Patent Application
20190061886
The invention relates to a component comprising at least one base plate, at least one cover plate arranged on said base plate and at least one damping layer arranged between the base plate and the cover plate. An advantageous use of a component of this kind is also proposed. The invention further relates to a method for manufacturing a component.
Components of this class are known from the prior art and can for example be used in the maritime industry, in particular in ship building.
The background for the use of materials of this kind is in particular justified by the currently very high value placed on comfort and occupational safety for people on board a ship. Since a key element of comfort and occupational safety is the vibrations that act on humans in a low-frequency range. A person on board a ship will react in a decidedly sensitive manner, particularly to vertical oscillations in the resonance range of 4 to 8 Hz along the spine and the lower jaw. The vibrations result in forces along the spine. The greatest forces act on the lumbar spine. If forces of this type act over a period of several years with a correspondingly high intensity, this could result in changes to the intervertebral discs and the vertebral bodies.
Almost 95% of the unpleasant oscillations on board a ship are caused by propeller-induced fluctuations in pressure and by excitation in the main engine. The oscillations caused by the drive area can be significantly impacted by a main engine foundation being adjusted accordingly, the engine geometry being tailored and the firing order being precisely defined. Furthermore, the vibrations caused by the propeller can be reduced by a large number of blades as they then always work in an irregular wake. The fewer blades are used, the more strain there is on the individual blades and the more there are fluctuations in torque and thrust in the wave conduction. It is important for the number of blades to be precisely tailored to the number of engine cylinders so the excitation of the propeller and the engine do not occur at the same time.
It is primarily hard materials such as steel or aluminium that are used in modern shipbuilding. The poor mechanical vibration damping of these materials means they encourage the transfer of sound waves. This means that to this day large-scale secondary damping and noise reduction over large areas such as decks and walls remain essential in spite of the aforementioned measures.
The deck coverings used to this day in shipbuilding can be broken down into three basic variants: standard flooring, vibration-damping floor and floating flooring. The construction of the deck covers is selected depending on the type of use of the deck areas and the dynamic stress to which they are subjected. Combinations of the individual variants are also possible.
Standard flooring generally consists of lightweight concrete applied at thicknesses of 0-30 mm to steel, aluminium or galvanized deck surfaces with very good grip. At thicknesses of 0-5 mm, the concrete layer serves to smooth out bumps and at greater thicknesses to distribute the pressure and stabilise the structure with good surface strength at a low specific weight of 1.0-1.2 kg/m2/mm.
Vibration-damped flooring constructions are typically used in areas with high levels of exposure to mechanical vibration on the supporting deck structure and where structures are directly exposed to both dynamic and impact-type stress. The principle of vibration-damped flooring consists of a specially tailored layer structure with one (or more) distinctly viscoelastic, rubber-like intermediate layers. This effectively dampens the supporting deck structure made of steel or aluminium and the vibration amplitudes of both this layer and the layers above this and the sound radiation into the environment are significantly reduced. Low shear modules in the viscoelastic layer cause good decoupling of the adjacent layers particularly in the case of the bending stress on supporting structures that is typical of mechanical vibration and impact noise. Both various types of lightweight concrete and steel plates are used as cover layers over the viscoelastic layer. The thickness of the concrete layer depends on the use and generally varies between 4 and 30 mm. Upper layers made of steel plates have thicknesses of between 1.5 and 2 mm. The specific weights of flooring designed to be vibration-damping is between 10 and 30 kg/m2. Flooring with higher specific weight generally has a higher level of damping, although the thickness of the viscoelastic layer is mostly uniform at 1.5-2 mm. The pronounced damping of the concrete layer also has an impact.
Finally, floating flooring constructions are used in areas with high airborne sound occurrence and considerable structure-borne sound intensity. In the case of floating flooring, the use of a mineral wool layer of 30 to 50 mm in thickness with a low elasticity module is generally a very effective method of vibration decoupling between the supporting deck structure and the deck plate. The deck plate is proportionally massive (thickness of approximately 30 mm) to increase this effect. At the same time, this layer serves to distribute the pressure and requires sufficiently high levels of rigidity. In some cases, the deck layer for its part consists of several layers, often of 1.5 to 3 mm thick steel plates including the viscoelastic intermediate layers. The resonance frequencies for the movement of the supporting layer and the upper cover layer are less than 100 Hz. Although it is not possible to achieve a reduction in the vibration amplitudes by means of decoupling for the range below the resonance frequency for physical reasons, the damping ability contained within the mineral wool (dissipation effects) achieves a significant damping of the forms of vibration in this frequency range coming from the supporting and upper layer. A considerable reduction in sound radiation is achieved for the frequency range above the lowest resonance frequency mentioned. The specific weights of flooring designed to be floating is between 25 and 70 kg/m2.
