A lightweight honeycomb panel structure

Abstract

The application discloses a light-weight honeycomb plate structure, which comprises a honeycomb plate body formed by integrally combining and arraying a plurality of a honeycomb units and a plurality of b honeycomb units; in the honeycomb plate body, the outer periphery of each a honeycomb unit is integrally distributed with six b honeycomb units in a circumferential array; the two sides of the honeycomb plate body are respectively marked as an A surface side and a B surface side; on the A surface side, each a honeycomb unit is lower than the surrounding b honeycomb units, so that each a honeycomb unit forms a honeycomb-shaped sunken groove on the A surface side of the honeycomb plate body, and the lower part of the six inner sides of the honeycomb-shaped sunken groove of each a honeycomb unit is hollowed out with a plurality of a ventilation hole; the application is suitable for special cabins, windowless secret rooms, curtain walls and acoustically sensitive spaces, and realizes intelligent environmental regulation and control.

Description

Technical Field

[0001] This invention belongs to the field of honeycomb panels. Background Technology

[0002] Partition walls or curtain walls in ship cabins, buildings, and other building envelopes often suffer from limited functionality and difficulty in achieving dynamic control. While existing honeycomb panel structures offer lightweight advantages, they generally exhibit the following drawbacks:

[0003] Static functional limitations: Most honeycomb panels only provide fixed thermal insulation / sound insulation performance and cannot be dynamically switched according to environmental needs (such as ventilation / sealing mode);

[0004] Ventilation and sound insulation are contradictory: while open designs allow for air exchange, they weaken sound insulation and light blocking performance; while sealed designs hinder air circulation.

[0005] Insufficient application of aerogel: The aerogel in existing filled honeycomb panels is usually statically filled, and the porosity cannot be actively controlled through deformation.

[0006] Therefore, there is an urgent need for a lightweight panel structure that can intelligently switch between ventilation and fully enclosed modes, simultaneously optimizing heat insulation, sound insulation, and light-blocking performance. Summary of the Invention

[0007] Purpose of the invention: In order to overcome the shortcomings of the existing technology, the present invention provides a lightweight honeycomb panel structure. This solution is suitable for special ship cabins, windowless enclosed rooms, high-end building curtain walls and acoustically sensitive spaces, and realizes intelligent environmental control.

[0008] Technical solution: To achieve the above objectives, the present invention provides a lightweight honeycomb panel structure, comprising a honeycomb panel formed by an integrated array of a number of a-cell cells and a number of b-cell cells; in the honeycomb panel, each a-cell cell has six b-cell cells arranged in a circular array around its outer periphery; the two sides of the honeycomb panel are respectively referred to as the A-side and the B-side.

[0009] On side A, each a-cell cell is lower than the surrounding b-cell cells, thus forming a honeycomb-shaped recessed groove on side A of the honeycomb panel. The lower part of the six inner sides of the recessed groove of each a-cell cell has several a-vent holes.

[0010] On side B, each a-cell cell is flush with each b-cell cell, and each b-cell cell has several b-vent holes cut out on its surface.

[0011] Furthermore, the honeycomb panel includes state a and state b.

[0012] In state a, several vent holes a and several vent holes b are connected through the cavity in the b honeycomb unit; in state b, the connection between several vent holes a and several vent holes b is broken.

[0013] Furthermore, each α-cell unit contains a sealed α-cell filling chamber.

[0014] Furthermore, the a-cell cell includes a recessed a-wall near the A-side and a b-wall near the B-side, with the a-cell filling chamber located between the recessed a-wall and the b-wall.

[0015] The b-cell unit includes a c-wall near the A-side and a d-wall near the B-side. The b-wall and d-wall are integral and flush. Each b-vent is distributed on the d-wall. An isolation wall parallel to the c-wall and d-wall is provided inside the b-cell unit. The wall between any two adjacent a-cell units and b-cell units is called the a-cell shared wall, and the wall between any two adjacent b-cell units is called the b-cell shared wall. The a-vents on each a-cell shared wall are located between the isolation wall and the sunken a-wall.

