Abstract
A sandwich component comprising: (i) a first main surface with a first cover layer and a second main surface with a second cover layer, the first cover layer and/or second cover layer having an opening, weakening, or marking in a lateral region and/or is provided with the same, (ii) at least one intermediate layer positioned between the first and second cover layers, and (iii) a polymer composition which is arranged between the first and the second cover layers substantially within the intermediate layer and/or in the region of the opening, weakening, or marking. A mechanical connection mechanism is fixed, or can be fixed, directly in the polymer composition through the first cover layer and/or the second cover layer and/or in the lateral region in the region of the opening, weakening, or marking so as to pass through the first cover layer and/or the second cover layer and/or the lateral region.
Claims
1. A process for producing a sandwich component having of an insert, which comprises the steps: providing the sandwich component comprising: a first main area having a first covering layer and a second main area having a second covering layer, where at least one of the first covering layer and the second covering layer has an opening, weakening or marking or an opening, weakening or marking is provided in a side region, and at least one intermediate layer positioned between the first covering layer and the second covering layer, introducing a crosslinkable polymer composition at the position of the marking or weakening or through the opening in at least one of the first covering layer, the second covering layer and the side region, into the intermediate layer, solidifying the polymer composition between the covering layers thereby forming the insert from the solidified polymer composition, and fixing a mechanical connecting means directly in the solidified polymer composition such that the mechanical connecting means protrudes through and from at least one of the first covering layer, the second covering layer and the side region, in the region of the opening, weakening or marking, wherein the connecting means is selected from the group consisting of a screw, a threaded rod, a clip, a bolt, bushings, sheaths, a spacer, pins, a nail, a hook, a clamp, a spring, rivets, pegs, profiles, brackets, hinges, and magnets.
2. The process as claimed in claim 1, wherein the crosslinkable polymer composition is an adhesive.
3. The process as claimed in claim 1, wherein the crosslinkable polymer composition has a pot life in a range from 1 to 15 seconds, measured in accordance with DIN EN 14022:2010.
4. The process as claimed in claim 1, further comprising joining the sandwich component to a further element, via the connecting means.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The figures show:
(2) FIGS. 1A-1H: Sectional sketches of sandwich components according to the invention with polymer compositions as inserts;
(3) FIGS. 2A-2C: Sectional sketches of sandwich components with polymer compositions as inserts;
(4) FIGS. 3A-3E: Variants of possible openings in the sandwich component according to the invention;
(5) FIGS. 4A-4C: Sectional sketches of sandwich components according to the invention with polymer composition as inserts and connecting means introduced into these;
(6) FIGS. 5A-5D: Sectional sketches of sandwich components according to the invention as corner connections (FIG. 5A, 5B), T-connections (FIG. 5C) or end connections (FIG. 5D);
(7) FIG. 6: Exothermic reaction on introduction of the polymer composition compared to liquid pegging;
(8) FIG. 7: A side view of a honeycomb plate;
(9) FIG. 8: A plan view of a honeycomb plate without second covering layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10) FIGS. 1A-1H show sandwich components 1 according to the invention having a first covering layer 11 and a second covering layer 12 which are separated by an intermediate layer 13. For the descriptions given below, an opening 31 was drilled through the first covering layer 11 and material of the intermediate layer 13 was removed. A crosslinked polymer composition 21 is present as insert in the region of an opening 31 and in the region of the intermediate layer 13.
(11) In FIG. 1A, the polymer composition 21 is in contact with the second covering layer 12. A connecting means can be applied to or introduced into the polymer composition 21, for example a screw can be screwed in.
(12) In FIG. 1B, the polymer composition 21 has a recess 22 which is configured for introduction of a connecting means, here a screw 41.
(13) FIG. 1C shows a polymer composition 21 as insert which is not in contact with the second covering layer 12. Here, a screw 41 has been introduced into the polymer composition 21.
(14) FIG. 1D shows a polymer composition 21 as insert which is not in contact with the second covering layer 12 and has a positioning aid 23, here a notch, in the polymer composition in the region of the opening 31. By means of the positioning aid 31, a screw 41 is positioned and introduced at the central region of the polymer composition.
(15) FIG. 1E shows a polymer composition 21 as insert which is not in contact with the second covering layer 12 and a screw 41 which has been prepositioned in the polymer composition, with the thread of the screw protruding from the sandwich component through an opening 31. The screw 41 was positioned in the region of the intermediate layer 13 before introduction of the polymer composition 21 and the polymer composition 21 was subsequently injected around the screw. A washer 42 and a nut 43 can be installed on the exposed thread of the screw 41.
(16) FIGS. 1C, 1D and 1E are particularly advantageous for decoupling of vibrations and acoustic and/or thermal decouplings. Furthermore, forces can be dissipated only onto one of the covering layers in a directed manner.
(17) In FIG. 1F, the polymer composition 21 is in contact with the second covering layer 12. The polymer composition 21 projects through the opening 31 out of the first covering layer 11 and has a positioning element or fixing element 23. A further element which is configured so as to form a positive connection with the positioning element or fixing element 23 can be installed on the positioning element or fixing element 23.
