Method for producing a cover wall section of a flexible cover, and cover with a cover wall made of at least one cover wall section produced by means of the method

Description

[0001] The present invention relates to a forming method for producing a cover wall section and a cover with a cover wall made of at least one cover wall section produced by means of the method and a method for producing the cover.

[0002] The invention also relates to a vehicle, an aircraft boarding bridge or stairs and a building connection, each with such a cover as a transition element.

[0003] The flexible cover is preferably a transition bellows. A generic transition bellows is designed, for example, as a folded or corrugated bellows. The folded or corrugated bellows has a bellows wall with folds or corrugations that surrounds a tunnel-like or channel-like bellows interior. The bellows wall consists of at least one multi-layered sheet-like structure that has a reinforcement coated on at least one side, preferably both sides, with a polymer coating. The reinforcement comprises at least one textile sheet-like structure or a film or similar.

[0004] During the production of the individual folds of a bellows, individual strips of material from the bellows wall material are sewn together accordion-like along one of their adjacent longitudinal edges. The other longitudinal edge, which may also contain a seam, pressed-in staples, or other elements, is enclosed with the material strip for an adjacent fold by a bellows clamping frame with a substantially U-shaped cross-section, in particular clamped or glued, or pressed into a clamping frame. The bellows clamping frames are thus arranged at the fold edges and stabilize them.

[0005] During the production of the individual corrugations of a corrugated bellows, individual strips of material from the bellows wall can generally be sewn together at their longitudinal edges to form the corrugations and / or held by aluminum profiles and clamped and connected by means of these. A corrugation can consist of a single strip of material or of several, for example, sewn together strips of material. The corrugation contour has corrugation crests and troughs, whereby the corrugations can be sewn together in the area of ​​the corrugation troughs, for example, and / or the longitudinal edges lying adjacent and sewn together in the area of ​​the corrugation troughs can also be enclosed by U-shaped bellows clamping frames, in particular clamped or glued or pressed into a clamping frame.

[0006] The effort required to manufacture the bellows or corrugated bellows is therefore relatively high.

[0007] From EP 0 922 621 A1, a bellows or part of a bellows is also known, wherein a textile insert is vulcanized into an elastomer layer and wherein the bellows is designed as a corrugated or folded bellows or a part thereof and the corrugations or folds are formed in one piece in their curvature, and wherein the textile insert is designed as a knitted fabric.

[0008] According to EP 0 922 621 A1, side walls, bottom, or top sections of the bellows can also be produced with several folds or corrugations arranged one behind the other using a suitable mold. With a sufficiently large mold, it is also possible to produce entire bellows or bellows halves. The advantage of bellows or bellows sections manufactured in one piece using this principle is that they also have a high level of durability, which results from the fact that the surface of the components can be kept absolutely flat.

[0009] The production can be carried out by inserting an elastomer layer into a mold with a fold or wave contour, placing a layer of knitted fabric on top of the elastomer layer and another elastomer layer on top of this knitted fabric, whereby the connection of the elastomer layers to each other and to the knitted fabric is achieved by vulcanization.

[0010] Furthermore, it is also known for the transition bellows or its wall to be designed without corrugations and folds. In this case, the wall is designed to be correspondingly elastic. This is disclosed, for example, in German patent application DE 10 2011 107 370 A1.

[0011] US 4,905,607 A discloses a generic transition floor with rigid rods. The transition floor is manufactured using a curved mold. Two elastomer-coated flat reinforcement members and the rigid rods are placed in the mold. An elastomer material is then applied to form a cover over the rigid rods, and the entire structure is cured.

[0012] DE 697 05 093 T2 discloses a bellows for railway crossing devices and a method for manufacturing the bellows. According to DE 697 05 093 T2, the bellows consists of a plurality of interconnected, flat modules, which are bonded to one another by vulcanization.

[0013] DE 593 970 C discloses a connecting bellows for railway carriages, consisting of a woven fabric core and rubber with metal reinforcements, wherein the woven fabric core and metal reinforcements are completely embedded in a continuous, molded rubber mass. Furthermore, according to DE 593 970, production is carried out by placing the woven fabric core with its folds on a mold, onto which rubber is applied in a warm state in such a way that a continuous rubber mass is created with a specific wall thickness and follows the folds, into which the fabric core and the rods or frames are embedded, thus achieving a homogeneous whole.

[0014] US 2012 / 0071286 A1 and DE 2 249 488 A1 each disclose a toothed belt and a method for producing the toothed belt.

[0015] GB 1 298 936 A deals with a conveyor belt.

[0016] The object of the present invention is to provide a simple and cost-effective molding method for producing a high-quality cover wall section for a flexible cover.

[0017] A further object is to provide a cover with such a cover wall and a method for producing the cover.

[0018] In addition, a vehicle, a passenger boarding bridge or staircase and a building connection should each be provided with such a cover as a transition element

[0019] These objects are achieved by a method having the features of claim 1 and a cover having the features of claim 12, as well as a method for producing the cover having the features of claim 14, a vehicle having the features of claim 15, an aircraft passenger boarding bridge or stairs having the features of claim 16, and a building connection having the features of claim 17. Advantageous developments of the invention are characterized in the respective subsequent subclaims.

[0020] The invention is explained in more detail below using a drawing as an example. The drawings show: Figure 1: Schematic view of a perspective view of a cover in the form of a bellows Figure 2: Highly simplified and very schematic cross section of a cover wall section produced according to the invention with a fold contour Figure 3: Highly simplified and very schematic cross section of a cover wall section produced according to the invention with a wave contour Figure 4: Highly simplified and very schematic cross-sectional view of a sheet material with a carrier fabric with a channel and reinforcing warp threads Figure 5: Schematic view of a top view of a carrier fabric of the sheet material according to an embodiment with reinforcing warp threads and reinforcing weft threads Figure 6: Simplified perspective view of a preferably used mold Figure 7: A cross section through the mold according to Figure 6 Figure 8: A top view of the mold according to Figure 6Figure 9: Schematic side view of a transition between two vehicle parts with a transition bellows in the form of a bellows

[0021] The cover 1 according to the invention ( Fig. 1 ) has a cover longitudinal direction 2a and a cover circumferential direction 2b perpendicular thereto. In addition, the cover 1 has a plurality of cover clamping frames 3 spaced apart from one another in the cover longitudinal direction 2a, circumferentially or extending in the cover circumferential direction 2b, as well as a cover wall 4 clamped into the cover clamping frames 3 or spanned by them. The cover wall 4 surrounds a tunnel-like or channel-like cover interior 5. In addition, the cover wall 4 has a cover wall outer side 4a and a cover wall inner side 4b. The cover wall 4 can, as in Fig. 1As shown, it can be completely closed all the way around. However, it can also be partially open in the circumferential direction and, for example, have a U-shaped cross-section.

