Method for producing objects

Abstract

A method for producing an object comprises the steps of providing a base element, providing a plurality of profiles, and fastening the profiles to a surface of the base element; the method further includes the steps of defining a plurality of constraining elements by one or more of the profiles, the constraining elements moving along a vertical axis relative to the base element, and applying a filler material onto the base element in at least one engagement portion cooperatively defined between the surface and the at least one constraining element.

Description

Technical Field

[0001] The invention relates to a method for producing a semi-finished object.

[0002] In other words, the present invention relates to the technical field of production processes aimed at producing a supporting base in the form of a semi-finished product, which supporting base can be defined as a "standard article" in the language used in the present invention: such an object can be used for the construction of complex objects both in the architectural and industrial fields (as well as in several sub-sectors of the latter), such as structural elements and frames, for example. Background Art

[0003] Prior art

[0004] In the prior art, it is known to use a support base which has a thickness and can have various shapes. Then a filling material is deposited, whose shape and size are adjusted after a removal operation, so as to obtain the final object.

[0005] In particular, the filling material is deposited on the base by an additive manufacturing (or overmolding or sintering) process.

[0006] Disadvantageously, the prior art shows that the filling material does not adhere properly to the base, and it is known to use honeycomb panels, ie panels equipped with a pair of panels and a honeycomb structure placed between the panels, to overcome this drawback.

[0007] Honeycomb panels can be used in a variety of areas due to their unique design, which makes them lightweight and therefore easy to use and install, while being highly (directionally) resistant to impacts, cracks and loads.

[0008] These panels can be used for the construction of complex objects both in the architectural and industrial fields, such as for example structural elements and frames, since they are both lightweight and durable due to the honeycomb structure.

[0009] In particular, one of the plates is milled and the filling material is fed between the honeycomb structures through the through-holes obtained by the milling. In this way, the material deposited between the cavities settles under the upper plate and cannot come out again. Disadvantageously, the honeycomb structure (which can be produced, for example, from plastic material) is anchored to the plates (usually made of metal) by gluing.

[0010] By gluing the honeycomb structure to the surface, the anchoring will depend entirely on the shear or tear properties of the adhesive and will last within a narrow thermal range, outside of which, even for a short time, the performance will be permanently lost due to misalignment of the components or impairment of the adhesive properties.

[0011] On the other hand, if the honeycomb structure were to be welded to the surface, the internal parts of the sandwich would be thermally stressed, compromising the interface between the cavity and the plate containing it in a way that cannot be verified or quantified from a “predictive” point of view.

[0012] In contrast, by opting for mechanical restraint (e.g. bolting the honeycomb structure to the surface), there would be a risk of cutting or more generally destroying the structural continuity of the functional components within the panel that perform “critical” load-bearing / structural functions.

[0013] Therefore, due to the above-mentioned connection methods, the performance and choice of materials to be deposited are limited, since the connections between the components of such an object may degrade and cause the collapse of the entire structure. Summary of the invention

[0014] Therefore, the technical task of the present invention is to provide a method for producing an object capable of overcoming the disadvantages of the prior art.

[0015] It is therefore an object of the present invention to provide a method for producing an object which allows to reduce production costs and to use a wider range of materials, thereby preventing the filling material from "slipping" from the base.

[0016] The specified technical task and purpose are substantially achieved by a method for producing an object, which method comprises one or more of the technical features set forth in the attached claims. The dependent claims correspond to possible embodiments of the invention.

[0017] According to the invention, a method for producing an object, in particular a method for producing a semi-finished object, is shown.

[0018] The method is implemented by providing at least one base element, preferably a layered element, and at least a plurality of profiles.

[0019] The method also includes fastening a profile to a surface of the base member and defining a plurality of restraining members along a vertical axis perpendicular to the laminar member by the one or more profiles.

[0020] Finally, the method comprises applying a filling material to the laminar element carrying the constraining element, preferably by means of an additive manufacturing process.

[0021] According to one aspect of the invention, the filler material is applied at least in an engagement portion cooperatively defined between the surface and the at least one constraining element.

[0022] Preferably, the base element is made of metal.

[0023] Preferably, the base element has a layered or curved shape.

[0024] Preferably, the profile is made of metal.

[0025] Preferably, the base element defines a smooth base.

[0026] Preferably, the profiles are arranged on the base element in such a way as to define a grid and are then welded to the base element.

[0027] Preferably, the profile defines a series of welded metal strips which are deflected, riveted or formed to create undercuts to define the above-mentioned restraining elements.

[0028] Preferably, the profile defines a series of metal strips which fit into grooves cut in the base element.

[0029] Preferably, the profile is defined by a preformed foam which is welded to or produced on the base element.