(18) Positioning elements or fixing elements can be brackets, angles, bolts, clips, sheaths, internal threads, screws, pins, recesses, projections, rails, barbs or rivets.
(19) In FIG. 1G, the polymer composition 21 has an internal thread 44 which is configured for screwing-in of a screw 41.
(20) FIG. 1H shows a sandwich component 1 in which the polymer composition 21 is in contact with the second covering layer 12 but not with the first covering layer 11. This is particularly advantageous for the decoupling of vibrations and acoustic and/or thermal decouplings. Furthermore, forces can be dissipated only onto one of the covering layers in a directed manner.
(21) FIGS. 2A-2C show further sandwich components 1 according to the invention having a first covering layer 11 and a second covering layer 12, with an intermediate layer 13 being positioned between the two covering layers 11, 12. In FIG. 2A, the first covering layer 11 has an opening 31. Material of the intermediate layer is removed by special undercut milling so as to predetermine the shape of the polymer composition 21 introduced afterward into the intermediate layer. A crosslinkable polymer composition 21 is injected through the opening 31 into a region of the intermediate layer 13. The polymer composition 21 forms an undercut and is in regions in contact with the surface of the first covering layer 11 facing the intermediate layer 13. An undercut is in this way formed on the first covering layer 11. A screw 41 is positioned in the crosslinked polymer composition 21. This ensures a high introduction of force. FIG. 2A is particularly advantageous for the decoupling of vibrations and acoustic and/or thermal decouplings. Furthermore, forces directed only onto one of the covering layers can be conducted away.
(22) In FIG. 2B, the polymer composition 21 is in contact with the second covering layer 12. Here, the shape of the polymer composition 21 in the solidified state is selected so that improved introduction of force is ensured. In the contact region between the polymer composition 21 and the second covering layer 12, the polymer composition 21 is widened in comparison with the region of the opening 31, so that a high conduction of force onto the covering layer 12 is possible.
(23) In FIG. 2C, the polymer composition 21 is in contact with the first covering layer 11 and the second covering layer 12. There is an opening 31 in the first covering layer 11. An opening 31′ is present in the second covering layer 12. The polymer composition 21 serves as spacer between the two covering layers 11, 12 in the case of local pressure perpendicular to the plate. The polymer composition 21 has a cut-out 22 which extends from the opening 31 to the opening 31′. As a result, a connecting means, for example a pin, can be inserted through the openings 31, 31′ and positioned. In this way, force-introducing joins can be produced via the first covering layer 11 and the second covering layer 12.
(24) FIGS. 3A-3E snow openings in a sandwich component according to the invention (cf. 31 in FIGS. 1A-1H and 2A-2C). The opening can be circular (FIG. 3A), circular with at least one notch (FIG. 38) or configured as straight slot (FIG. 3C), as slot curved on one side or slot curved on two sides (FIG. 3D). The opening car, likewise have a plurality of, preferably two, circular openings for introduction of the polymer composition of the component according to the invention (FIG. 3E). In FIGS. 36 to 3E, the openings provide an anti-rotation safeguard for the polymer composition (cf. 21 in FIGS. 1A-1H and 2A-2C) in the sandwich component (cf. 1 in FIGS. 1A-1H and 2A-2C) when the polymer composition is arranged in the region of the opening.
(25) FIGS. 4A-4C show sandwich components according to the invention having a polymer composition as insert and connecting means introduced into this (FIGS. 4A to 4C).
(26) In FIG. 4A, the polymer composition 21 is in contact with the second covering layer 12. The polymer composition 21 is configured as insert into which a hook 42 as connecting means has been introduced directly.
(27) In FIG. 4E, the polymer composition extends into the intermediate layer 13 and forms undercuts on the first covering layer 11. A profile 43 as connecting means has been inserted directly into the polymer composition configured as insert.
(28) In FIG. 4C, the polymer composition likewise extends into the intermediate layer 13 and forms undercuts on the first covering layer 11. A threaded rod 44 has been introduced directly into the polymer composition 21.
(29) FIGS. 5A-5D show sandwich components according to the invention having corner joins (FIGS. 5A, 5B), T-joins (FIG. 5C) or end joins (FIG. 5D).
(30) FIG. 5A shows a sandwich component 1 having a first sandwich plate and a second sandwich plate. The first sandwich plate is formed by a first covering layer 11 and a second covering layer 12, with the covering layers 11 and 12 being separated by an intermediate layer 13. The first covering layer 11 has an opening 31. The second covering layer 12 has an opening 31′. The second sandwich plate is formed by a first covering layer 11′ and a second covering layer 12′, with the covering layers 11′ and 12′ being separated by an intermediate layer 13′. The first sandwich plate and the second sandwich plate form a corner join, with the first covering layer 11 being in contact with the first covering layer 11′, the second covering layer 12 being in contact with the second covering layer 12′ and the intermediate layer 13 being in contact with the intermediate layer 13′.