[0022] Furthermore, the cover clamping frames 3 are preferably each substantially rectangular. Consequently, the cover 1 preferably has a substantially rectangular cross-section or is box-shaped. However, the cover clamping frames 3 can also have any other shape, e.g., they can be rounded and / or slightly curved—at least in some areas. In addition, the cover wall 4 has a preferably horizontal cover base 6, a preferably horizontal cover roof 7, and two preferably vertical cover side walls 8. The cover base 6 and the cover roof 7 each merge into the cover side walls 8 via cover wall corner regions 9.

[0023] The cover 1 is preferably a bellows with a bellows roof, bellows side walls, and bellows base. The cover longitudinal direction 2a thus corresponds in this case to a bellows longitudinal direction. The cover clamping frames 3 are bellows clamping frames, and the cover wall 4 is a bellows wall with a bellows wall outer side and a bellows wall inner side, etc.

[0024] The bellows is preferably a corrugated or folded bellows 10 ( Fig. 1 or 9).

[0025] In the bellows 10, the cover wall 4 is formed in a conventional manner like an accordion and has a fold contour 11 with folds 12 ( Fig. 2 ). The folds 12 each have fold flanks 13, which merge into one another in pairs via alternating first or inner and second or outer fold edges 14a;b. Furthermore, the folds 12 are arranged adjacent to one another in the longitudinal direction 2a of the cover.

[0026] At least some of the fold edges 14a;b, the cover wall 4 is also clamped in a cover clamping frame 3.

[0027] In the case of the corrugated bellows 10, the cover wall 4 has a corrugated contour 15 with corrugations 16 in a manner known per se ( Fig. 3 ). The individual corrugations 16 each have a U-shaped cross-section. The corrugations 16 are also arranged adjacent to one another in the cover longitudinal direction 2a. In addition, the corrugations 16 each have a rounded corrugation crest 17. The individual adjacent corrugations 16 also each merge into one another via an inner corrugation edge 18. A corrugation trough 19 is also present between adjacent corrugations 16, as viewed from the cover wall outer side 4a.

[0028] On at least part of the inner corrugated edges 18, the cover wall 4 is also clamped in a cover clamping frame 3.

[0029] As is also known per se, the cover wall 4 consists of a multi-layered surface structure 20 ( Fig. 4 ). The multi-layer, flexible sheet-like structure 20 has a central, flat reinforcement layer or a central, flat reinforcement 21, which has an outer or exterior polymer coating 22 on both sides. The polymer coating 22 forms the outer side of the multi-layer sheet-like structure 20.

[0030] The multi-layered sheet-like structure 20 also has a first spatial direction or surface direction 20a and a second spatial direction or surface direction 20b perpendicular thereto. The multi-layered sheet-like structure 20 has a surface extension in the first and second surface directions 20a;b. Furthermore, the sheet-like structure 20 has a thickness direction or height direction 20c, which is perpendicular to the two surface directions 20a;b. The sheet-like reinforcement member 21 consequently also has a surface extension in the first and second surface directions 20a;b and a height or thickness extension in the thickness direction 20c.

[0031] The polymer coating 22 consists of a polymer matrix 22, in which fillers, in particular flame-retardant fillers, are preferably embedded. The polymer matrix 22 consists in particular of a polymer material or polymer according to DIN 7724-1993-04. The polymer matrix 22 preferably consists of an elastomer according to DIN 7724-1993-04. Elastomers are therefore dimensionally stable but elastically deformable polymers whose glass transition point is below the operating temperature. The elastomers can deform elastically under tensile and compressive loads, but then return to their original, undeformed shape.The polymer matrix 22 preferably consists of vulcanized rubber (rubber), in particular of vulcanized silicone rubber (silicone rubber) or vulcanized natural rubber (natural rubber), or of CSM (chlorosulfonated polyethylene) or EPDM (ethylene propylene diene rubber) or EVA (ethyl vinyl acetate) or PVC (polyvinyl chloride) or of PU (polyurethane) or mixtures thereof.

[0032] According to a preferred embodiment of the invention, the sheet-like structure 20, preferably the strength member 21, has channels 23 for receiving at least one cover clamping frame 3.

[0033] The channels 23 can be formed in different ways. Preferably, the channels are created according to German patent application DE 10 2016 109 070 A1.

[0034] In this case, the reinforcement member 21 comprises a carrier fabric 24. The carrier fabric 24 comprises, in a manner known per se, warp threads 25 extending in the first surface direction 20a and weft threads 26 crossing the warp threads 25 and extending parallel to the second surface direction 20b. The first surface direction 20a thus corresponds to a warp direction 27, and the second surface direction 20b thus corresponds to a weft direction 28 of the carrier fabric 24.

[0035] The warp and weft threads 25; 26 are preferably monofilament threads or multifilament threads. Monofilament threads each consist of a single monofilament. Multifilament threads consist of several monofilaments. The monofilaments can each be formed as a single piece (monolithic) or have a core / sheath structure. A multifilament thread can comprise different monofilaments, e.g., made of different materials. In addition, the warp and weft threads 25; 26 can also consist of staple fiber yarn, including with a filament core, or of twisted yarn made of this yarn, or of hybrid twisted yarn. Hybrid twisted yarns consist of monofilament and multifilament threads.

[0036] According to the embodiment of the cover according to the invention, the carrier fabric 24 is now designed such that it has at least one channel or a passage or a passage 23, which extends perpendicular to the height direction 20c or in at least one of the two surface directions 20a;b through the carrier fabric 24. Preferably, the carrier fabric 24 has a plurality of channels 23. The channels 23 have at least one, preferably two, channel ends at which they each open into the environment.

[0037] The channels 23 are created by appropriate binding or weaving of the warp and / or weft threads 25;26 (see Figure 4 ).

