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Semi-continuous thermoplastic honeycomb panel production line concept

Semi-continuous thermoplastic honeycomb panel production line concept

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Article
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All thermoplastic sandwich materials can offer weight and cost savings. The cost advantage of an automated production of thermoplastic sandwich parts can only beutilized if the core material is produced in a cost efficient automated process as well. Researchand development activities have been intensified in the last years and resulted in several n...

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... schematic view of a line for the production of ThermHex sandwich panels with a deep drawing process is shown in figure 9. The foil is pre-heated and formed in a stepwise process. ...

Citations

... 49 Another manufacturing way is known as the ThermHex concept. 50 The core structure can be produced in a continuous process in one production line. Starting from an endless thermoplastic foil, a half-hexagonal web is formed by deep drawing or vacuum forming. ...
... In a following step, the skin laminates can be directly fusion bonded to the core. 50 Foams show lower mechanical properties than honeycombs, though they feature some advantages such as acoustic damping or insulation. 47 Additionally, thermoplastic foams exhibit a good thermoformability. ...
... 11 In the literature, a few investigations on simultaneous forming and joining of 3-D sandwich structures applying compression moulding or in situ foaming are reported. 30,31,44,50,89 Reynolds et al. 31 applied non-isothermal compression moulding for manufacturing PP-based composite sandwich structures. Besides investigations on flat panels, he also studied the one-step manufacturing of slightly curved 3-D sandwich beams, which featured a 4000 mm radius. ...
Article
Composite sandwich structures show promising lightweight properties for the aviation industry. Nowadays time-consuming manufacturing methods still prevent an extensive application of composite sandwiches, which can be overcome by the use of thermoplastic polymers in skins and core. During manufacturing of thermoplastic composite (TPC) sandwich structures, the joining of skins and core is a critical step. Therefore, several skin-core joining methods have been under investigation and development in the published literature, which can be categorized into adhesive bonding or fusion bonding. Fusion bonding by means of vacuum moulding, compression moulding or in situ foaming shows great potential for joining sandwich skins and core. Although various phenomena such as core collapsing or skin deconsolidation challenge the processes. This article aims to present an overview of research that has been done in the area of manufacturing TPC sandwich structures and will serve as a baseline and aid for further research and development efforts.
... This concept has proven to be feasible for different types of thermoplastic materials [12]. Thermoplastic folded honeycomb samples have been produced from PP, PET, PC and PA foils. ...
Conference Paper
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The demands for automotive interior and exterior panels request an optimal combination of materials and cost efficient production processes. Mechanical and acoustical requirements and a weight target result today often in the selection of a sandwich design with a cost efficient and recyclable core material. Two new cost efficient honeycomb materials and their continuous production processes have been developed at the K.U.Leuven. These materials and production methods enable an automated in-line production of paper and polypropylene (PP) based honeycombs for automotive sandwich panels and parts. The production concepts, possible material combinations and basic material properties for automotive sandwich parts are presented.
Chapter
As a large-scale industry, airlines are still striving to use lighter materials in aircraft for two reasons: improved energy efficiency and reduced CO2 emissions. However, for use in the aircraft cabin, the material must also be of high mechanical strength and thermal stability, in accordance with Federal Aviation Administration (FAA) requirements. Thermoplastics are not only lightweight, but can also be remelted and remolded, resulting in the production of new thermoplastic composites with improved properties and easy processing. As a material of great potential, the thermoplastic market expected in the future aeronautics sector is also addressed.
Article
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Zusammenfassung Die hohen Anforderungen für Bauteile im Automobilbau verlangen nach einer optimalen Kombination von leichten Materialien und kostengünstigen automatisierten Prozessen. Die geforderten mechanischen und akustischen Eigenschaften und die Vorgaben für Gewicht und Kosten erfordern häufig einen Sandwichaufbau. Wiederverwertbare kostengünstige Wabenkerne aus Papier oder Polypropylen könnten eine Alternative zu Schaumkernen darstellen. Zwei neue kostengünstige Wabenkernmaterialien und deren Herstellungsverfahren, die eine kontinuierliche und automatisierte Produktion erlauben, wurden an der K.U.Leuven entwickelt. Diese werden im Folgenden vorgestellt und mit traditionellen Sandwichmaterialien und Herstellungsverfahren verglichen. Ferner werden Materialeigenschaften, mögliche Materialkombinationen und Anwendungen im Automobilbau diskutiert.