[0016] Each c-wall and the isolation wall form a pressure transmission chamber. Any two adjacent pressure transmission chambers are connected through the connecting holes on the common wall of each b-cell. At least one pressure transmission chamber on the cellar plate is connected to the output end of the pressure control air pump.

[0017] An elastic airbag a is provided in the honeycomb cavity between the d wall and the isolation wall, and an elastic airbag b is provided in the center of the elastic airbag a; the elastic airbag a contains a variable spherical air chamber, and also includes a pressure transmission pipe that connects the variable spherical air chamber and the pressure transmission chamber; between the elastic airbag a and the elastic airbag b is a variable aerogel filling chamber filled with aerogel powder.

[0018] Furthermore, both a elastic airbag and b elastic airbag are made of elastic latex or elastic silicone.

[0019] Furthermore, in state a, the outer wall of the spherical elastic airbag a is tangent to the inner wall surfaces of the d wall, the isolation wall, the shared wall of each a honeycomb, and the shared wall of each b honeycomb; a ring of a empty chambers is formed around the upper outer periphery of the elastic airbag a, and the a empty chambers are connected to the honeycomb-shaped sinking groove through several a vent holes; a ring of b empty chambers is formed around the lower outer periphery of the elastic airbag a, and the b empty chambers are connected to the outside world on the B side through several b vent holes; six sets of vertically connected channels are formed around the waist of the elastic airbag a, and the upper and lower ends of each connecting channel connect the a empty chambers and the b empty chambers vertically.

[0020] Furthermore, apart from the a elastic air bladder, b elastic air bladder, and aerogel powder filler, the honeycomb panel is made of polyurethane / hollow silica microsphere composite material.

[0021] Furthermore, in state b, the air pressure in the pressure transmission chamber of each b honeycomb unit rises from p1 to p2. Under the action of internal pressure, the b elastic airbags expand significantly outward, thereby squeezing the aerogel powder in the variable aerogel filling chamber and increasing the pressure in the variable aerogel filling chamber. This causes the a elastic airbags, which are filled with aerogel powder, to continue to expand outward. During the outward expansion of the a elastic airbags, they are constrained by the inner wall of the honeycomb cavity they are in. The expansion of the a elastic airbags continues until the inner wall surfaces of the a elastic airbags and the d wall, the isolation wall, the shared wall of each a honeycomb, and the shared wall of each b honeycomb change from being tangent to being flat. At this point, the original b empty chambers, connecting channels, and a empty chambers are all filled with aerogel powder, and the connection between several a vent holes and several b vent holes is blocked. At this point, the honeycomb plate enters state b.

[0022] Beneficial effects: This invention achieves dynamic multi-functional switching.

[0023] State a: Achieving limited ventilation + sound / light attenuation.

[0024] b-state: Achieve airtight isolation (air permeability ≈ 0) + enhanced heat and sound insulation (thermal conductivity of dense aerogel layer ≤ 0.02 W / m·K) + complete light protection.

[0025] Lightweighting and structural innovation:

[0026] The one-piece molded honeycomb array (polyurethane / hollow silica microsphere composite material) combines strength and thermal insulation, and reduces density by more than 30%; pneumatic drive enables state switching without mechanical moving parts, improving reliability and avoiding wear.

[0027] Energy efficiency and comfort improvements:

[0028] The aerogel powder is compacted in state b and gas exchange is cut off, which significantly improves the overall thermal insulation performance of the board; the honeycomb-shaped recessed groove on side A also has the function of sound absorption and decoration, avoiding the need for an additional acoustic treatment layer. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of the honeycomb panel.

[0030] Figure 2 These are schematic diagrams of the honeycomb panel from two different perspectives.

[0031] Figure 3 Schematic diagrams of the smallest unit of a honeycomb panel from two different perspectives;

[0032] Figure 4 for Figure 3 A sectional view;

[0033] Figure 5 for Figure 4 Sectional view along axis AA;

[0034] Figure 6 This is a schematic diagram illustrating the switching between state a and state b. Detailed Implementation

[0035] The invention will now be further described with reference to the accompanying drawings.