[0038] Of course, the formation of the channels 23 can also be achieved by other types of binding and weaving techniques as well as other types of knitting and manufacturing techniques than in Figure 4shown can be realized. For example, in the case of fabrics, the warp and weft threads 25; 26 should be woven together in such a way that both single-layer, channel-free fabric regions 29 and two-layer fabric regions 30 with two single-layer, unconnected fabric layers 31a; 31b are formed from the same warp and weft threads 25; 26 or the same thread material.

[0039] Furthermore, it is within the scope of the invention that the reinforcement 21 is multi-layered and consists of several textile fabrics, each of which is bonded to one another by means of an adhesive layer made of a polymer. At least one of the textile fabrics is the described carrier fabric 24. Preferably, however, the reinforcement 21 consists of the carrier fabric 24. Furthermore, an adhesive layer, preferably made of a polymer, can also be present between the polymer coating 22 and the reinforcement 21.

[0040] It is of course also within the scope of the invention for the channels 23 in the sheet-like structure 20, in particular in the reinforcement member 21, to be formed in a different way. For example, they can be formed according to EP 2 091 766 A1. The bellows wall according to EP 2 091 766 A1 has a textile upper side and a textile underside, which are connected to one another by pile threads. For example, the reinforcement member has a spacer fabric made of two fabrics connected to one another by the pile threads (double fabric). The pile threads keep the upper and underside or the two fabrics at a distance and are spaced from one another in the axial direction of the bellows, so that lanes or channels are formed.

[0041] Instead of woven fabrics, other textile fabrics can of course also be held at a distance using the pile threads. In particular, the textile spacer fabric can also be a spacer knit, preferably a spacer warp-knitted or spacer knitted fabric. Furthermore, different textile fabrics can also be connected to one another using the pile threads.

[0042] The channels 23 can also be designed according to WO 2013 / 023634 A1. WO 2013 / 023634 A1 discloses a corrugated bellows in which the bellows wall has a strength member comprising two fabrics that are connected to one another in such a way that guides in the form of loops are formed. The loops serve to hold the bellows frames and thus facilitate assembly. They thus also represent channels. The fabrics are connected to one another by sewing, knitting, knitting, welding, or gluing. The fabrics can be single-layer or multi-layer fabrics, each comprising at least one textile fabric. The textile fabric is preferably a woven or knitted fabric, preferably a warp-knitted or crocheted fabric, or raschel fabric.

[0043] According to a further advantageous embodiment ( Fig. 4 , 5) the carrier fabric 24 additionally has at least two surface regions 32a;b, wherein the two surface regions 32a;b differ from one another in at least one mechanical property. Preferably, the two surface regions 32a;b differ with regard to at least one mechanical strength property. Particularly preferably, the two surface regions 32a;b differ in at least one surface direction 20a;b with regard to the maximum tensile force FH according to DIN EN ISO 13934-1:2013 and / or the maximum tensile force elongation ε H according to DIN EN ISO 13934-1:2013 and / or the ratio of tensile force according to DIN EN ISO 13934-1:2013 to elongation according to DIN EN ISO 13934-1:2013.

[0044] In particular, the carrier fabric 24 is designed according to DE 10 2017 102 626 A1. The carrier fabric 24 preferably has, for example, a base fabric 33 and reinforcement regions 34. The base fabric 33 is formed by the (base) warp threads 25 and (base) weft threads 26. And in the region of the reinforcement regions 34, the carrier fabric 24 has a plurality of additional reinforcement warp threads 25a and / or reinforcement weft threads 26a, which are woven into the base fabric 33 or interwoven with it in addition to the base warp threads 25 and / or base weft threads 26. "Additional" means that the reinforcement warp threads 25a and / or reinforcement weft threads 26a are not present instead of the base warp threads 25 and / or base weft threads 26, but in addition to them. The warp thread density or the weft thread density of the carrier fabric 24 is therefore higher in the reinforcement areas 34 than in the non-reinforced areas.

[0045] It is, of course, also within the scope of the invention that another textile fabric is used instead of the carrier fabric, e.g., a knit, preferably a knitted or warp-knitted fabric, or a nonwoven fabric with at least two surface areas that differ with respect to at least one mechanical property. The reinforcement can also comprise several, even different, such textile fabrics.

[0046] The reinforcement areas 34 are specifically provided where the carrier fabric 24 is subjected to greater stress during the respective use and shaping, or where greater strength or rigidity is required. For example, lower strength or greater elasticity is preferred in the cover wall corner areas 9 of the cover wall 4. This will be discussed in more detail below.

[0047] The production of the cover wall 4 by means of the method according to the invention is preferably carried out by means of a molding device or a molding tool 35 according to the invention ( Fig. 6-8 ).

[0048] The molding device 35 has an inner mold 36, preferably at least one outer mold shell 37, a stand 38 and a clamping element holding part 39.

[0049] The stand 38 serves to position the molding device 35 on the respective surface. Consequently, both the inner mold 36 and the clamping element holding part 39 are attached to the stand 38.

[0050] The inner mold 36 can be cuboid-shaped and has a preferably flat upper mold surface 40a and a preferably flat lower mold surface 40b vertically opposite thereto. The inner mold 36 can be formed from metal or reinforced plastic profiles or the like. Furthermore, the inner mold 36 has a circumferential mold wall 41. The mold wall 41 has four longitudinal wall sides 42, which each merge into one another in pairs via wall corner regions 43.

[0051] The mold peripheral wall 41 represents a surface 44 to be molded or a molding surface 44 of the molding device 35. The molding surface 44 serves to shape the cover wall 4. It thus has a shaping contour corresponding to the contour of the cover wall 4 to be produced. In the present case, the molding surface 44 serves to produce a wave contour 15 with two waves 16. The molding surface 44 is adapted accordingly to produce a fold contour 11. In addition to the wave or fold contour, any other contours are possible. To name just one example, a rectangular contour is also possible. The contour can be uniform in the circumferential direction and / or in the axial direction. However, it can also vary in the circumferential and / or axial direction, e.g., in the contour depth.In addition, contours are possible that are combinations of different basic contours, such as a wave, fold, and / or other basic contours. Another example is a single wave contour along the long sides, but a double wave contour in the corner areas.