The disadvantage of the above-mentioned flooring variants, however, is that all of them have a very high specific weight as a ratio of their acoustic effect. Additional surface weights of up to 70 kg/m2 are reached in areas where the sound is particularly critical.
In order to counteract this problem, the prior art of DE 10 2014 007 066 B3 proposes components consisting of two surface layers made of a steel material and a non-metallic core layer arranged between the surface layers. The components have structure-borne sound-damping properties and can be used for constructions preferably in the maritime industry, such as shipbuilding. A special core layer should be used to improve the suitability for welding.
WO 2015/047081 A1 describes a method for the construction of a construction panel with two metal plates and an acoustic insulating layer arranged between them. The metal plates can be connected to one another by means of a welding stud to prevent delamination.
It has been shown, however, that when used, in other words in the welded state, the known components cannot achieve the operational stability or rigidity requirements or can only achieve them with a significant amount of effort.
Against this background, the object of the invention is to provide a component, a method for the manufacture of a component and the use of a component, wherein the necessary operational stability and rigidity properties can be achieved at a low weight by means of a reliable process.
The object is achieved according to a first aspect of the invention by means of a component, in particular one manufactured according to a method according to the invention, comprising
The object is achieved according to a second aspect of the invention by means of a method for the manufacture of a component, in particular a component according to the invention, the method comprising:
Among other things, the invention is based on the knowledge that the requirements for operational stability and stiffness can be met in particular in a weight-saving and reliable manner when the stiffening element is being or is connected both to the base plate and the cover plate. As a result, the stimulation of local structures (for example starting from global ship vibrations) can be reduced considerably by the use of components according to the invention or components manufactured according to the invention in the (supporting) structure. In shipbuilding in particular, secure welding of both the base plate and the cover plate based on a T-joint or a cross joint was, to date, not possible using welding processes that are common in shipyards.
Connecting the stiffening element to the base plate and the cover plate creates an non-detachable bond between these components. This can be achieved by means of a firmly bonded process, in particular by welding. Adhesion and/or soldering are also conceivable firmly bonded procedures.
The base plate and/or the cover plate is for example a steel plate or an aluminium plate. For example, the base plate and/or the cover plate are designed to be essentially flat. For example, the base plate and/or the cover plate have a thickness of 1 to 10 mm, preferably 2 to 5 mm. For example, the thickness of the base plate is essentially 3 mm. Further plates can in principle also be provided.
The damping layer in particular provides sound-absorbing properties. For example the damping layer is a non-metallic damping layer. For example the damping layer consists of a plastic layer. For example the damping layer is designed as a film. For example the damping layer consists of a silicone-containing material. However, all other materials with a sufficient damping function are fundamentally conceivable. It is also conceivable for further damping layers to be provided. The base plate, the cover plate and the damping layer arranged between them in particular form a multilayer or a sandwich structure.
The stiffening element can also be designed as a plate, in particular a steel or aluminium plate. For example, the stiffening element is essentially at an angle, in particular at a right-angle, in the connection area on the base plate and/or cover plate. For example the connection element is attached in the connection area with a T-joint or inclined joint.
Preferably, the base plate is on the cover plate side essentially exclusively in the connection area and optionally at least in sections in the edge area free from the cover plate and the damping layer. This means that otherwise the base plate is preferably extensively covered by the cover plate or preferably several cover plates and the corresponding damping layers. The base plate is preferably free from a damping layer or a cover plate on the side facing away from the cover plate.
The part of the connection area that is free from the cover plate and the damping layer can in particular be selected depending on the thickness of the stiffening element. For example, the width of the area that is free from the cover plate and the damping area is between 10 and 20 mm, for example around 16 mm.