(31) A first polymer composition 21 has been injected through the opening 31 into a region of the intermediate layer 13 and a region of the intermediate layer 13′, with the polymer composition 21 being in contact with the surfaces of the covering layers 11 and 11′ which face the intermediate layers 13 and 13′. Likewise, a second polymer composition 21′ has been injected through the opening 31′ into a region of the intermediate layer 13 and a region of the intermediate layer 13′, with the polymer composition 21 being in contact with the surfaces of the covering layers 12 and 12′ which face the intermediate layers 13 and 13′. The first polymer composition 21 and the second polymer composition 21′ preferably have the same chemical composition. A corner join between two sandwich plates is in this way produced in a particularly simple way. The advantages described above for sandwich components likewise apply here.
(32) FIG. 5B differs from FIG. 5A in that a single opening 31 has been formed in the first covering layer 11, through which opening a polymer composition 21 is injected. Here, the polymer composition 21 is in contact with the surfaces of the covering layers 11, 11′, 12, 12′ which face the intermediate layers 13 and 13′. The polymer composition 21 forms a strut between the covering layers in the region of the corner join. A corner join between two sandwich plates is in this way produced in a particularly simple way. The advantages described above for sandwich components likewise apply here.
(33) FIG. 5C shows a T-join between a first sandwich plate and a second sandwich plate. The first sandwich plate is configured as described for FIG. 5B. The second sandwich plate has an opening 31′ in the first covering layer 11′. The first sandwich plate and the second sandwich plate are arranged at an angle of essentially 90°. The opening 31′ of the second sandwich plate is arranged in the region of the intermediate layer 13 on the first sandwich plate. Other angles are likewise possible for particular applications. A polymer composition 21 is injected through the opening 31 into a region of the intermediate layer 13 and into a region 13′. Here, part of the polymer composition 21 goes through the opening 31′ into the intermediate layer 13′. The polymer composition 21 joins the covering layers 11, 12, 11′ and 12′. A T-join between two sandwich plates is in this way produced in a simple way. The advantages described above for sandwich components likewise apply here.
(34) FIG. 5D shows a sandwich component 1 having a first covering layer 11 and a second covering layer 12, with the covering layers 11, 12 being separated by an intermediate layer 13. A cover is arranged as rail 51 in an end region of the covering layers 11 and 12 and is in contact with the surfaces of the covering layers 11 and 12 which face away from the intermediate layer 13 and with the region of the intermediate layer 13 which is not in contact with the covering layers 11, 12. The rail 51 has an opening 31″ which is arranged in the abovementioned region of the intermediate layer 13. A polymer composition 21 has been injected through the opening 31″ into the end region of the intermediate layer 13. The polymer composition is in contact with surfaces of the covering layers 11 and 12 which face the intermediate layer 13.
(35) FIG. 6 shows the temperature curve for a polymer composition (A) according to the invention and a commercial liquid pegging composition (B), measured in the core. The time is plotted in min:sec on the X axis and the temperature is plotted in C on the Y axis.
(36) For the comparison, a two-part mold composed of polyethylene was produced. The mold has a circular hole having a diameter of 10 mm and a depth of 15 mm. The polymer compositions were introduced at room temperature by means of cartridges and the course of the temperature was measured by means of a temperature sensor and plotted. The temperature measurement was carried out at a depth of 4 mm.
(37) The course of the temperature is exothermic for both systems, with the polymer composition according to the invention (A, core 3058_1) displaying a considerably higher core temperature of 80° C. compared to the comparative composition of the liquid pegging composition (B) with a core temperature of 50° C. In addition, this is attained more quickly, i.e. within 15 seconds. The comparative composition attains the maximum core temperature after about 1 min 15 sec.
(38) Thus, better anchoring, for example as a result of partial melting or melting of the intermediate layer composed of thermoplastics, for example in sandwich components having an intermediate layer composed of polystyrene, is achieved in a sandwich component by means of the polymer composition according to the invention. Aluminum sandwich components often have polymer coatings which likewise melt in regions due to the high temperature of the polymer composition and lead to improved anchoring. Furthermore, plastic screws, for example, car, in this way be anchored better in the polymer composition introduced.
(39) FIG. 7 shows a side view of a honeycomb plate as sandwich component. The honeycomb plate has a main area H1 of a first covering layer 11, a main area H2 of a second covering layer 12 and an intermediate layer 13 which is positioned between the covering layers and has honeycombs W. The main areas H1 and H2 face away from the intermediate layer 13. The side regions S1 and S2 are formed by the covering layers 11 and 12 and the intermediate layer 13. Of course, a sandwich component or a honeycomb plate having rectangular main areas H1, H2 has four side regions.
(40) FIG. 8 shows a plan view of a honeycomb plate as described for FIG. 6, with the second covering layer 12 not being depicted to give a better view. The intermediate layer 13 is formed by the honeycombs W. In the side region of the honeycomb plate, a polymer composition can be introduced by means of the process of the invention.