[0052] The mold peripheral wall 41 or the molding surface 44 has, in particular, two circumferential, convex, outwardly curved shaping sections 45, which are arranged adjacent to one another, in particular vertically. The curved shaping sections 45 serve to shape or produce the waves 16. Between the two curved shaping sections 45 there is a circumferential, groove-like depression 46, the shape of which corresponds to the shape of a wave trough 19 to be produced. In addition, a circumferential groove 47 is provided adjacent to each of the two curved shaping sections 45. One groove 47 is thus arranged between the upper curved shaping section 45 and the mold upper side 40a, and the other groove 47 is arranged between the lower curved shaping section 45 and the mold lower side 40b.

[0053] The grooves 47 and the recess 46 serve according to the invention to accommodate clamping elements 48 ( Fig. 8), which will be discussed in more detail below.

[0054] The inner mold 36 can, for example, be constructed in several parts and preferably consist of several, e.g., two, individual plates 36a;b that are detachably connected to one another, in particular screwed together. However, it can also be constructed in another way. For example, the inner mold 36 can also be divided transversely to the circumferential direction into several segments that can, in particular, be detachably connected to one another. The inner mold 36 does not necessarily have to be solid. Rather, it can also be constructed, for example, from metal profiles or profiles made of a fiber composite material such as GRP.

[0055] The outer mold shell 37, which is not mandatory but can be provided, for example, if a particularly smooth surface is desired, has a counter-mold surface 49 corresponding to the shaping contour 44 of the inner mold 36. The outer mold shell 37 can also be formed in several parts, with several segments, in particular segments that can be releasably connected to one another.

[0056] In particular, the counter-molding surface 49 has two, in particular vertically, adjacent, concave, inwardly curved, groove-like shaping sections 50 for shaping or producing the waves 16. The groove-like shaping sections 50 are thus formed corresponding to the curved shaping sections 45 of the inner mold 36.

[0057] Between the two groove-like shaping sections 50 there is an elongated elevation 51 corresponding to the recess 46 of the inner mold 36 for producing a wave trough 19.

[0058] In addition, the outer mold shell 37 has a corner edge 52 adjacent to each of the two channel-like shaping sections 50, which is formed to correspond to one of the two grooves 47. The corner edges 52 serve in particular for positive engagement in one of the two grooves 47 during the shaping process, which will be discussed in more detail below.

[0059] Furthermore, the outer mold shell 37 is preferably U-shaped. This allows the outer mold shell 37 to encompass each of the longitudinal wall sides 42 and the two adjacent wall corner regions 43 during the molding process.

[0060] The outer mold shell 37 is displaceable relative to the inner mold 36 and, in particular, can be pressed against or clamped to the inner mold 36. Conversely, the inner mold 36 can also be pressed against or clamped to the outer mold shell 37 in the manner of an expansion tool.

[0061] The inner mold 36 and / or the outer mold shell 37 are also preferably heatable.

[0062] The clamping element holding part 39 is arranged opposite the outer mold shell 37. Furthermore, it is preferably designed as a retaining plate. It can also be attached to the stand 38.

[0063] The clamping element holding part 39 is also preferably U-shaped and has a central holding part wall section 54 and two adjoining leg walls 55, preferably projecting at right angles thereto. The leg walls 55 each have a connected end and an opposite free end with a preferably vertical end edge 56.

[0064] The central retaining part wall section 54 preferably also extends parallel to one of the wall longitudinal sides 42, and the leg walls 55 extend toward the inner mold 36. They are each arranged adjacent to one of the wall corner regions 43.

[0065] Furthermore, the two leg walls 55 each have three clamping element receiving slots 56 arranged adjacent to one another. The clamping element receiving slots 56 are preferably arranged vertically one above the other. They each extend from the end edge 56, preferably horizontally, into the leg wall 55 and terminate in a, e.g., widened, slot end 57.

[0066] Contrary to what is shown in the figures, according to a preferred embodiment, the clamping element receiving slots 56 can also taper towards the respective slot ends 57, i.e., the slot width of the clamping element receiving slots 56 decreases towards the slot end 57. This allows clamping elements 48 of different thicknesses to be clamped effectively.

[0067] The edges in the area of ​​the clamping element receiving slots 56 are preferably rounded to minimize the risk of damage to the clamping elements 48 during clamping.

[0068] The manufacturing method according to the invention for producing a cover wall section 4c will now be explained in more detail below: First, the multi-layer textile sheet material 21 is produced by coating the reinforcement 21 on at least one side, preferably on both sides, with the polymer coating 22. The coating is preferably carried out in a manner known per se, preferably by a coating process, calendering, extrusion, compression molding, a spraying process, or injection molding. According to the invention, however, it is not essential that the polymer coating 22 is already cured, in particular vulcanized, before the desired shaping. Rather, a completely unvulcanized sheet material 20 or a merely partially vulcanized sheet material 20 can also be used in the method according to the invention, which is only fully or partially cured, in particular fully or partially vulcanized, during the shaping process.

[0069] The clamping elements 48 are then inserted into the channels 23 in the cover wall material web thus produced from the multi-layered sheet material 20.

[0070] Alternatively, the clamping elements 48 can also be inserted into the channels 23 prior to coating. This may make it particularly easy to insert the clamping elements 48 into the channels 23, since the reinforcement 21 typically exhibits greater flexibility before coating than after coating and / or the risk of narrowing the channels 23, e.g., due to the penetration of polymer during coating, is reduced. For example, the clamping elements 48 can be inserted directly into the channels 23 created during weaving of the reinforcement 21. Alternatively, the clamping elements can be inserted into the channels 23 after the reinforcement 21 has been completed, but before coating.

[0071] According to the invention, the elongated tensioning elements 48 are flexible, bendable tensioning elements 48, preferably tensioning cables or tensioning hoses. Thus, according to the invention, the tensioning elements 48 are slack or flexible.

[0072] In particular, the clamping elements 48 are preferably corrugated tubes that can be easily bent without kinking. These are preferably additionally braided, so that the clamping elements 48 have a substantially smooth outer surface and can thus be easily inserted into the channels 23.

[0073] Preferably, the clamping elements 48 are also designed such that they can be hardened by heating. They can therefore be transformed from their flexible or pliable state into a hardened, dimensionally stable state by heating. Other processes can also be used to harden the clamping elements 48. In principle, any type of physical or chemical hardening is suitable. For example, hardening by a chemical reaction can be used as an alternative or in addition to hardening by heating. Hardening does not have to be complete; rather, partial hardening is also understood to mean partial hardening.