Since at least one base plate, at least one cover plate, at least one damping layer and at least one stiffening element are provided, the component can also comprise several base plates, cover plates, damping layers and/or stiffening elements (for example two, three, four or more). In this respect, the base plate, the cover plate, the damping layer or the stiffening element are to be understood as the at least one base plate, the at least one cover plate, the at least one damping layer or the at least one stiffening element. Where several base plates, cover plates, damping layers and/or stiffening elements are provided, the above-mentioned or following descriptions apply to at least one base plate, one cover plate, one damping layer or one stiffening element preferably to all of the base plates, cover plates, damping layers and stiffening elements present.
According to a preferred embodiment of the aspects, the stiffening element is strip-shaped, in particular as Holland Profile. For example, the stiffening element is essentially designed as a rectangular profile. A Holland Profile, also termed a bead profile, is essentially a profile with a waling on one side, in particular a rounded L-shaped profile, in particular according to DIN EN 10067. Other profile forms can for example also be used.
According to a preferred embodiment of the first aspect, the stiffening element is firmly bonded, in particular by means of welding to the base plate and the cover plate.
According to a preferred embodiment of the second aspect, the stiffening element is being firmly bonded, in particular by means of welding to the base plate and the cover plate.
The connection is for example achieved using pressure and/or heat. For example, the connection is achieved with or without a welding additive. For example, MIG welding, MAG welding, laser welding, laser hybrid welding or autogenous welding are used. Other welding methods can for example also be used. Adhesive or soldering methods can also be used. For example, the firmly bonded connection is achieved automatically or manually.
As explained above, the stiffening element can in particular be connected in the connection area by means of a T-joint. Fillet welds are preferably used in this instance.
The following parameters have been proven to be particularly advantageous during the welding process. The welding is preferably carried out using a solid wire electrode. It has been demonstrated that a solid wire leads to a very good appearance of the weld and flat weld transitions and few splashes. The materials supplied can therefore take on the function of bridging a gap. A solid wire electrode made of steel is for example used, for example the wire has the alloy components 0.1 C, 1.0 Si and 1.7 Mn in % by weight (for example Böhler EMK8). According to another example, the wire has the alloy components 0.08 C, 1.05 Si and 1.65 Mn in % by weight (for example Union K56). For example a wire diameter of 0.8-1.2 mm is used. The welding is preferably carried out in an Ar—CO2 atmosphere (for example with around 82% Ar and around 18% CO2). An advantageous wire feed speed is between 5 and 15 m/min, for example 8 m/min or 13 m/min. Other welding additives, in particular those in a wire form, can for example also be used.
According to a preferred embodiment of the first aspect, the stiffening element has a one-sided or both-sided chamfered edge on the side facing the base plate. Alternatively, the stiffening element can also be planar, in other words not chamfered, on the side facing the base plate.
Accordingly, according to a preferred embodiment of the second aspect, the method further comprises:
The side of the stiffening element that faces the base plate is for example in contact with the base plate (for example in a T-joint). The side that faces the base plate is for example a front face with two edges, one or both of which are chamfered. The stiffening element is chamfered at an angle of between 20° and 50°, preferably between 30° and 40°, in particular relative to the surface of the stiffening element.
According to a preferred embodiment of the second aspect, the method further comprises:
The process reliability can be further increased and a particularly precise alignment of the individual components relative to one another can be achieved by means of a fixing of the stiffening element to the base plate, in particular upstream of the actual connection of the stiffening element to the base plate and the cover plate. For example, the fixing can be achieved by means of isolated spot welding (MIG, MAG or autogenous).
According to a preferred embodiment of the first aspect, the damping layer is firmly connected to the base plate and the cover plate, in particular adhered.
Accordingly, according to a preferred embodiment of the second aspect, the cover plate is being firmly connected to the base plate by means of the damping layer.
Firmly bonded connections, in particular adhesion, enable a flat and stable connection to be achieved in a simple manner. The connecting of cover plate and/or base plate to the damping layer is preferably carried out after the (temporary) fixing of the stiffening elements. The damping layer is preferably designed as a self-adhesive layer. The final connection of the stiffening element to the cover plate and the base plate is then preferably carried out.
In this respect, it is particularly advantageous if, according to a preferred embodiment of the second aspect, the method further comprises:
If the cover plate already has a damping layer, the cover plate can be arranged on the base plate together with the damping layer in a single work step and for example adhered thereto because of the self-adhesive damping layer. The cover plate forms a patch or a composite with the damping layer and can be applied in this composite. Individual cover plates each already with damping layers can be arranged on the base plate in the manner of a patchwork and connected thereto. Alternatively, only one cover plate with an already applied damping layer can be applied to a base plate and connected thereto, with the dimensions of the cover plate essentially corresponding to the dimensions of the base plate.
