Abstract: The aim of the invention is to shape a flat web material (12) into a constant three-dimensional structure with a plurality of folds along differently oriented folding lines and with elevations and depressions. This is achieved in that the flat web material is inserted between a lower holding die (20b) and an upper holding die (20a), which are largely flat, consist of a flat material, and have pre-shaped bending lines that lie over one another in a precise manner when lying against the flat web material. A lower (30b) and an upper molding die (30a) are then guided thereto and brought into position, said molding dies consisting of a flat material with specified folding lines which oppose one another in a precise manner.

Abstract: A method of manufacturing a three-dimensional preform for a structural component made of a fiber composite material includes simultaneously laying a plurality of dry fibers on a workpiece carrier having a contour that corresponds to an intended three-dimensional shape of the perform and then fixing the fibers on an edge of the workpiece carrier. These steps are repeated in accordance with a predetermined fiber laying pattern until the three-dimensional perform has been completely formed. In addition, between each repetition, the fibers are cut beyond a segment of the fibers fixed on the edge of the workpiece carrier. After the three-dimensional preform has been completely formed, the three-dimensional preform is removed from the workpiece carrier and transferred to a subsequent manufacturing step. An apparatus configured to perform this method is also disclosed.

Abstract: A method of manufacturing a three-dimensional preform for a structural component made of a fiber composite material includes simultaneously laying a plurality of dry fibers on a workpiece carrier having a contour that corresponds to an intended three-dimensional shape of the perform and then fixing the fibers on an edge of the workpiece carrier. These steps are repeated in accordance with a predetermined fiber laying pattern until the three-dimensional perform has been completely formed. In addition, between each repetition, the fibers are cut beyond a segment of the fibers fixed on the edge of the workpiece carrier. After the three-dimensional preform has been completely formed, the three-dimensional preform is removed from the workpiece carrier and transferred to a subsequent manufacturing step. An apparatus configured to perform this method is also disclosed.

Abstract: This invention is directed to a honeycomb core structure having a high compression modulus. The core structure comprises (a) a plurality of interconnected walls having surfaces which define a plurality of honeycomb cells, wherein the cell walls are formed from a nonwoven sheet and (b) a cured resin in an amount such that the weight of cured resin as a percentage of combined weight of cured resin and nonwoven sheet is at least 62 percent.

Abstract: This invention is directed to a folded tessellated core structure having a high compression modulus. The core structure comprises a nonwoven sheet and a cured resin in an amount such that the weight of cured resin as a percentage of combined weight of cured resin and nonwoven sheet is at least 50 percent, The nonwoven sheet further comprises fibers having a modulus of at least 200 grams per denier (180 grams per dtex) and a tenacity of at least 10 grams per denier (9 grams per dtex) wherein, prior to impregnating with the resin, the nonwoven sheet has an apparent density calculated from the equation Dp=K×((dr×(100?% r)/% r)/(1+dr/ds×(100?% r)% r), where Dp is the apparent density of the sheet before impregnation, dr is the density of cured resin, ds is the density of solid material in the sheet before impregnation, % r is the cured resin content in the final core structure in weight %, K is a number with a value from 1.0 to 1.

Abstract: This invention is directed to a folded tessellated core structure having a high compression modulus. The core structure comprises a nonwoven sheet and a cured resin in an amount such that the weight of cured resin as a percentage of combined weight of cured resin and nonwoven sheet is at least 50 percent, The nonwoven sheet further comprises fibers having a modulus of at least 200 grams per denier (180 grams per dtex) and a tenacity of at least 10 grams per denier (9 grams per dtex) wherein, prior to impregnating with the resin, the nonwoven sheet has an apparent density calculated from the equation Dp=K×((dr×(100?% r)% r)/(1+dr/ds×(100?% r)% r), where Dp is the apparent density of the sheet before impregnation, dr is the density of cured resin, ds is the density of solid material in the sheet before impregnation, % r is the cured resin content in the final core structure in weight %, K is a number with a value from 1.0 to 1.

Abstract: This invention is directed to a honeycomb core structure having a high compression modulus. The core structure comprises (a) a plurality of interconnected walls having surfaces which define a plurality of honeycomb cells, wherein the cell walls are formed from a nonwoven sheet and (b) a cured resin in an amount such that the weight of cured resin as a percentage of combined weight of cured resin and nonwoven sheet is at least 62 percent.

Abstract: A filter element (1) with a tubular folded bag (2) of folded filter material, which has a plurality of fold blades (3) adjacent each other in the longitudinal direction (10) of the folded bag (2) a closure cover (4) is attached at at least one axial end (7) of the folded bag (2). In order to provide a filter element which can be bent to any desired curved form while maintaining a high degree of filtration performance, and can be produced in a cost effective manner, the fold blades (3) of a folded bag (2) are provided with a combination of diagonal folds extending at an angle relative to each other such that the fold blades (3) in the longitudinal direction (10) of the folded bag extend back and forth and thereby form a three-dimensional crown structure (18). At least the outer margin of the closure cover (4) has a form corresponding to the crown structure (18) of the fold blades (3).

Abstract: A filter element (1) with a tubular folded bag (2) of folded filter material, which has a plurality of fold blades (3) adjacent each other in the longitudinal direction (10) of the folded bag (2) a closure cover (4) is attached at at least one axial end (7) of the folded bag (2). In order to provide a filter element which can be bent to any desired curved form while maintaining a high degree of filtration performance, and can be produced in a cost effective manner, the fold blades (3) of a folded bag (2) are provided with a combination of diagonal folds extending at an angle relative to each other such that the fold blades (3) in the longitudinal direction (10) of the folded bag extend back and forth and thereby form a three-dimensional crown structure (18). At least the outer margin of the closure cover (4) has a form corresponding to the crown structure (18) of the fold blades (3).

Abstract: A folded core structure is produced by embossing fold lines into a flat planar material web, initiating folds along the fold lines on the upper and lower surfaces of the material web, proceeding with the formation of the folds along the fold lines to deform the material web from its two-dimensional starting configuration to a three-dimensional folded configuration, and post-processing the folded material web to stabilize or fix the folded configuration thereof. A composite structural panel is produced by bonding a cover layer onto at least one surface of the folded core structure. An apparatus preferably includes embossing or creasing rolls to form the fold lines in the material web, air nozzles or folding rolls to initiate the folding process, bristle brush rolls to complete the folding process, and further folding rolls to enhance and fix the folded configuration, optionally in connection with heating, cooling, applying a coating onto, or impregnating a resin or binder into the material web.

Abstract: A folded core structure is produced by embossing fold lines into a flat planar material web, initiating folds along the fold lines on the upper and lower surfaces of the material web, proceeding with the formation of the folds along the fold lines to deform the material web from its two-dimensional starting configuration to a three-dimensional folded configuration, and post-processing the folded material web to stabilize or fix the folded configuration thereof. A composite structural panel is produced by bonding a cover layer onto at least one surface of the folded core structure. An apparatus preferably includes embossing or creasing rolls to form the fold lines in the material web, air nozzles or folding rolls to initiate the folding process, bristle brush rolls to complete the folding process, and further folding rolls to enhance and fix the folded configuration, optionally in connection with heating, cooling, applying a coating onto, or impregnating a resin or binder into the material web.