[0036] As attached Figures 1 to 6 A lightweight honeycomb panel structure is shown, such as Figure 1 and 2 As shown, a honeycomb panel 1 is formed by an integrated array of several a-cell cells 2 and several b-cell cells 3; in the honeycomb panel 1, six b-cell cells 3 are integratedly distributed in a circular array on the outer periphery of each a-cell cell 2.

[0037] like Figure 2 The two sides of the honeycomb panel 1 are respectively designated as side A and side B.

[0038] On side A, each a-cell cell 2 is lower than the surrounding b-cell cells 3, thus forming a honeycomb-shaped recessed groove 5 on side A of the honeycomb panel 1. The lower part of the six inner sides of the recessed groove 5 of each a-cell cell 2 is hollowed out with several a-vent holes 4.

[0039] On side B, each a-cell cell 2 is flush with each b-cell cell 3, and each b-cell cell 3 has several b-vent holes 6 cut out on its surface.

[0040] The honeycomb panel 1 includes state a and state b;

[0041] In state a, several a vent 4 and several b vent 6 are connected through the cavity in the b honeycomb unit 3;

[0042] In state b, the connection between several a vent holes 4 and several b vent holes 6 is broken.

[0043] like Figure 4 , 5 As shown in Figures 6 and 7, each a-cell cell 2 contains a sealed a-cell filling chamber 18, which is filled with thermal insulation and sound insulation materials, such as aerogel powder.

[0044] Cellular cell 2 includes a recessed a-wall 19 near the A-side and a b-wall 72 near the B-side, with a-cell filling chamber 18 located between the recessed a-wall 19 and the b-wall 72; Cellular cell 3 includes a c-wall 8 near the A-side and a d-wall 71 near the B-side, with the b-wall 72 and d-wall 71 being integral and flush, and each b-vent 6 distributed on the d-wall 71.

[0045] The interior of b-cell unit 3 is provided with an isolation wall 9 parallel to c-wall 8 and d-wall 71; the wall between any two adjacent a-cell units 2 and b-cell units 3 is denoted as a-cell shared wall 17, and the wall between any two adjacent b-cell units 3 is denoted as b-cell shared wall 80.

[0046] The ventilation holes 4 on the common wall 17 of each a-cell are all located between the surface of the isolation wall 9 and the surface of the sunken a-wall 19.

[0047] Each c-wall 8 and the isolation wall 9 form a pressure transmission chamber 10. Any two adjacent pressure transmission chambers 10 are connected through the connecting holes on the common wall 80 of each b-cell. At least one pressure transmission chamber 10 on the cellar plate 1 is connected to the output end of the pressure control air pump.

[0048] An a elastic airbag 15 is provided in the honeycomb cavity between the d wall 71 and the isolation wall 9, and a b elastic airbag 12 is provided in the center of the a elastic airbag 15; both the a elastic airbag 15 and the b elastic airbag 12 are made of elastic latex or elastic silicone; the a elastic airbag 15 contains a variable spherical air chamber 14, and also includes a pressure transmission pipe 11 that connects the variable spherical air chamber 14 to the pressure transmission chamber 10. The pressure transmission pipe 11 also serves to connect and support the b elastic airbag 12; between the a elastic airbag 15 and the b elastic airbag 12 is a variable aerogel filling chamber 13 filled with aerogel powder; the aerogel powder, with its extremely light weight (density 50~150 kg / m³), ultra-low thermal conductivity (≤0.020 W / (m·K)) and significant sound insulation ability (20dB sound insulation with 1cm thickness), can fully utilize the advantages of its nanoporous structure.

[0049] In state a, the outer wall of the spherical elastic airbag 15 is tangent to the inner wall surfaces of the d wall 71, the isolation wall 9, the common wall 17 of each a honeycomb, and the common wall 80 of each b honeycomb; an a-cavity 7 is formed around the upper outer periphery of the elastic airbag 15, and the a-cavity 7 is connected to the honeycomb-shaped sinking groove 5 through several a-vent holes 4; an b-cavity 16 is formed around the lower outer periphery of the elastic airbag 15, and the b-cavity 16 is connected to the outside of the B-side through several b-vent holes 6; six sets of vertically connected channels 20 are formed around the waist of the elastic airbag 15, and the upper and lower ends of each channel 20 connect the a-cavity 7 and the b-cavity 16 vertically.

