angle of around 30 to 40 on the side that faces the base plate 2. FIG. 4 shows the chamfered edges 14 that occur as a result. The stiffening elements 6, 8 are arranged on the base plate 2 and fixed thereto (temporarily), preferably by means of weld points.

[0088] The areas between the longitudinal and transverse stiffening elements 6, 8 are then each provided with the self-adhesive cover plates 4. A predefined distance is maintained between the adhered patch (consisting of a cover plate 4 and a damping layer 10 designed as a film, film thickness for example around 50 m) and the surrounding longitudinal and transverse stiffening elements 6, 8. This distance may vary depending on the thickness of the stiffening element. As can be seen in FIG. 4, the base plate 2 is also free from the cover plate 4 and the damping layer 10 in sections in the connection area 12. The free area has a width 16 of around 16 mm in this case.

[0089] The cover plate 4 is then fixed with the damping layer 10 against thermal distortion selectively at a precisely defined distance on the base plate 2 using fusion welding technology. The stiffening elements 6, 8 are then welded in a T-joint both to the base plate 2 and the cover plate 4 surrounded by a fillet weld 18.

[0090] To this end, FIG. 5a shows an enlarged image of the connection area 14 already shown in FIG. 4 after welding. The fillet welds 18, which connect the stiffening elements 6, 8 both to the base plate 2 and the cover plate 4, can be seen. A wire electrode, in particular a solid wire electrode, is used to create the fillet welds 18. In one embodiment, a wire electrode of Bhler EMK8 type with a wire thickness of 1.0 mm and a wire feed speed of 13 m/min at around 240 A is used. In an alternative embodiment, a wire electrode of Union K56 type with a wire thickness of 1.2 mm and a wire feed speed of 8 m/min in pulsed operation is used. In both cases, welding was carried out in an atmosphere of 82% Ar and 18% CO.sub.2. The use of the wires leads to a very good weld appearance, flat weld transitions and low levels of splashing during manufacture. It should be noted in particular that no undercuts and no delamination have occurred.

[0091] In order for the composite of cover plate 4 and damping later 10 not to lift off from the base plate 2 as a result of thermal distortion, a point by point connection to base plate 2 on the surface of cover plate 4 is provided by means of MIG point welding. To this end, the composite of cover plate 4 and damping layer 10 is provided with one or more bores (not shown) before adhesion to base plate 2 and, when adhered, is welded to base plate 2 flush with the surface.

[0092] During the manufacture of large components, for example for large segments of the ship, individual sandwich elements or composites made of base plate 2, cover plate 4 and damping layer 10 are connected by means of a butt joint. Correspondingly adjacent plates 2, 4 are shown in FIG. 3 on the left-hand side in area 13. The following method has been proven to ensure error-free coverage of the plates 2, 4. The edges of the cover plate 4 are briefly heated to around 900 to 1000 C. in the joint region using an autogenous flame. The local heating leads to thermal decomposition of the adhesive layer, thereby reducing possible imperfections during the subsequent welding process. In this case, the distance of the base plates 2 for welding is around 1 mm and the distance of the cover plates 4 is around 3 mm. The use of a wire electrode, in particular a metal powder filling wire (for example of a Robofil M71 type or a Union K56 type) has proven to be effective for welding a butt joint.

[0093] FIG. 5b shows welding carried out using a butt joint and an I-weld 20. In one embodiment, a wire electrode of a Union K56 type with a wire thickness of 1.2 mm and a wire feed speed of 6 m/min was used. The welding was carried out in an atmosphere of 82% Ar and 18% CO.sub.2. The above-mentioned wire leads to a good weld appearance and flat weld transitions. The joining processes described can be carried out both by means of manual and automated welding. The use of a laser hybrid process is in particular conceivable.

[0094] The welded components described above were subjected to a cyclical load change test. An upper load of 20 kN and a lower load of 2 kN were used. It has been demonstrated that for example at a start distance load range of 0.227 mm a change in distance of just 0.051 mm was able to be achieved with a distance load range of 0.227 mm after 2.010.sup.6 load changes. With a further sample, for example, from a starting distance load range of 0.218 mm a change in distance of just 0.013 mm was able to be achieved with a distance load range of 0.221 mm after 2.010.sup.6 load changes. The components were therefore able to meet the necessary operational reliability and rigidity requirements with a low weight.

[0095] Alternatively to this and not shown here, the base plate or the base plates and the cover plate or the cover plates have essentially the same dimensions and are connected or adhered to one another by means of a damping layer, in particular where necessary they can also be fixed locally by means of weld points. In contrast to the method described above (patchwork), a predefined connection area is uncovered up to the base plate for connection to the stiffening elements by means of the local ablation of an area of the cover plate and the damping layer connected thereto by means of thermal processing and/or machining. The ablation can for example be carried out by means of plasma gouging or milling. After this, the connection can be carried out with the stiffening elements in the uncovered areas, as described above.

[0096] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0097] The use of the terms a and an and the and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms comprising, having, including, and containing are to be construed as open-ended terms (i.e., meaning including, but not limited to,) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., such as) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0098] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.