[0030] Preferably, the step of fastening the profile to the base element is performed by welding or sintering the profile.

[0031] Preferably, the base element is cut out so as to form a plurality of grooves in said base element, and the fastening step is performed by fitting the profiles into the respective grooves.

[0032] Advantageously, the base element has both a morphological and a structural function.

[0033] Advantageously, the method is cost effective compared to existing production methods of the prior art.

[0034] Advantageously, the constraining element prevents the filling material from detaching from the laminar element.

[0035] Advantageously, the specific structure made of base elements, profiles and restraining elements, as well as the materials from which the different components are made, makes it possible to use different filling materials and thus to work at different temperatures than those used in the prior art.

[0036] According to another aspect of the present invention, there is provided a semi-finished object which is made or can be made by the above production method.

[0037] Other characteristics and advantages of the invention will become more apparent from the indicative and therefore non-limiting description of an embodiment of a method for producing a semi-finished object. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The invention will be explained below with reference to the accompanying drawings, which are provided for illustration purposes only and therefore not for limiting purposes, in which:

[0039] Figure 1 is a schematic diagram of a semi-finished object obtained by the method of the present invention;

[0040] Figure 2Ais a schematic diagram of an alternative embodiment of the object;

[0041] Figure 2B It is a reference Figure 2A A schematic diagram of the steps of the method object of the present invention in an embodiment of the object;

[0042] Figure 3 is a schematic diagram of another embodiment of a semi-finished object; and

[0043] Figure 4 is a schematic diagram of an assembly of another embodiment of a semi-finished object;

[0044] Figure 5 is a schematic diagram of another embodiment of a semi-finished object. DETAILED DESCRIPTION

[0045] The present invention relates to a method for producing a semi-finished object 1 (in other words, the method aims at providing a semi-finished or finished product); the method is implemented by providing a base element 2, which in turn comprises a surface 2a (for example, positioned as the "upper" surface in the accompanying drawings, but this surface can be any surface oriented in any way according to the needs at the time).

[0046] The base element 2 may be made in the shape of a flat or curved laminar element, but more generally, the base element 2 may have any shape suitable for obtaining the final semi-finished object 1 .

[0047] For example, the base element 2 may be made of metal or other material, and the method may therefore conveniently comprise a first step in which a metal base is provided.

[0048] The base element 2 has a smooth surface 2a (or in any case a predetermined surface roughness, also by using appropriate surface processing of the method) which is suitable for receiving the remaining structural components provided by the invention, such as participating to the necessary extent in the development of the restraint reaction: for this purpose, the method also includes providing a plurality of profiles 3.

[0049] The profile 3 is to be understood as a wall with a constant or variable cross section, or as a straight or curved (eg sinusoidal) element: according to another embodiment of the invention, the profile 3 can also be understood as a foam (eg a so-called "metal foam").

[0050] In general, the profile 3 according to the invention is any element having a specific shape or length suitable for manufacturing an object 1 .

[0051] According to the invention, the profiles 3 may be arranged to define a grid element, wherein the profiles 3 are "interwoven" (or cross-linked with each other to form a matrix pattern), e.g. Figure 2A and Figure 2BAs shown in the implementation method in .

[0052] The profiles 3 may be arranged to define a honeycomb structure having any topology and / or spatial geometry according to the needs at the time: as a non-limiting example, the honeycomb structure may have a plurality of spherical, ie spherical, hemispherical or substantially spherical cavities.

[0053] In other words, profiles 3 of different shapes can be connected together or placed side by side to define a specific shape.

[0054] Operationally, the step of providing profiles 3 defines a plurality of containment cells 3a: the term "containment cell" 3a is therefore understood as a portion of the "empty" space defined between the various profiles 3, each containment cell 3a thus being able to have a parallelepiped or cylindrical shape or other shapes defined by the arrangement of the profiles 3.

[0055] The method also comprises a step of fastening the profile 3 to the upper surface 2a of the laminar element 2: this fastening step thus defines, together with the base element 2, the bottom of each housing cell 3a.

[0056] The method also comprises a step of fastening the profile 3 to the base element 2 by interlocking, welding or sintering, for example by welding the profile 3 to the upper surface 2a of the layered element 2 (in other words, the steps of the method described so far make it possible to obtain a grid welded to a smooth base).

[0057] In one embodiment of the method, a step of cutting out the base element 2 can be provided so as to form a plurality of grooves on its surface 2a: in this way, the step of fastening the profile 3 to the laminar element 2 is carried out by fitting the profile 3 into corresponding grooves defined on its upper surface 2a (thus, in this embodiment an object 1 is manufactured which is defined by a series of metal strips fitted into grooves cut in the base element 2).