According to a preferred embodiment of the aspects, the damping layer is formed as a film, in particular with a thickness of less than 200 μm, preferably less than 100 μm. Designing the damping layer as a film means sound dampening can be achieved in a particularly weight-saving manner. In addition to this, a damping layer designed as a film can also be advantageously provided on the cover plates, so these can be applied together with the cover plates. The thickness of the film is preferably in the range from 20-100 μm, preferably 40-60 μm, for example around 50 μm.
According to a preferred embodiment of the aspects, the component has several base plates, several cover plates and/or several stiffening elements. For example at least two base plates, cover plates and/or stiffening elements are provided. In particular, several cover plates and/or stiffening elements can be connected to a base plate. As already mentioned, the cover plates (in particular including the damping layer that is already connected to them) can be arranged on the base plate in patchwork form. In particular, the stiffening elements can surround an area on the base plate in which a cover plate with the damping layer can then be arranged.
A stiffening element can preferably span several (for example two) base plates, increasing the stiffness and rigidity where there are several base plates provided.
According to a preferred embodiment of the first aspect, the component comprises at least two base plates each with at least one cover plate arranged on it, adjacent base plates with the cover plates arranged thereon being connected to one another in a butt joint.
Accordingly, according to a preferred embodiment of the second aspect, several base plates are provided each with at least one cover plate arranged on them, wherein the method further comprises:
For example, at least two base plates are provided. The base plates can for example be firmly connected by means of welding, in particular with an I-weld or V-weld in a butt joint. A further improvement in the rigidity and stiffness of the component can be achieved as a result of the adjacent base plates being connected to one another and the adjacent cover plates also being connected to one another.
In order for the plates to be included in the connection in a reliable manner, it has proven advantageous for the damping layer and/or an adhesive provided to firstly be decomposed in the area to be connected. In order to do this, the edges of the cover plate that are to be connected are initially heated to around 900 to 1000° C. (for example using an autogenous flame) to stimulate thermal decomposition. It has been demonstrated that subsequent welding results in fewer imperfections. Connection is preferably carried out by means of a wire electrode, for example a metal powder filling wire. For example, the wire has the alloy components 0.03 C, 1.35 Mn and 0.06 Si in % by weight (for example Robofil M71). According to another example, the wire has the alloy components 0.08 C, 1.05 Si and 1.65 Mn in % by weight (for example Union K56). For example a wire diameter of 1.2-1.6 mm is used. It has been demonstrated that a good weld appearance and flat weld transitions can be achieved.
According to a preferred embodiment of the aspects, the component has at least one longitudinal stiffening element and transverse stiffening element as stiffening elements. For example, the longitudinal stiffening element and the transverse stiffening element run essentially transverse, in particular at right angles, to one another. Several longitudinal stiffening elements and several transverse stiffening elements are preferably provided.
According to a preferred embodiment of the first aspect, the stiffening element on the one hand and the cover plate and the damping layer on the other are at a predefined distance from one another in the connection area.
Accordingly, according to a preferred embodiment of the second aspect, the cover plate, the damping layer and the stiffening element are arranged relative to one another such that a predefined distance is maintained between the stiffening element on the one side and the cover plate and the damping layer on the other in the connection area. The stiffening element can for example be connected to the base plate and the cover plate by means of welding by the welding additive (such as a solid wire electrode) that is introduced.
It has been demonstrated that maintaining a predefined distance can improve the properties of the component. The stiffening element is therefore initially not in contact with the cover plate and the damping layer. The distance can particularly preferably be determined depending on the thickness of the reinforcing element.
According to a preferred embodiment of the aspects, the component is a supporting structural component of a ship, in particular a component of a ship's hull, a ship's wall, a ship's bulkhead, a ship's ventilation duct and/or a ship's deck. There are high requirements in terms of rigidity and operational stability with simultaneously high levels of sound insulation in this area in particular.
According to a preferred embodiment of the second aspect, the method further comprises:
By, in part, fixing the cover plate before connecting the stiffening element to the base plate, a precise arrangement of the individual components can in particular be achieved. It has been demonstrated that otherwise thermal distortion can in particular affect the distance of the cover plate, for example to the stiffening element. The fixing in spots can for example also realized by firmly bonding, in particular by welding, in particular fusion welding.
