Method for reinforcing a foam material as well as a sandwich component

• US 20080176024A1
• Filed: 01/22/2008
• Published: 07/24/2008
• Est. Priority Date: 01/23/2007
• Status: Active Grant

• Current Assignee: Airbus Operations GmbH (Airbus SE)
• Original Assignee: Airbus Operations GmbH (Airbus SE)
• Inventors: Endres, Gregor Christian, Weber, Hans-Jurgen
• Granted Patent: US 7,891,096 B2
• Time in Patent Office: Days
• US Class Current: 428/99
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/72 Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components B29C70/742 takes precedence
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49618 Restoring existing member, e.g., reinforcing, repairing
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49833 Punching, piercing or reaming part by surface of second part
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24116 Oblique to direction of web
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/249923 Including interlaminar mechanical fastener
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle

Abstract

Provided is a method for reinforcing a foam material in which a working region is first prescribed. A gap that at least partially encloses the prescribed working region in a two-dimensional manner is created in the foam material. A strut is introduced into the foam material, extending from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material. From a further aspect, a sandwich component with a core which comprises a foam material is provided. A fibrous sheet-like material arranged in the foam material at least partially encloses a working region of the sandwich component in a sheet-like manner. At least one strut is incorporated in the foam material and extends from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material.

Claims

1. A method for reinforcing a foam material with the following method steps:

prescribing a working region;

creating a gap, at least partially enclosing the working region in a two-dimensional manner;

incorporating a fibrous sheet-like material in the gap in the foam material;

introducing a strut into the foam material, extending from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material; and

infiltrating the fibrous sheet-like material with a matrix system.

2. The method according to claim 1, wherein the gap penetrated by the fibrous sheet-like material is filled with the matrix system.

3. The method according to claim 1, wherein the creation of the gap comprises the following sub-steps:

removing the foam material in the working region;

preparing an embedding part, which is formed in a way corresponding to the working region such that it substantially fills it while leaving the gap; and

inserting the embedding part into the working region.

4. The method according to claim 3, wherein the incorporation of the fibrous sheet-like material comprises the covering of an outer surface of the embedding part with the fibrous sheet-like material before the insertion of the embedding part.

5. The method according to claim 3, wherein the incorporation of the fibrous sheet-like material comprises the covering of an inner surface of the working region with the fibrous sheet-like material before the insertion of the embedding part.

6. The method according to claim 1, wherein the introduction of the strut comprises the following sub-steps:

creating a hole in the foam material, extending from the entry surface of the foam material from outside the working region to at least the fibrous sheet-like material; and

drawing at least one bundle of fibers into the hole.

7. The method according to claim 6, wherein a step of filling the hole penetrated by the at least one bundle of fibers with the matrix system is also provided.

8. The method according to claim 6, wherein the creation of the hole is performed by sticking a needle through the foam material and the fibrous sheet-like material as far as an exit surface of the foam material.

9. The method according to claim 1, wherein, after the introduction of the strut, a step of at least partially removing the foam material including the strut within the working region is performed.

10. The method according to claim 9, further comprising a step of inserting an insert part into the working region, the diameter of the insert part being at least ⅔

of the diameter of the working region and at most less than the diameter of the working region.

11. The method according to claim 10, wherein, before the step of removing the foam material (106) including the strut, the following steps are also performed:

forming or arranging at least one outer layer on at least one surface of the foam material; and

creating an outer layer opening in the at least one outer layer over the working region,

the diameter of the outer layer opening being at least ⅔

of the diameter (d2) of the working region and at most less than the diameter (d1) of the working region.

12. A sandwich component, comprising:

a core, which comprises a foam material;

a fibrous sheet-like material, which is arranged in the foam material and at least partially encloses a working region of the sandwich component in a sheet-like manner; and

at least one strut, which is incorporated in the foam material and extends from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material.

13. The sandwich component according to claim 12,

wherein the fibrous sheet-like material is infiltrated with a resin, the at least one strut being integrated in the resin.

14. The sandwich component according to claim 12,

wherein the at least one strut has at least one bundle of fibers, which is infiltrated with a resin.

15. The sandwich component according to claim 12,

wherein the working region is filled with the foam material.

16. The sandwich component according to claim 12,

wherein the at least one strut extends through the sheet-like material to an exit surface of the foam material.

17. Sandwich component according to claim 12, wherein at least one surface of the foam core is formed by an outer layer.

18. The sandwich component according to claim 17,

wherein the outer layer completely covers the working region.

19. The sandwich component according to claim 17,

wherein an outer layer opening is formed in the outer layer (216, 216′

) within the working region;

the diameter of the outer layer opening being at least ⅔

of the diameter (d2) of the working region and at most less than the diameter (d1) of the working region.

20. The sandwich component according to claim 19,

wherein an insert part is inserted in the foam material within the working region, the diameter of the insert part being in particular approximately equal to the diameter (d1) of the outer layer opening.

21. The sandwich component according to claim 20,

wherein the insert part comprises a fastening element for fastening the sandwich component to further components.

22. The sandwich component according to claim 20,

wherein the working region is substantially filled with a filling material, in which the insert part is integrated.

23. The sandwich component according to claim 22,

wherein the insert part has a lateral depression profile, which is at least partially filled by the filling material.

24. The sandwich component according to claim 22,

wherein the filling material comprises an adhesive,

in particular an expansion adhesive, and the insert part and the fibrous sheet-like material are bonded to each other by the filling material.