[0074] For example, the flexible, non-dimensionally stable tensioning elements 48 are tensioning hoses filled with a heat-curable material or a material that can be hardened by a chemical reaction. The tensioning hoses can be inserted into the channels 23 already filled, or they can be inserted into the channels 23 empty and then filled, for example, using a vacuum process. Alternatively, they can be tensioning cables, e.g., based on glass, polyester, or natural fibers, that are impregnated with a heat-curable material or a material that can be hardened by a chemical reaction. According to a further embodiment, the tensioning elements can be made of a material that initially allows flexible deformation but can be hardened, for example, by the influence of heat or other chemical or physical treatment.In addition, the clamping elements can be designed in the manner of a shrink tube, which shrinks due to the influence of heat or other chemical or physical treatment and, as a result of the shrinking process, contributes to the necessary pressure for clamping the sheet-like structure 20 against the molding surface 44.

[0075] The thermosetting material is preferably a thermosetting polymer. It is preferably a thermosetting plastic, such as an epoxy resin and / or phenolic resin, and / or a thermoplastic polymer or a high-strength elastomer compound.

[0076] As an alternative to a thermosetting material, a two-component system with a binder and a hardener can be used to convert the clamping elements 48 into the hardened, dimensionally stable state.

[0077] After inserting the clamping elements 48, the sheet-like structure 20, together with the clamping elements 48, is draped onto the molding surface 44 of the inner mold 36. The upper side of the sheet-like structure 20, which rests against the molding surface 44, later forms the inner side 4b of the cover wall.

[0078] In particular, the sheet-like structure 20 is draped on the longitudinal wall side 42 facing the mold shell 37 and on the two wall corner regions 43 adjoining this longitudinal wall side 42.

[0079] Preferably, the sheet-like structure 20 is reinforced in the region of the longitudinal wall side 42 and more elastic in the region of the two wall corner regions 43. The sheet-like structure 20 therefore preferably has a lower maximum tensile force elongation ε H according to DIN EN ISO 13934-1:2013 in the region of the longitudinal wall side 42 than in the two wall corner regions 43. High flexibility of the sheet-like structure 20 in the region of the wall corner regions 43 is advantageous for good shaping. A low maximum tensile force elongation ε H in the region of the longitudinal wall side 42 makes it stiffer and imparts stability to the cover 1, in particular to the bellows.

[0080] Subsequently, the sheet-like structure 20 is fixed according to the invention by means of the clamping elements 48 to the inner mold 36 and clamped against the molding surface 44 ( Fig. 8 ).

[0081] For this purpose, the clamping elements 48 are clamped around the impression surface 44, preferably in such a way that one clamping element 48 is arranged in the groove-like depression 46 and one clamping element 48 is arranged in each of the grooves 47.

[0082] In the preferred embodiment of the invention shown, the clamping elements 48 are clamped around the longitudinal wall side 42 facing the mold shell 37 and the adjoining wall corner regions 43, as well as the two adjoining longitudinal wall sides 42 and the adjoining wall corner regions 43. In the region of the longitudinal wall side 42 facing the clamping element holding part 39, the clamping elements 48 each intersect and are clamped, in particular clamped, with their free clamping element ends 48a in one of the clamping element receiving slots 56.

[0083] By means of the clamping elements 48, the sheet-like structure 20 is thus fixed to the inner mold 36. Furthermore, the clamping elements 48 ensure that the sheet-like structure 21 also lies completely against the molding surface 44.

[0084] Alternatively or additionally, the clamping elements 48 can be tensioned by means of cables or other clamping devices. For this purpose, the clamping elements 48 can each be connected at their end regions to cables or other clamping devices with which the clamping elements 48 can be clamped against the molding surface 44. The required clamping force can be achieved by mechanical, electrical, hydraulic, pneumatic means, or other means.

[0085] Subsequently, the outer mold shell 37 is moved toward the inner mold 36 such that the sheet-like structure 20 is arranged therebetween in a form-fitting manner. In particular, the upper side of the sheet-like structure 20 facing the outer mold shell 37 rests against the counter-impression surface 49.

[0086] At least when the polymer coating 22 has not yet cured and in particular vulcanized, at least one of the two molds 36; 37 is subjected to heat so that the polymer coating 22 cures, preferably is vulcanized.

[0087] To heat the molds 36;37, they can be transferred, for example, to a heating chamber, an autoclave or an oven.

[0088] Alternatively, heat pipes or heating mats can be incorporated into the molds 36;37 or the profile parts.

[0089] Furthermore, the curing, preferably vulcanization, of the polymer coating 22 and / or the curing of the clamping elements 48 can be effected by exposure to UV or IR radiation or hot air, or by an induction process by exposure to an electromagnetic field. The sheet-like structure 20 can initially be exposed only from the outside to UV or IR radiation or hot air or an electromagnetic field, whereby the polymer coating 22 or the clamping elements 48 are completely or at least partially cured. If desired, the sheet-like structure 20 can then be removed from the molds 36; 37 and further exposed to UV or IR radiation or hot air or an electromagnetic field for complete curing. It is also possible to design the molds 36; 37 such that the UV or IR radiation or the hot air or the electromagnetic field can pass through them to the sheet-like structure 20. For example,For this purpose, the molds 36; 37 can be provided with holes. Furthermore, the mold 36 can be made of glass that is transparent to IR radiation, so that the UV or IR radiation or the electromagnetic field passes through the mold 36 to the sheet 20 stretched against the molding surface 44.

[0090] By curing the polymer coating 22, the sheet-like structure 20 is fixed in its basic shape. In the present case, after curing, the sheet-like structure 20 has a wave contour 15 with two waves 16. Furthermore, it is U-shaped and has two cover wall corner regions 9. The cured sheet-like structure 20 thus forms a cover wall section 4c of a cover wall 4 to be produced.

[0091] "Fixed in its basic shape" means that the sheet-like structure 20 retains its basic shape without external stress. Of course, the sheet-like structure 20 can deform reversibly, particularly elastically, when used as a cover wall 4 in order to follow relative movements of components connected by the cover 1, particularly the bellows. However, the basic shape, i.e., the wave or fold contour 15; 11, remains essentially unchanged.