[0058] After the cutting and assembly steps, according to the method, a step of welding the profile 3 to the base element 2 may be provided: if the profile 3 is defined by foam, the latter may be preformed and welded or made directly on the base element 2 .

[0059] The method also comprises defining a plurality of restraining elements 4 by means of one or more profiles 3 along a vertical axis "Z" transverse to and, for example, perpendicular to the base element 2: in this way, the restraining elements 4 are therefore active at least along the vertical axis "Z" and, in other words, the method comprises providing restraining elements 4 having the function of retaining filling material 6, as will be explained more clearly below.

[0060] To this end, the method comprises producing a joint portion cooperatively defined between the surface 2a and at least one of the constraining elements 4 : the constraining element 4 thus defines a retaining effect and / or function along an axis perpendicular to the upper surface 2a of the base element 2 .

[0061] In one possible embodiment of the present invention, the step of defining a plurality of restraining elements 4 is carried out by locally deforming one or more profiles 3, for example (but not limited to), the deformation of the profile 3 is carried out by drawing, or indenting, or bending or rolling the profile 3.

[0062] Alternatively, the step of defining the plurality of restraining elements 4 is performed by shaping the profile 3 to produce undercuts. Figure 5 Possible shapes of profile 3 are shown to create a restraining element 4, under which filler material 6 can penetrate and be retained. For example, profile 3 can be shaped to define a T-shaped or inverted L-shaped restraining element. Alternatively, profile 3 can be shaped so that it has an "accordion" shape, or is characterized by a surface (along the vertical axis "Z") being embossed or presenting protrusions, the size of which is less than half the distance between one profile and the other, and greater than 0.5 mm, the extent to which the polymer shrinks during cooling; these protrusions will act as restraining elements.

[0063] The restraining element 4 can be defined at the top of the profile 3 (i.e. the maximum distal portion of the profile 3 relative to the base element 2), or can be defined in the middle portion of the profile 3 (i.e. the portion inserted between the surface 2a and the maximum distal portion), or as described in the above paragraph, along a vertical surface.

[0064] In other words, the restraining element 4 is made by riveting the profile 3 so as to create a portion intersecting the vertical axis "Z" perpendicular to the upper surface 2a.

[0065] The above-mentioned step of defining multiple constraint elements 4 can be carried out by defining one or more holes in at least one profile 3: in other words, the method involves creating through holes in one or more profiles 3 so that the thereby created "channel" defines constraints along an axis perpendicular to the upper surface 2a.

[0066] In the presence of these holes, the filling material will spread into the through holes, preventing the remaining material deposited in each receiving unit 3a from moving along the vertical axis "Z".

[0067] According to another possible embodiment of the method, the step of defining a plurality of constraining elements 4 is performed by arranging one or more profiles 3 at a predetermined inclination angle "A" relative to the surface 2a; in other words, the inclined profiles 3 define the constraining elements 4 by intersecting with the vertical axis "Z".

[0068] According to one aspect of the invention, the profiles 3 can be inclined (relative to the vertical direction leaving the surface 2a) to facilitate the insertion of the filling material: in this geometrical / topological possibility, the inclined profiles 3 can also alternate with non-inclined profiles 3 along the extension direction of the base element 2 (thus parallel to the vertical axis "Z").

[0069] Quantitatively, the inclined profile 3 may be inclined at an angle of 45° to 90° relative to the base element 2 (ie relative to the vertical axis “Z”).

[0070] As regards the step of defining a plurality of restraining elements 4, this can be carried out by crossing the profiles 3 with a plurality of inserts 5 fastened at the top or middle portion of each profile 3, as Figure 4 As shown in the example in: In turn, the inserts 5 can be fastened before or after the step of welding the profile 3 to the base element 2 (the figure shows by way of example that the inserts 5 give the profile 3 a roughly T-shape, wherein each insert 5 intersects the vertical axis "Z").

[0071] Each accommodating unit 3a comprises at least one constraining element 4, in which respect the step of defining the constraining element 4 may be a combination of the above-mentioned steps (in other words, a single object 1 may have a constraining element 4 made by deforming, tilting or drilling the profile 3 and / or by adding an insert 5).

[0072] The method further comprises applying a filling material 6 to the base element 2 carrying the restraining elements 4 , preferably by means of an additive manufacturing or overmolding process: the filling material 6 is applied at least in a joint portion cooperatively defined between a surface 2a of the base element 2 and at least one restraining element 4 .