[0050] Except for a) elastic airbags 15, b) elastic airbags 12, and aerogel powder filler, the honeycomb panel 1 in this scheme is entirely 3D printed. The 3D printing material is a polyurethane / hollow silica microsphere composite material, using thermoplastic polyurethane (TPU) as the matrix and incorporating 10–45 wt% hollow mesoporous silica microspheres (particle size 10–1000 nm). Uniform dispersion is ensured through biconical melt blending. This material offers a balanced thermal insulation and mechanical properties: the hollow structure of the microspheres significantly reduces thermal conductivity, while the TPU matrix provides elasticity (hardness 85–98A), and the tensile strength remains >15 MPa, making it suitable for building energy-saving components. Furthermore, the 3D printing process exhibits high adaptability, low melt viscosity, and good flowability, effectively avoiding nozzle clogging in FDM printing, making it suitable for printing complex panel components.

[0051] Working principle:

[0052] When in use, the A-side of the honeycomb panel 1 faces indoors and the B-side faces outdoors. The discretely distributed honeycomb-shaped recessed grooves 5 on the A-side of the honeycomb panel 1 play an acoustic role in reducing indoor echo.

[0053] The airtight ventilation characteristics of the honeycomb panel 1 in state a: In state a, outdoor air passes through the b vent 6, b chamber 16, connecting channel 20, a chamber 7, several a vent 4, and honeycomb-shaped sink 5 in sequence to finally reach the room. At the same time, the above-mentioned tortuous connecting path effectively consumes the propagation of light and sound waves, thereby achieving the characteristics of limited light blocking and sound insulation while ventilating, and finally achieving the ventilation effect in a windowless sealed room scenario, realizing normal air exchange and heat exchange between the indoor and outdoor environments.

[0054] The process of transitioning from state a to state b:

[0055] When complete isolation between indoors and outdoors is required, a pressure-controlled air pump supplies high-pressure air to the pressure-transmitting chamber 10 of any b-cell unit 3 on the honeycomb panel 1. Since any two adjacent b-cell units 3 pressure-transmitting chambers 10 are connected through the connecting holes on the b-cell common wall 80, the air pressure in the pressure-transmitting chambers 10 of all b-cell units 3 rises from p1 to p2. The pressure in each pressure-transmitting chamber 10 is transmitted to the variable spherical air chamber 14 through the pressure-transmitting pipe 11, causing the b-elastic airbag 12 to expand significantly outward under the action of internal pressure, thereby squeezing outward the aerogel powder in the variable aerogel filling chamber 13, and making the variable aerogel... The pressure inside the filling chamber 13 increases, causing the a-elastic airbag 15, which is filled with aerogel powder, to continue expanding outward. Since the a-elastic airbag 15 is originally constrained within the honeycomb cavity, its outward expansion is constrained by the inner wall of the honeycomb cavity. Therefore, the expansion of the a-elastic airbag 15 stops when the inner wall surfaces of the a-elastic airbag 15 and the d-wall 71, the isolation wall 9, the shared wall 17 of each a-cell, and the shared wall 80 of each b-cell change from being tangential to being planar. At this point, the original b-cell 16, the connecting channel 20, and the a-cell 7 are all filled with aerogel powder. Figure 6 As shown in the figure below; at this time, the connection between several a vent holes 4 and several b vent holes 6 is blocked; at this time, the honeycomb panel 1 enters state b.

[0056] The honeycomb panel 1, in state b, has properties such as air insulation, heat insulation, and greater sound and light insulation.

[0057] If it is necessary to return to state a, the pressure in the spherical air chamber 14 can be reduced from p2 to p1 by using a pressure control air pump.

[0058] Technical features of this solution:

[0059] 1. Acoustic optimization basic structure:

[0060] The A-side of the honeycomb panel 1 is designed as a discretely distributed honeycomb-shaped recessed groove 5. When the A-side faces the room, the groove structure effectively reduces indoor reverberation and improves acoustic comfort through diffuse sound wave reflection.