[0092] At the same time as the surface structure 20, the clamping elements 48 also advantageously harden and become dimensionally stable due to the application of heat.

[0093] The hardened sheet 20 with the hardened clamping elements 48 is then removed from the molding device 35. The protruding, unnecessary portions of the clamping elements 48 are preferably cut off.

[0094] Optionally, this may be followed by a sealing or sealing step, e.g., to close any remaining openings to the channels 23.

[0095] The cured sheet-like structure 20 and the hardened clamping elements 48 thus form a cover, in particular a bellows section, of a cover 1 to be produced, in particular a bellows to be produced. The dimensionally stable sheet-like structure 20 forms a cover wall section 4c, in particular a bellows wall section, of the cover wall 4, in particular the bellows wall 4, and the hardened, dimensionally stable clamping elements 48 form the cover clamping frames 3, in particular the bellows clamping frames, or at least a part thereof.

[0096] Several cover sections produced in this way can then be assembled to form a cover half or an entire cover 1. In particular, several bellows sections produced in this way can be assembled to form a U-shaped bellows half or an entire bellows. In particular, the cover wall sections 4c can be sewn and / or welded and / or glued together and / or connected by means of a frame. The clamping elements 48 do not necessarily have to be connected to one another. It is sufficient if the cover wall sections 4c are connected to one another. If necessary, the clamping elements 48 can, however, be connected to one another, e.g., using transfer profiles.

[0097] A particularly advantageous feature is that the clamping elements 48 are already integrated into the cover wall sections 4c. Subsequent assembly is therefore no longer necessary. Since the clamping elements 48 are initially flexible, slack, or pliable, cover wall sections 4c with cover wall corner areas 9 can also be easily manufactured in a single operation.

[0098] In particular, the method according to the invention can also be used to produce annular cover wall sections 4c in a single shaping step. For this purpose, a single sheet-like structure 20 is preferably draped around the entire inner mold 36, with edge regions of the sheet-like structure 20 preferably overlapping, so that a closed ring is created. The edge regions of the sheet-like structure 20 can be connected by vulcanizing the polymer coating 22. The edge regions of the sheet-like structure 20 are preferably connected—at least in a region between adjacent channels 23—before the sheet-like structure 20 is draped onto the mold 36. For example, the edge regions can be sewn together.

[0099] In this case, a single outer mold shell 37 can be used and individual sections of the sheet 20 can be heated and cured one after the other, or several outer mold shells 37 can be used and the entire sheet 20 can be heated and cured in one operation.

[0100] In this way, by means of the method according to the invention, an entire cover 1, in particular an entire bellows, with a closed, circumferential cover wall 4 can be produced in a single shaping step, without the need for cover sections to be subsequently connected to one another. For this purpose, the molds 36; 37 have corresponding molding surfaces 44; 49, e.g., with the corresponding number of curved or groove-like shaping sections 45; 50. The cover wall 4 consists of a single cover wall section 4c, which can consist of one or more sheet-like structures 20: Instead of a single sheet-like structure 20, several sheet-like structures 20 can be draped with their edge regions overlapping around part or the entire inner mold 36, thereby producing, for example, U-shaped or annular cover wall sections 4c in a single operation.Also, multiple sheet-like structures 20 can be draped adjacent to one another and overlapping in the vertical direction. A tensioning element 48 can extend, for example, through multiple adjacently arranged sheet-like structures 20. The multiple sheet-like structures 20 can differ, among other things, in the textile used, the polymer coating used, and / or the degree of vulcanization.

[0101] According to a further embodiment of the method according to the invention, the clamping elements 48 are not arranged in channels 23 of the reinforcement member 21, but are clamped externally around the sheet material 20 draped on the inner mold 36. In this case, too, it is ensured that the sheet material 20 rests fully against the molding surface 44, and that the wave contour 16 or fold contour 11 is formed precisely. The clamping elements 48 are removed after the molding process. Thus, only a cover wall section 4c is produced without cover clamping frame elements.

[0102] And according to a further embodiment of the invention, during the curing and molding process, only the clamping elements 48 are cured and fixed in their shape. The polymer coating(s) of the sheet-like structure 20 is / are already cured, in particular vulcanized. The shape of the cover wall section 4c is thus fixed due to the shape fixation of the clamping elements 48. In this case, the clamping elements 48 are positioned in channels 23 of the reinforcement member 21 as described in the first embodiment.

[0103] The advantage of the method according to the invention is therefore in particular the high-quality shaping of the cover wall 4 or cover wall sections 4c, which is ensured by the use of the clamping elements 48.

[0104] If the clamping elements 48 are arranged in the channels 23 and cured, cover wall sections 4c with cover clamping frame elements or an entire cover wall 4 with cover clamping frame 3 of a cover 1, in particular a bellows, can be produced in one operation.

[0105] According to a first embodiment of the invention, the bellows according to the invention is used for a gangway 58, at which two vehicle parts 59a;b of a vehicle 60 are movable relative to one another, in particular, are connected to one another in an articulated manner, in order to protect the gangway 58 from weather and drafts. The vehicle 60 is preferably an articulated bus 61 or a rail vehicle, in particular a passenger train, a tram, a metro, or a subway. The two vehicle parts 59a;b are in particular rotatable relative to one another about a vertical axis of rotation and / or displaceable relative to one another in the direction of travel and / or displaceable transversely to the direction of travel and / or rotatable about a longitudinal axis of the vehicle (rolling).

[0106] According to a further embodiment of the invention, the bellows according to the invention is a transition bellows for protecting the transition of an aircraft boarding bridge or stairs to the aircraft and / or to the terminal.

[0107] Or, according to a further embodiment of the invention, the bellows according to the invention is a transition bellows for protecting the transition between two building parts, for example for protecting the transition between a bridge and a building section.

[0108] The bellows can be formed from several flat bellows elements (not shown), each of which has two straight clamping frame elements between which a flat structure 20 is clamped.

[0109] In summary, the cover 1 according to the invention is thus a transition element, preferably a transition bellows, for vehicles, building connections or for passenger boarding bridges or stairs, preferably with a planar or rectangular cross-section or a U-shaped cross-section. The transition element, preferably the transition bellows, serves to protect a transition between two vehicle parts that are connected to one another in a movable manner, or between two building parts or an aircraft or a building with a passenger boarding bridge, in particular between two vehicle parts that are connected to one another in an articulated manner, from external influences. Each of the aforementioned uses is in itself a use according to the invention.