According to a preferred embodiment of the second aspect, the method further comprises:
The recesses are for example designed as bores. It has been demonstrated that the introduction of recesses into the cover plate and the damping layer enables direct joining (in particular welding, for example MIG point welding) of the cover plate and the base plate (in addition to the connection via the damping layer described). This reduces the risk of delamination of the base plate and cover plate, for example as a result of thermal distortion. The joining is preferably carried out in the state of the cover plate and the base plate already connected (in particular adhered) via the damping layer.
Accordingly, the component preferably has recesses in the cover plate and the damping layer, the cover plate being joined together with the base plate in the region of the recesses. The recesses can for example be closed by means of a welding additive.
Components according to the first aspect can advantageously be used in particular for construction machinery, agricultural machinery, transformers or vehicles.
According to a third aspect, a component according to the first aspect is used particularly advantageous in ship building, in particular for a supporting ship's structure, for a ship's hull, for a ship's wall, for a ship's bulkhead, for a ship's ventilation duct and/or for a ship's deck, as there are high requirements in terms of rigidity and operational reliability with simultaneously high sound damping in this field.
Correspondingly manufactured components are also disclosed by the description above and below of the method steps according to the preferred embodiments of the second aspect. By the disclosure of components according to preferred embodiments of the first aspect also the respective method steps for their manufacture shall be disclosed.
The invention is described in greater detail below using exemplary embodiments in connection with the drawing, in which:
However, the manufacture of the component 1 preferably does not occur in the order shown. This will now be described in particular with reference to the further figures.
The areas between the longitudinal and transverse stiffening elements 6, 8 are then each provided with the self-adhesive cover plates 4. A predefined distance is maintained between the adhered patch (consisting of a cover plate 4 and a damping layer 10 designed as a film, film thickness for example around 50 μm) and the surrounding longitudinal and transverse stiffening elements 6, 8. This distance may vary depending on the thickness of the stiffening element. As can be seen in
The cover plate 4 is then fixed with the damping layer 10 against thermal distortion selectively at a precisely defined distance on the base plate 2 using fusion welding technology. The stiffening elements 6, 8 are then welded in a T-joint both to the base plate 2 and the cover plate 4 surrounded by a fillet weld 18.
To this end,
In order for the composite of cover plate 4 and damping later 10 not to lift off from the base plate 2 as a result of thermal distortion, a point by point connection to base plate 2 on the surface of cover plate 4 is provided by means of MIG point welding. To this end, the composite of cover plate 4 and damping layer 10 is provided with one or more bores (not shown) before adhesion to base plate 2 and, when adhered, is welded to base plate 2 flush with the surface.
During the manufacture of large components, for example for large segments of the ship, individual sandwich elements or composites made of base plate 2, cover plate 4 and damping layer 10 are connected by means of a butt joint. Correspondingly adjacent plates 2, 4 are shown in
The welded components described above were subjected to a cyclical load change test. An upper load of 20 kN and a lower load of 2 kN were used. It has been demonstrated that for example at a start distance load range of 0.227 mm a change in distance of just 0.051 mm was able to be achieved with a distance load range of 0.227 mm after 2.0×106 load changes. With a further sample, for example, from a starting distance load range of 0.218 mm a change in distance of just 0.013 mm was able to be achieved with a distance load range of 0.221 mm after 2.0×106 load changes. The components were therefore able to meet the necessary operational reliability and rigidity requirements with a low weight.
Alternatively to this and not shown here, the base plate or the base plates and the cover plate or the cover plates have essentially the same dimensions and are connected or adhered to one another by means of a damping layer, in particular where necessary they can also be fixed locally by means of weld points. In contrast to the method described above (patchwork), a predefined connection area is uncovered up to the base plate for connection to the stiffening elements by means of the local ablation of an area of the cover plate and the damping layer connected thereto by means of thermal processing and/or machining. The ablation can for example be carried out by means of plasma gouging or milling. After this, the connection can be carried out with the stiffening elements in the uncovered areas, as described above.
All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This patent application is a continuation of PCT/EP2016/059408, filed Apr. 27, 2016, the entire teachings and disclosure of which are incorporated herein by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2016/059408 | Apr 2016 | US |
| Child | 16171079 | US |