[0061] 2.a. Operating mechanism of ventilation mode:

[0062] Gas flow path: Outdoor air enters the room sequentially through the b vent 6 on side B → b empty chamber 16 → connecting channel 20 → a empty chamber 7 → a vent 4 → honeycomb-shaped sink trough 5.

[0063] Sound insulation and light blocking: The tortuous flow path consumes sound wave and light energy through multiple refractions / reflections.

[0064] Heat exchange: The airflow path passes through the panel to achieve indoor and outdoor heat transfer.

[0065] 3. Switching control between states a and b (closed mode):

[0066] Pneumatic drive: The pressure-controlled air pump inputs high-pressure gas (p1→p2) into the pressure transmission chamber 10, and the air pressure is transmitted to the variable spherical air chamber 14 through the pressure transmission pipe 11.

[0067] Airbag deformation: The inner layer b elastic airbag 12 expands under internal pressure, squeezing the powder in the variable aerogel filling chamber 13; the outer layer a elastic airbag 15 expands outward under the pressure of the powder until it is in close contact with the inner wall of the honeycomb cavity (d wall 71, isolation wall 9, common wall 17 of each a honeycomb and common wall 80 of each b honeycomb).

[0068] Channel blockage: The inflated elastic airbag 15 completely fills the empty chamber 16, connecting channel 20 and empty chamber 7, cutting off the connection path between the a / b ventilation holes.

[0069] 4.b→a state reset: release the pressure of the variable spherical air chamber 14 to p1, the airbag elastically contracts to restore the initial tangential state, and the airflow channel reopens.

[0070] Technical effects:

[0071] 1. Dynamic multi-function switching:

[0072] State a: Achieve limited ventilation (controllable airflow rate) + sound / light attenuation (tortuous path loss ≥15dB sound pressure level).

[0073] b-state: Achieve airtight isolation (air permeability ≈ 0) + enhanced heat and sound insulation (thermal conductivity of dense aerogel layer ≤ 0.02 W / m·K) + complete light protection.

[0074] 2. Lightweighting and Structural Innovation:

[0075] The one-piece molded honeycomb array (polyurethane / hollow silica microsphere composite material) combines strength and thermal insulation, and reduces density by more than 30%; pneumatic drive enables state switching without mechanical moving parts, improving reliability and avoiding wear.

[0076] 3. Improved energy efficiency and comfort:

[0077] The aerogel powder is compacted in state b, which significantly improves the overall thermal insulation performance of the board (the thermal resistance value is increased by more than 50%); the honeycomb-shaped recessed groove 5 on side A also has a sound-absorbing and decorative function, avoiding the need for an additional acoustic treatment layer.

[0078] 4. Project applicability:

[0079] 3D printing technology ensures the precise molding of complex airways and airbag cavities; a single air pump controls the switching of the entire plate's state, simplifying installation and maintenance costs.

[0080] The following is a summary of the existing structure and the characteristics of this solution.

[0081]

[0082] This design is particularly suitable for windowless enclosed spaces (such as special ship cabins, laboratories, and cleanrooms), high-end building curtain walls, and acoustically sensitive spaces, achieving intelligent environmental control while ensuring building safety.