[0073] In other words, the filling material 6 (which may be a polymer material, for example) is deposited inside the containing unit 3a and spreads into the constraining element 4 (when they are in the form of through holes) or under the constraining element 4 (when they are defined by a deformation or inclination of the profile 3 or by the addition of an insert 5): in this way, the filling material 6 is "attached" to the constraining element 4 and its movement along the vertical axis "Z" is prevented by the constraining element 4.

[0074] Advantageously, the method provides a step for producing an undercut in which the filling material 6 penetrates and adheres, thereby preventing it from sliding along the vertical axis "Z"; in this way, the object 1 made by the present method ensures that material deposited on the interface structure is not removed therefrom.

[0075] In particular, for example Figure 2B As can be seen in FIG. 4 , the filling material 6 is held by corresponding restraining elements 4 , which prevent it from escaping from the base element 2 .

[0076] The method also includes a milling step for producing the standard object 1, or by this method, a supporting base for the filling material 6 can be produced, which supporting base can be defined by a grid welded to a smooth base, a series of welded metal strips deflected or riveted to a "base plate" (or more generally, a base element 2), a series of metal strips assembled in grooves cut into the base support and then optionally welded, or a pre-formed foam welded or manufactured on top of the base element or plate 2.

[0077] In an alternative embodiment, the method includes the possibility of using a metal powder sintered onto the metal surface of the base (or also the possibility of using a weld made without auxiliary gas): this produces a superstructure with a "bubble" or more generally "open cell" topology that rests on the base surface 2a, in which the polymer can slide.

[0078] Advantageously, the support member produced by the use of the present method has a unique morphology and, at the same time, performs a unique structural function, giving the object 1 as a whole in the context of the method particularly effective properties in terms of the ability of the polymer materials to interpenetrate each other (thereby establishing significant overall confinement): according to the present invention, this interpenetration ability is far greater than that achieved by the above-mentioned known methods, in which the polymer materials, for the various reasons mentioned above, are unable to reach all the pre-arranged internal spaces or reach and fill them in an incomplete manner, or do not "penetrate" deeply into the honeycomb structure.

[0079] Advantageously, the method disclosed and described herein allows various products to be produced in a particularly efficient manner: the present invention therefore also consists of an object 1 made by the method described above and / or claimed hereinafter.

Claims

1. A method for producing an object (1), comprising the following steps: - providing a base element (2), - providing a plurality of profiles (3); as well as - fastening the profile (3) to a surface (2a) of the base element (2), preferably to an upper surface of the base element (2), Characterized in that the method further comprises the following steps: - a plurality of restraining elements (4) defined by one or more of said profiles (3), said restraining elements being movable at least along a vertical axis (Z) transverse to and preferably perpendicular to said base element (2); and - applying a filling material (6) to said base element (2) at least in a joint portion cooperatively defined between said surface (2a) and at least one of said constraining elements (4).

2. Method according to claim 1, wherein the step of defining said plurality of constraining elements (4) is performed by locally deforming one or more profiles (3).

3. The method according to claim 2, wherein the local deformation of one or more profiles (3) is performed by drawing, or indentation, or bending, or calendering, or forming.

4. Method according to one or more of the preceding claims, wherein the step of defining a plurality of constraining elements (4) is performed by defining one or more holes in at least one profile (3).

5. Method according to one or more of the preceding claims, wherein the step of defining said plurality of constraining elements (4) is carried out by arranging one or more profiles (3) at a predetermined angle of inclination (A) relative to said surface (2a). The method according to claim 5 , wherein the inclination angle (A) is 45° to 90°.

7. A method according to one or more of the preceding claims, wherein the step of defining said plurality of restraining elements (4) is carried out by crossing said profile with a plurality of inserts (5) which are fastened or capable of being fastened in the top or middle part of each profile (3).

8. Method according to one or more of the preceding claims, wherein the step of providing said profiles (3) is carried out in such a way that said profiles (3) define a grid element in which said profiles (3) are interwoven with one another.

9. Method according to one or more of the preceding claims, wherein the step of providing said profile (3) is carried out in such a way that said profile (3) defines a honeycomb structure.

10. A method according to claim 8 or 9, wherein the step of providing the profile (3) defines a plurality of accommodating units (3a), and wherein the step of defining the plurality of restraining elements (4) is carried out in such a way that each accommodating unit (3a) includes at least one restraining element (4).

11. Method according to one or more of the preceding claims, wherein the step of fastening the profile (3) to the base element (2) is performed by welding or sintering the profile (3) to the base element (2).

12. Method according to one or more of the preceding claims, comprising a step of cutting the base element (2) to produce a plurality of grooves in the base element (2), the fastening step being carried out by fitting the profiles (3) into the corresponding grooves.

13. Method according to one or more of the preceding claims, further comprising a milling step for producing the object (1).

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