[0110] Accordingly, the invention also relates to a vehicle 60, in particular a rail vehicle or an articulated bus 61, comprising at least two vehicle parts 59a;b which are movably connected to one another at a transition 58, preferably connected to one another in an articulated manner, wherein the vehicle 60 has at least one transition element according to the invention for each transition 58, preferably a transition bellows, in particular a folding or corrugated bellows 1;10, which protects the transition 58.

[0111] In addition, the invention relates to an aircraft passenger boarding bridge or stairs, wherein the aircraft passenger boarding bridge or stairs has at least one transition element according to the invention, preferably a transition bellows, preferably a folding or corrugated bellows 1; 10.

[0112] The invention also relates to a building connection comprising two building parts connected to one another at a transition, wherein the building connection has at least one transition element according to the invention, preferably a transition bellows, preferably a folding or corrugated bellows 1; 10 for protecting the transition between the two building parts.

[0113] As already explained, it is also within the scope of the invention that the reinforcement 21 is multi-layered and consists of several textile fabrics, each of which is bonded to one another by means of an adhesive layer made of a polymer. An adhesive layer made of a polymer can also be present between the polymer coating 22 and the reinforcement 21. Consequently, it is also within the scope of the invention that the adhesive layers, or only the adhesive layers, only harden during the heating of the fabric 20. The only important thing is that the fabric 20 itself is heat-curable. For this purpose, it has at least one heat-curable polymer layer.

[0114] It is also within the scope of the invention to produce a smooth or uncorrugated and fold-free or uncontoured or flat cover wall section 4c without folds or wave contours simply by curing the tensioning elements 48. In this case, the sheet-like structure 20 is designed to be correspondingly elastic, preferably in accordance with DE 10 2011 107 370 A1. The hardening of the tensioning elements 48 contributes to shaping and stiffening, so that the cover 1, in particular the bellows, retains its (basic) shape and is, in particular, less flexible to forces acting in the transverse direction or the cover circumferential direction 2b (or perpendicular to the cover longitudinal direction 2a). The basic shape can, for example, be flat, rectangular, or U-shaped, as described above.

[0115] Furthermore, the folds 12 and corrugations 16 can also have a shape other than that shown. The corrugations 16 can, for example, have a trapezoidal or rectangular shape.

Claims

1. Shaping method for producing a cover wall portion (4c) for a cover (1), wherein the cover (1) is a gangway element, preferably gangway bellows, for vehicles, building connections, or for air passenger bridges or air passenger stairs, and is preferably designed to be planar or to be rectangular in cross section or U-shaped in cross section, wherein the gangway element, preferably the gangway bellows, is used to protect a gangway between two vehicle parts which are connected to one another so as to be movable relative to one another, or between two building parts, or between an aircraft or a building and an air passenger bridge, in particular a gangway between two vehicle parts which are connected to one another in an articulated manner, against external influences, wherein the cover wall portion (4c) comprises at least one multilayer sheet material (20) which comprises a reinforcement material (21) and a polymer coating (22) which is provided on at least one side, preferably on both sides, the shaping method comprising the following steps: a) providing the at least one multilayer sheet material (20), b) draping the at least one multilayer sheet material (20) on a molding surface (44) of a mold (36) and tensioning the at least one multilayer sheet material (20) against the molding surface (44) by means of at least one elongate, flexible, non-dimensionally stable tensioning element (48), c) curing the at least one multilayer sheet material (20) and / or the at least one tensioning element (48) such that the cover wall portion (4c) is fixed in its shape.

2. Shaping method according to claim 1, characterized in that the at least one multilayer sheet material (20) is cured and in particular heated such that it is fixed in its shape, and / or the at least one tensioning element (48) is cured and in particular heated such that it is fixed in its shape.

3. Shaping method according to claim 1 or claim 2, characterized in that a cover wall portion (4c) is produced which has a folded or corrugated contour (11; 15) having at least one fold (12) or corrugation (16), the molding surface (44) has a corresponding shaping contour for forming the folded or corrugated contour (11; 15), the at least one multilayer sheet material (20) is tensioned against the molding surface (44) by means of the at least one tensioning element (48) such that the at least one multilayer sheet material (20) has the folded or corrugated contour (11; 15), and the at least one multilayer sheet material (20) and / or the at least one tensioning element (48) is cured and in particular heated such that the at least one multilayer sheet material (20) is fixed in its shape which has the folded or corrugated contour (11; 15).

4. Method according to claim 2 or claim 3, characterized in that the at least one provided multilayer sheet material (20) comprises at least one polymer layer made of a thermosetting polymer, wherein the at least one polymer layer is cured when the sheet material (20) is heated, and the sheet material (20) is thereby fixed in its shape, which in particular has the folded or corrugated contour (11; 15), wherein optionally one or both polymer coatings (22) consist of the thermosetting polymer.

5. Method according to any of the preceding claims, characterized in that the flexible tensioning element (48) is a tensioning rope or a tensioning tube, wherein the tensioning tube is preferably a corrugated tube, in particular a braided corrugated tube.

6. Method according to any of the preceding claims, characterized in that the at least one tensioning element (48) is flexible before curing and in particular heating and is fixed in its shape when cured, e.g. by heating, wherein the multilayer sheet material (20) is preferably fixed in its shape, which has the folded or corrugated contour (11; 15), by fixing the at least one tensioning element (48) in its shape, wherein the at least one tensioning element (48) is preferably a) a tensioning tube filled with a thermosetting material which cures when the tensioning tube is heated, and / or b) a tensioning rope impregnated with a thermosetting material which cures when the tensioning rope is heated, wherein the thermosetting material is preferably a thermosetting polymer, preferably epoxy resin and / or phenolic resin and / or a thermoplastic polymer or an elastomer mixture with a high Shore hardness.

