Stock material or miscellaneous articles – All metal or with adjacent metals – Honeycomb – or with grain orientation or elongated elements...
Patent
1990-03-12
1990-12-04
Zimmerman, John J.
Stock material or miscellaneous articles
All metal or with adjacent metals
Honeycomb, or with grain orientation or elongated elements...
428597, 428603, 52799, 294695, 291636, 72185, 156205, 156211, E04C 232, B21D 1308, B21D 1310
Patent
active
049753347
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
This invention relates to a method of making the metallic core of a composite panel; to a method of making the panel and to a panel using the core.
DESCRIPTION OF THE PRIOR ART
In the past it has been usual in the manufacture of composite panels having metallic non-solid cores for both the cores and the resultant panels to be manufactured in batches. Although many kinds of non-solid cores have been used there has been a tendency to favour honeycomb structures as presenting good strength characteristics but these require batch production methods to be used. Both batch production and the use of cores of honeycomb formation are expensive and there is a significant market for cheaper panels having lesser strength characteristics.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved method of making a metallic core for a composite panel which can be produced from coiled sheet material in a continuous process, an improved method of making the panel incorporating the core and an improved panel.
According to one aspect of the present invention there is provided a continuous process for making a core for a composite panel comprising cutting spaced apart tongues in columns from a metallic sheet characterised in that the tongues are foldable about base lines in the columns each base line being separated from the next tongue in the column by a web; folding the sheet to form a castellated structure having continuous side walls constituted by the spaces between adjacent columns of tongues with the webs of adjoining rows respectively lying in spaced apart parallel planes and oppositely folding the tongues of adjoining columns to lie alongside adjacent side walls with their extremities remote from their base lines extending in an appropriate one of the planes.
Another aspect of the invention provides a process for making a composite panel in which a core formed according to the preceding paragraph is passed continuously through profile compression means which closes the side walls closely against the tongues and in which after said means, sheet material from second and third coils is passed respectively on each side of the core and stuck thereto.
The invention also provides a composite panel comprising a core having spaced apart tongues arranged in columns in a metallic sheet characterised in that the tongues are folded about base lines in the columns each base line being separated from the next tongue in the column by a web; the sheet being castellated having continuous side walls constituted by the spaces between adjacent columns of tongues with the webs of adjoining rows respectively lying in spaced apart parallel planes and the tongues of adjoining columns lying alongside adjacent side walls with their extremities remote from their base lines extending in an appropriate one of the planes and the core being covered on each side with sheet material stuck thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects of the invention will now be described by way of example with reference to the accompanying drawing in which:
FIG. 1 is a diagrammatic view of a machine for continuous production of a core and a composite panel,
FIG. 2 is a third angle projection of part of a sheet to form a core,
FIG. 3 is a similar view of a core folded from the sheet of FIG. 2 with the tongues cross-hatched for clarity, and
FIG. 4 is a fragmentary view of part of a sheet with a modified tongue shape.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 this shows a machine for making a core and composite panel according to the present invention. The machine is arranged for in line intermittent and continuous operation and comprises a first coil 1 of aluminium alloy mounted on a decoiler 2, sheet 3 from the coil 1 is fed through rollers 4 and successively through an oiler 5 and a shearing station 6 of known type. The sheet 3 then passes through further guide rolls 7 to a known castellation former 8 and a known bending station 9. Because
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British Alcan Aluminium PLC
Zimmerman John J.
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