[0083] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A lightweight honeycomb panel structure, characterized in that: It includes a honeycomb panel (1) composed of a number of a-cell cells (2) and a number of b-cell cells (3) arranged in an integrated array; in the honeycomb panel (1), each a-cell cell (2) has six b-cell cells (3) arranged in a circular array on its outer periphery. The two sides of the honeycomb panel (1) are respectively designated as side A and side B; On the A-side, each a-cell cell (2) is lower than the surrounding b-cell cells (3), thereby forming a honeycomb-shaped sinking groove (5) on the A-side of the honeycomb plate (1). The lower part of the six inner sides of the honeycomb-shaped sinking groove (5) of each a-cell cell (2) is hollowed out with several a-venting holes (4). On the B side, each a-cell cell (2) is flush with each b-cell cell (3), and each b-cell cell (3) has several b-vent holes (6) cut out on its surface. The honeycomb panel (1) includes state a and state b; In state a, several a vents (4) and several b vents (6) are connected through the cavity inside the b honeycomb unit (3); In state b, the connection between several a vents (4) and several b vents (6) is broken; Each a-cell cell (2) contains a sealed a-cell filling chamber (18); The a-cell cell (2) includes a recessed a-wall (19) near the A-side and a b-wall (72) near the B-side, and the a-cell filling chamber (18) is located between the recessed a-wall (19) and the b-wall (72). The b-cell unit (3) includes a c-wall (8) near the A-side and a d-wall (71) near the B-side. The b-wall (72) is integral with and flush with the d-wall (71). Each b-vent (6) is distributed on the d-wall (71). The b-cell unit (3) is provided with an isolation wall (9) parallel to the c-wall (8) and the d-wall (71). The wall between any two adjacent a-cell units (2) and b-cell units (3) is called the a-cell common wall (17), and the wall between any two adjacent b-cell units (3) is called the b-cell common wall (80). The a-vent (4) on each a-cell common wall (17) is between the isolation wall (9) and the sunken a-wall (19). Each of the c-walls (8) and the isolation wall (9) forms a pressure transmission chamber (10). Any two adjacent pressure transmission chambers (10) are connected through the connecting holes on the common wall (80) of each b-cell. At least one of the pressure transmission chambers (10) on the honeycomb plate (1) is connected to the output end of the pressure control air pump. An a elastic airbag (15) is provided in the honeycomb cavity between the d wall (71) and the isolation wall (9), and a b elastic airbag (12) is provided in the center of the a elastic airbag (15); the a elastic airbag (15) is a variable spherical air chamber (14), and also includes a pressure transmission pipe (11) that connects the variable spherical air chamber (14) and the pressure transmission chamber (10); between the a elastic airbag (15) and the b elastic airbag (12) is a variable aerogel filling chamber (13) filled with aerogel powder.

2. The lightweight honeycomb panel structure according to claim 1, characterized in that: Both the a elastic airbag (15) and the b elastic airbag (12) are made of elastic latex or elastic silicone.

3. The lightweight honeycomb panel structure according to claim 1, characterized in that: In state a, the outer wall of the spherical elastic airbag (15) is tangent to the inner wall surfaces of the d wall (71), the isolation wall (9), the common wall of each a honeycomb (17), and the common wall of each b honeycomb (80); a ring of a empty chambers (7) is formed on the upper outer periphery of the elastic airbag (15), and the empty chambers (7) are connected to the honeycomb-shaped sinking groove (5) through several a ventilation holes (4); a ring of b empty chambers (16) is formed on the lower outer periphery of the elastic airbag (15), and the b empty chambers (16) are connected to the outside of the B side through several b ventilation holes (6); six sets of vertically connected channels (20) are formed around the waist of the elastic airbag (15), and the upper and lower ends of each channel (20) connect the empty chambers (7) and the empty chambers (16) vertically.

4. The lightweight honeycomb panel structure according to claim 3, characterized in that: Except for a elastic airbag (15), b elastic airbag (12) and aerogel powder filler, the honeycomb plate (1) is made of polyurethane / hollow silica microsphere composite material.

5. A lightweight honeycomb panel structure according to claim 3, characterized in that: In state b, the air pressure in the pressure transmission chamber (10) of each b honeycomb unit (3) rises from p1 to p2. Under the action of internal pressure, the b elastic airbag (12) expands significantly outward, thereby squeezing the aerogel powder in the variable aerogel filling chamber (13) outward, and increasing the pressure in the variable aerogel filling chamber (13), thereby causing the a elastic airbag (15) filled with aerogel powder to continue to expand outward. During the outward expansion of the elastic airbag (15), it is constrained by the inner wall of the honeycomb cavity. During the expansion of the elastic airbag (15), the expansion stops when the outer wall of the elastic airbag (15) and the inner wall surfaces of the d wall (71), the isolation wall (9), the common wall of each a honeycomb (17), and the common wall of each b honeycomb (80) change from being tangent to being flat. At this time, the original b cavity (16), the connecting channel (20), and the a cavity (7) are all filled with aerogel powder, and the connection between several a ventilation holes (4) and several b ventilation holes (6) is blocked. At this time, the honeycomb plate (1) enters the b state.

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