Shaping structure, composite part comprising such a shaping structure, method for manufacturing such a composite part

Abstract

This shaping structure (1) comprises two shaping sheets (5, 7) facing each other at a distance from one another. According to the invention, the shaping structure (1) further comprises a macroporous spacer sheet (9), the spacer sheet (9) being arranged between the two shaping sheets (5, 7) and being corrugated in such a way as to form a series of alternating even peaks (18) and odd peaks (20) distributed in a first direction (D1) of the shaping structure, at least one of the even peaks (18) being attached to the first shaping sheet (5), at least one of the odd peaks (20) being attached to the second shaping sheet (7), each peak (18, 20) attached in this way defining an attachment surface (22, 26) for attachment to the shaping sheet (5, 7) to which this peak (18, 20) is attached.

1 . A shaping structure comprising two shaping sheets facing each other at a distance from one another, the shaping structure being characterized in that the shaping structure further comprises a macroporous spacer sheet the spacer sheet being arranged between the two shaping sheets and being corrugated in such a way as to form a series of alternating even peaks and odd peaks distributed in a first direction of the shaping structure, at least one of the even peaks being attached to the first shaping sheet at least one of the odd peaks being attached to the second shaping sheet each peak attached in this way defining an attachment surface for attachment to the shaping sheet to which this peak is attached. 
     
     
         2 . The shaping structure according to  claim 1 , characterized in that:
 it is provided that at least two successive even peaks are attached to the first shaping sheet thus respectively defining two successive attachment surfaces and a length between peaks, measured parallel to the first direction between these two successive attachment surfaces has a value of between 1.0 times and 1.5 times the value of a surface length of the attachment surface this surface length being measured parallel to the first direction.   
     
     
         3 . The shaping structure according to  claim 1  characterized in that:
 the even peaks are regularly distributed in the first direction and 
 the odd peaks are regularly distributed in the first direction. 
 
     
     
         4 . The shaping structure according to  claim 2  characterized in that at least one of the attachment surfaces is the seat of an attachment using an attachment agent, such as a thermoplastic binder, attaching the peak in question with the shaping sheet in question, the attachment agent being distributed on the attachment surface of this peak. 
     
     
         5 . The shaping structure according to  claim 2  characterized in that at least one of the attachment surfaces is the seat of an attachment by welding of the peak in question with the shaping sheet in question, and in that the attachment sheet in question comprises a layer of heat-sensitive material used for this welding. 
     
     
         6 . The shaping structure according to  claim 2  characterized in that at least one of the attachment surfaces is the seat of an attachment by sewing of the peak in question with the shaping sheet in question. 
     
     
         7 . The shaping structure according to  claim 1  characterized in that among the two shaping sheets at least one shaping sheet comprises a layer of nonwoven material. 
     
     
         8 . The shaping structure according to  claim 7 , characterized in that the layer of nonwoven material comprises a glass web comprising glass fibers connected to one another. 
     
     
         9 . The shaping structure according to  claim 7  characterized in that the macropores of the spacer sheet have a nominal size of between about 2 and 40 mm, preferably between 5 and 20 mm. 
     
     
         10 . The shaping structure according to  claim 2  characterized in that the macroporous spacer sheet comprises a grid of longitudinal threads and transverse threads connected at their intersections. 
     
     
         11 . The shaping structure according to  claim 10 , characterized in that the grid of threads has a density of threads of between 0.25 and 5 threads per centimeter, preferably between 0.5 and 2 threads per centimeter. 
     
     
         12 . A composite part characterized in that the composite part comprises:
 a shaping structure according to  claim 10  and   a central layer formed by a hardenable or cross-linkable material, respectively in the hardened or cross-linked state, the central layer occupying the space between the two shaping sheets the spacer sheet extending within the central layer.   
     
     
         13 . The composite part according to  claim 12 , characterized in that the hardenable or cross-linkable material has a foamed structure when it is respectively in the hardened or cross-linked state. 
     
     
         14 . The method for manufacturing a composite part according to  claim 12  characterized in that the manufacturing method comprises a step a) for introducing hardenable or cross-linkable material, respectively in a non-hardened or non-cross-linked state, between the two shaping sheets of the shaping structure in order to form the central layer the two shaping sheets delimiting the shape of the central layer by shaping of the hardenable or cross-linkable material between these two shaping sheets.