A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the shee
A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the sheet material by means of a set of teeth carried on a knife element. The pointed structures may pierce through the softer lamina such that the protruding tips may be bent over or clinched to prevent their easy withdrawal. Two such texturized lamina may be used to sandwich and pierce through the softer lamina and are co-clinched by the other. In this way a light and stiff laminate is created.
대표청구항▼
1. A continuous process for making a laminate sheet, comprising: a) supplying a metal sheet from a continuous roll, the metal sheet having a textured face textured with a plurality of piercing structures, each piercing structure having a respective pointed tip;b) supplying a second material from a c
1. A continuous process for making a laminate sheet, comprising: a) supplying a metal sheet from a continuous roll, the metal sheet having a textured face textured with a plurality of piercing structures, each piercing structure having a respective pointed tip;b) supplying a second material from a continuous roll of the second material;c) heating the second material so that the second material is softer than the metal sheet;d) after step c), bringing the textured face into contact with the second material;e) after step d), forcing the metal sheet and the second material together to partially pierce the second material with the plurality of piercing structures, leaving a contact gap between the metal sheet and the second material;f) after step e), cooling the second material to harden the second material;g) after step f), forcing the metal sheet and the second material together to fully pierce the second material with the plurality of piercing structures and bring the metal sheet and the second material into contact;h) after step g), bending over at least some of the pointed tips to lock the metal sheet and the second material together. 2. The continuous process of claim 1, further comprising prior to step a), gouging the metal sheet to raise the piercing structures from the metal sheet. 3. The continuous process of claim 1, further comprising: i) supplying a second metal sheet from a second continuous roll, the second metal sheet having a second textured face textured with a second plurality of piercing structures, the second plurality of piercing structures each having a respective second pointed tip;j) bringing the second textured face into contact with the second material so that the metal sheet and second metal sheet sandwich the second material; andk) simultaneously with step e), forcing the second metal sheet and the second material together to partially pierce the second material with the second plurality of piercing structures, leaving a second contact gap between the second metal sheet and the second material;l) simultaneously with step g), forcing the second metal sheet and the second material together to fully pierce the second material with the second plurality of piercing structures, and bring the second metal sheet and the second material into contact. 4. The continuous process of claim 1, further comprising, after step h), taking up the laminate sheet on a take-up reel. 5. The continuous process of claim 1, wherein step e) comprises feeding the metal sheet and the second material between pressure rolls. 6. The continuous process of claim 1, wherein steps g) and h) comprise feeding the metal sheet and the second material between pressure rolls. 7. The continuous process of claim 1, wherein step g) comprises piercing the piercing structures through the second material so that the pointed tips protrude from the second material. 8. The continuous process of claim 1, further comprising heating the metal sheet. 9. A continuous process for making laminate sheets, comprising: a) supplying a metal sheet from a continuous roll, the metal sheet having a textured face textured with a plurality of piercing structures, each piercing structure having a respective pointed tip;b) supplying a second material from a second continuous roll, the second material being softer than the metal sheet;c) bringing the textured face of the metal sheet adjacent the second material; andd) continuously feeding the metal sheet and the second material between a first set of pressure rollers to force the metal sheet and the second material together, to partially pierce the second material with the plurality of piercing structures of the metal sheet, leaving a contact gap between the metal sheet and the second material;e) after step d), continuously feeding the metal sheet and the second material between a second set of pressure rollers to force the metal sheet and the second material together, to fully pierce the second material with the plurality of piercing structures of the metal sheet and bring the metal sheet and the second material into contact, and secure the metal sheet and second material together to form a laminate sheet; andf) collecting the laminate sheet on take-up reel. 10. The continuous process of claim 9, further comprising, prior to step a), gouging the metal sheet to raise the piercing structures from the metal sheet. 11. The continuous process of claim 9, further comprising: g) prior to step f) bending over at least some of the pointed tips of the metal sheet to lock the metal sheet and the second material together. 12. The continuous process of claim 11, wherein step g) comprises forcing the pointed tips to pierce through the second material and contact one of the pressure rollers, whereby contact with the one of the pressure rollers bends over the pointed tips. 13. The continuous process of claim 9, further comprising: g) supplying a second metal sheet having a second face textured with a second plurality of piercing structures, the second plurality the piercing structures of the second plurality each having a respective pointed tip;f) simultaneously with step c), bringing the second face into contact with the second material so that the metal sheet and second metal sheet sandwich the second material; andg) simultaneously with step d), continuously feeding the second metal sheet between the first set of pressure rollers to force the second metal sheet and the second material together to partially pierce the second material with the second plurality of piercing structures, leaving a second contact gap between the second metal sheet and the second material;h) simultaneously with step e), continuously feeding the second metal sheet between the second set of pressure rollers, to force the metal sheet and the second material together to fully pierce the second material with the plurality of piercing structures, and bring the metal sheet and the second material into contact. 14. The continuous process of claim 9, further comprising heating at least one of the metal sheet and the second material.
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