7. Method according to any of the preceding claims, characterized in that, preferably before draping, the at least one elongate tensioning element (48) is arranged in a channel (23) of the multilayer sheet material (20), preferably of the reinforcement material (21), wherein the multilayer sheet material (20) preferably comprises - a reinforcement material (21) which has a woven reinforcement fabric (24) made of warp threads (25) and weft threads (26), wherein the warp and weft threads (25; 26) are woven together such that the woven reinforcement fabric (24) has both single-layer woven fabric regions (29) and at least one at least double-layer woven fabric region (30) having at least two woven fabric layers (31a; b) which are not connected to one another such that the channel (23) is formed between each of the woven fabric layers (31a; b); and / or - a reinforcement material (21) which has two sheet materials which are connected to one another such that guides in the form of loops are formed, which guides each form the channel, wherein the sheet materials are preferably connected to one another by stitching, warp knitting, weft knitting, bonding or gluing, and / or the sheet materials each comprise at least one textile fabric, wherein the textile fabric is, in each case, preferably a woven or knitted fabric, in particular a warp knitted fabric or a weft knitted fabric; and / or - a textile spacer fabric made of two textile fabrics connected to one another by pile threads, wherein the pile threads keep the two textile fabrics at a distance such that at least one channel is formed, wherein the textile spacer fabric is preferably a woven spacer fabric or knitted spacer fabric, preferably a warp knitted spacer fabric or a weft knitted spacer fabric.

8. Method according to any of the preceding claims, characterized in that the at least one elongate tensioning element (48) for tensioning the at least one multilayer sheet material (20) is tensioned around the molding surface (44), wherein the tensioning element (48) or, in the case of a plurality of tensioning elements (48), at least some of the tensioning elements (48) are preferably each arranged in a groove-like depression (46) in the molding surface (44), and / or wherein preferably in the region of a depression (46), a corrugation trough (19) of the corrugated contour (15), or a fold edge (14b) of the folded contour (11) is formed.

9. Method according to any of the preceding claims, characterized in that a) a plurality of multilayer sheet materials (20) are draped on the molding surface (44), wherein adjacent multilayer sheet materials (20) preferably overlap in their edge regions, wherein the multilayer sheet materials (20) are preferably connected to one another in the overlapping edge regions by curing the polymer coatings (22), and / or b) in a shaping step, an annular cover wall portion (4c) or a complete annular cover wall (4) is produced from a single or a plurality of multilayer sheet materials (20).

10. Method according to any of the preceding claims, characterized in that - a first region of the at least one multilayer sheet material (20) is tensioned against a region of the molding surface (44) in which the molding surface is strongly curved, and - a second region of the at least one multilayer sheet material (20) is tensioned against a region of the molding surface (44) in which the molding surface is less strongly curved, wherein the multilayer sheet material (20) has a higher elongation at maximum force εH, according to DIN EN ISO 13934-1:2013, in the region of the more strongly curved region than in the less strongly curved region.

11. Method according to any of the preceding claims, characterized in that a) a mold shell (37) which has a counter-molding surface (49) corresponding to the molding surface (44) is used, wherein the mold shell (37) is moved toward the inner mold (36) before heating such that the at least one multilayer sheet material (20) is arranged in a form-fitting manner therebetween and a top side of the at least one multilayer sheet material (20), which faces the outer mold shell (37), preferably rests on the counter-molding surface (49), and / or b) the at least one elongate tensioning element (48) is tensioned on the outside around the multilayer sheet material (20) draped on the mold (36).

12. Cover (1) comprising a cover wall (4) which preferably has a folded or corrugated contour (11; 15), wherein the cover (1) is a gangway element, preferably gangway bellows, for vehicles, building connections, or for air passenger bridges or air passenger stairs, and is preferably designed to be planar or to be rectangular in cross section or U-shaped in cross section, wherein the gangway element, preferably the gangway bellows, is used to protect a gangway between two vehicle parts which are connected to one another so as to be movable relative to one another, or between two building parts, or between an aircraft or a building and an air passenger bridge, in particular a gangway between two vehicle parts which are connected to one another in an articulated manner, against external influences, and wherein the cover (1) comprises at least two cover tensioning frames (3), and the cover wall (4) is clamped into the cover tensioning frames (3), and the cover tensioning frames (3) are each arranged in a channel (23) of the cover wall (4), characterized in that the cover wall (4) comprises at least one cover wall portion (4c) produced according to the method according to any of the preceding claims, and the cured, dimensionally stable tensioning elements (48) form the cover tensioning frames (3) or at least a part thereof.

13. Cover (1) according to claim 12, characterized in that a) the cover (1) has a folded contour (11) and the folded contour (11) has a plurality of adjacent folds (12), wherein the folds (12) each have fold flanks (13) which each merge into one another in pairs via alternating inner and outer fold edges (14a;b), and wherein the cover wall (4) is clamped into a cover tensioning frame (3) at at least some of the fold edges (14a;b), wherein the cover tensioning frame (3) consists of at least one cured tensioning element (48), wherein channels (23) are optionally provided in both the inner and the outer fold edges (14a;b) in which cover tensioning frames (3) in the form of cured tensioning elements (48) are at least partially arranged, or b) the cover (1) has a corrugated contour (15), and the corrugated contour (15) has a plurality of adjacent, in particular U-shaped, corrugations (16) which each merge into one another via a corrugation edge (18), wherein the cover wall (4) is clamped into a cover tensioning frame (3) at at least some of the corrugation edges (18), wherein the cover tensioning frame (3) consists of at least one cured tensioning element (48).

14. Method for producing a cover (1) according to claim 12 or claim 13, characterized in that at least one cover wall portion (4c) of the cover wall (4) is produced according to the method according to any of claims 1 to 11.

15. Vehicle (60), in particular a rail vehicle or articulated bus (61), having at least two vehicle parts (59a;b) which are connected to one another at a gangway (58) so as to be movable relative to one another, and are preferably connected to one another in an articulated manner, characterized in that, for each gangway (58), the vehicle has at least one gangway element according to claim 12 or claim 13, in particular gangway bellows, preferably folding or corrugated bellows (10), which protects the gangway (58).

16. Air passenger bridge or air passenger stairs, characterized in that the air passenger bridge or air passenger stairs have at least one gangway element according to claim 12 or claim 13, preferably gangway bellows, preferably folding or corrugated bellows (10), for protecting the gangway of the air passenger bridge or air passenger stairs to the aircraft and / or to the terminal.

17. Building connection having two building parts connected to each other at a gangway, characterized in that the building connection has at least one gangway element according to claim 12 or claim 13, preferably gangway bellows, preferably folding or corrugated bellows (10), for protecting the gangway of the two building parts.