Joints and connections – Inflatable connector
Reexamination Certificate
1999-11-24
2002-11-19
Browne, Lynne H. (Department: 3679)
Joints and connections
Inflatable connector
C403S297000, C403S280000
Reexamination Certificate
active
06481911
ABSTRACT:
The invention relates to a jointing method for joining preformed bodies and to a composite of preformed bodies.
It is especially in light-weight structural engineering that has always been a problem in joining individual structures—termed preformed bodies in the following—in keeping with the requirements of the later application. What is required more particularly is a combination of high mechanical loading capacity and durability with minimum weight and optimum cost effectiveness for the composite and thus also for jointing. This is also basically a problem in other fields, for instance, in shipbuilding, where particularly large-area preformed bodies, for example hull segments, need to be joined to each other.
One possibility of saving weight is to make use of preformed bodies of a foamed material, more particularly of a metal foam material or fractions of such materials. Proposed in DE 43 18 540 A1 is the use of metal foam material in automobile production in which body panels are employed as foamed metal preformed bodies comprising one or two solid metal skins and a foamed layer of metal foam. For securing fitted items to these body panels mention is made of self-cutting screws and dowel-type fasteners. In the publication “Metallschaume 1997”, MIT Bremen, in the article entitled “Joining of Aluminum Foams” by N. Sedliakova et. al., screw fasteners, soldered, cemented and welded joints as well as the use of foamed fasteners are described as methods of joining foamed metal preformed bodies. Similar is the procedure with laminated plastics/metal bodies, i.e. preformed bodies which consist of a layer of plastics and at least one layer of a metallic material. Known for these materials are rivet, screw and cemented joints.
These are the accepted methods for joining preformed bodies, the advantages and disadvantages of which are well known in engineering. Also, the joining of two or more preformed bodies made exclusively of laminated plastics bodies and even exclusively of metal by such methods is in many cases problematic.
An object of the invention is to provide a firm composite of preformed bodies and to provide a jointing technique suitable for fabricating the composite. More particularly, an intention is to enable preformed bodies of laminated composite materials to be joined together into a firm composite. Preferably, it is achieved that preformed bodies of any kind of material, even dissimilar materials can be joined together.
In a first step in accordance with the invention, the preformed bodies to be joined are located relative to each other in their position required for the composite. Preferably, they are clamped to each other. In a jointing zone in which the preformed bodies are to be joined, a space, into which the preformed bodies protrude, is encased by a jointing clamp and thus defined. The jointing clamp may be the clamping just mentioned for locating the preformed bodies prior to forming the composite, or it may be positioned not until after locating. An encasement of the encased space may be formed by the jointing clamp and the preformed bodies in common. Preferably, the jointing clamp forms the encasement by itself and the preformed bodies protrude into the space encased as defined. The encasement of this space is preferably closed on all sides, but may also, however, in principle have openings, more particularly be perforated. A filler is filled into the space encased by the jointing clamp or positioned already prior to the jointing clamp being positioned in the jointing zone, which in this case is then subsequently encased. Preferably, first the encased space is formed and then the filler is filled into the encased space. The filler is arranged such that, once the filler has consolidated, a compacting pressure materializes in the encased space which is received by the encasement and acts on the preformed bodies in the encased space, thus resulting in the preformed bodies being compacted into a solid composite by both the jointing clamp and the filler.
The filler consolidates from a preferably flowable condition. Not only a fluid material, but also a foamable material, preferably a foamable plastics material, put into the encased space for foaming and subsequently consolidated is flowable during foaming according to the invention and represents a preferred filler. In principle, it is not necessary that the filler be flowable prior to consolidating, although this is preferred. It may also be consolidated from a plastic or elastic condition by being compressed. After consolidating, the filler may be elastic, it preferably being rigid, i.e. not pliant after consolidation.
The filler is filled preferably so that it fills out the encased space totally, although in principle partial filling is sufficient to produce a reliable joint, preferably both positively and non-positively of the preformed bodies which in the anticipated loading conditions receive and transfer the forces involved. The filler urges against the encasement from within. The preformed bodies, jointing clamp and filler combine to form a compacted composite.
The jointing clamp is formed by a tubular cylindrical section or comprises a tubular cylindrical section, preferably an elongated tubular cylindrical section with which the jointing clamp forms the encased space. The jointing clamp is provided with an opening or slit in its tubular cylindrical section. The slit extends to advantage up to at least one face end of the tubular cylindrical section, and it being configured particularly preferably as a full-length slit so that the tubular cylindrical section of the jointing clamp is slit throughout longitudinally. The jointing clamp is fitted, mounted, pushed in place or otherwise located relative to the preformed bodies placed in accordance with each other on joining sections configured accordingly on the preformed bodies. In the starting position prepared for press compaction of the filler, joining sections of the preformed bodies to be jointed thus protrude into the space defined by the jointing clamp. Preferably, a joining section protrudes into the space encased by it also when a jointing clamp is configured integrally. A joining section of a preformed body may be formed at an edge of the preformed body or also at any other joining location of the preformed body serving to make the joint.
Preferably, a prefabricated separate jointing clamp is employed as the jointing clamp. This separate jointing clamp is placed on the preformed bodies to be joined by it clasping the preformed bodies or at least parts thereof. In this arrangement, the jointing clamp may already clampingly locate the preformed bodies to be joined together in their position desired for the composite relative to each other. A non-clamping application of the jointing clamp is likewise possible, however.
Should more than two preformed bodies abut in a common jointing zone, such a composite of preformed bodies may be produced particularly simply by using a separate jointing clamp. The jointing clamp provided for this purpose may be formed, for example, by a star-shaped jointing clamp section.
A preformed body preferably employed is a laminated composite comprising at least one structured layer, for example, structured honeycombed, or at least one layer of a foamed material, more particularly a foamed metal or foamed plastics material. This layer is applied to a skin of a compatible base material or is sandwiched between two such skins. A typical material pairing for a preformed body is formed by foamed aluminum and solid aluminum, foamed plastics and solid plastics, foamed plastics and solid aluminum, or a layer of structured plastics or metal in combination with solid plastics or solid metal. One, several, or each of the preformed bodies to be joined may also consist solely of a foamed material.
The invention also lends itself to advantage in fabricating preformed bodies of conventional plastics, sheet metal or other profiles, sections or shells. More particularly, it is of advantage in joining all materials which are problematic in th
Browne Lynne H.
Cottingham John R.
RatnerPrestia
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