How to make an object

Abstract

The method for manufacturing an article comprising at least one honeycomb panel (1) is carried out by providing a honeycomb panel and carving it to form a deposition path (P) of a predetermined depth, a filler material (4) being applied along the deposition path (P) to at least partially fill the deposition path (P).

Description

[Technical field]

[0001] The present invention relates to the technical field of manufacturing processes, in particular manufacturing processes relating to or aimed at the manufacture of honeycomb panels and structures comprising honeycomb panels.

[0002] In particular, the invention relates to a method for manufacturing an object, in particular an object comprising at least one honeycomb panel. [Background technology]

[0003] Honeycomb panels are special panels with a honeycomb structure surrounded by two plates which can be used in a wide variety of fields thanks to their special shape, which makes the special panels light and therefore easy to use and install, while at the same time being (directionally) highly resistant to impacts, cracks and loads.

[0004] These panels can be used in both the architectural and industrial sectors to manufacture complex objects such as structural elements or frames and are lightweight and strong thanks to their honeycomb structure.

[0005] Due to the wide range of potential applications, there is therefore a strong demand in industry for new manufacturing and processing processes that allow making the most of the special properties, especially the mechanical properties, that are imparted to such objects by their structural morphology.

[0006] As is typical of highly optimized materials, honeycomb panels offer excellent properties in their intended field and use. However, these properties can rapidly degrade if stress / strain vectors are applied from different directions or with different intensities. Apart from this, honeycomb panels do not offer any fixing points that run normal to the plane unless they are joined. If the decision is made to add such accessories, problems arise depending on the method of fixing the additional elements.

[0007] Bonding an element to a surface, for example, depends entirely on the shear or peel properties of the adhesive, which last within a narrow temperature range and, even for a short period of time, outside that temperature range there is a permanent loss of properties due to component misalignment or degradation of the adhesive properties.

[0008] Welding the elements subjects the sandwich to thermal stresses on the inside and compromises the interface between the honeycomb and the pair of plates that contain it in a way that cannot be verified or quantified in a "predictive" manner.

[0009] Fixing with bolts carries the risk of cutting off functional and critical components within the panel, especially in such optimized elements. Summary of the Invention

[0010] In this context, the technical problem underlying the present invention is to propose a method for manufacturing an object, which overcomes at least some of the drawbacks of the known technology mentioned above.

[0011] In particular, it is an object of the present invention to provide a particularly effective and efficient method for manufacturing an object comprising a honeycomb panel, which makes it possible to simplify the manufacture and processing of such panels while enhancing the advantages offered by the particular structural configuration of said panels.

[0012] The specified technical problem and the specified object are substantially achieved by a method for manufacturing an object, which comprises the technical features set out in one or more of the appended claims.

[0013] In accordance with the present invention, a method for manufacturing an article comprising at least one honeycomb panel is presented.

[0014] The method is carried out by providing at least one honeycomb panel.

[0015] Preferably, the honeycomb panel comprises a honeycomb structure defined by a pair of plates and a plurality of honeycombs disposed between the pair of plates.

[0016] The honeycomb panel is then carved to form a deposition path of a predetermined depth.

[0017] In particular, the honeycomb panel is carved into at least one of its plates to expose and provide access to a plurality of honeycombs adjacent the deposition path.

[0018] In accordance with the present invention, the volume created by the cut grooves being interrupted in the honeycomb cavities, particularly those cavities that will be undercut relative to the top plate, creates a useful volume for adhering within the panel itself and for creating a strong peel and shear resistant section.

[0019] The filler material is applied along the deposition path to at least partially fill the deposition path itself and the undercut area formed as a result of the connection between the engraved groove and the existing cavity.

[0020] Specifically, the filler material is applied so as to penetrate and preferably fill the honeycombs that have become accessible as a result of the carving operation of the honeycomb panel.

[0021] Advantageously, the application of the filler material is carried out by means of an additive manufacturing (or overmolding) process.

[0022] Preferably, the application of the filler material is performed so as to realise a part of the object, i.e. so that said filler material extends outside the deposition path defining the predetermined structure.

[0023] In particular, the filler material is applied such that a predetermined structure is defined that extends outside the deposition path, preferably extending away from the deposition path.

[0024] Alternatively or additionally, the deposition path extends along at least an edge portion of the honeycomb panel.

[0025] Preferably, the method is carried out by positioning at least two honeycomb panels and carving at least a portion of an edge of each of said at least two honeycomb panels.

[0026] More preferably, the method is carried out by abutting the chiseled edges of at least two honeycomb panels and applying a filler material across the edges to connect and securely bind the honeycomb panels together.

[0027] Alternatively or additionally, the deposition path extends along at least one fold line of the honeycomb panel.

[0028] Preferably, the method is carried out in this regard by folding the honeycomb panel around at least one fold line, as shown in Figures 6A and 6B, following the performance of engraving on the honeycomb panel to establish a deposition path across the engraving that defines the fold lines of the honeycomb panel, as shown in particular in Figure 5.

[0029] Preferably, the filler material is applied along the deposition path to assist in the initiation and subsequent maintenance of the fold in the honeycomb panel.

[0030] Advantageously, the methods presented and described herein allow for a particularly efficient production of a wide range of products based on or comprising honeycomb panels.

[0031] The dependent claims, which are included herein for reference, correspond to various embodiments of the invention. [Brief description of the drawings]

[0032] Further features and advantages of the invention will become more apparent from the disclosure of exemplary, but not exclusive and therefore non-limiting preferred embodiments of a method for manufacturing an object, as illustrated in the accompanying drawings, in which: [Fig. 1A-11H] 1 illustrates various possible ways of performing one of the steps of the method. [Figure 2A-2L] 1 shows honeycomb panels with different internal structures. [Figure 3A-3D] 1 illustrates various possible methods of applying filler material to a honeycomb panel. [Figure 4A-4D] 1 illustrates various possible methods of applying filler material to a honeycomb panel. [Diagram 5] 1 illustrates the execution of certain steps of a method in which a honeycomb panel is engraved and then folded around the engraved path. [Figure 6A-6B] 1 illustrates the execution of several specific steps of the method by which a honeycomb panel is engraved and then folded around the engraved path. [Figure 7A-7B] 6A and 6B show the application of filler material within the engraved paths of the folded panels, respectively. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The method disclosed herein is aimed at the manufacture of an object comprising at least one honeycomb panel 1 .

[0034] In other words, the method has the object of producing at least one honeycomb panel 1, ie a semi-finished or finished product comprising a panel having inside it a structure defining a plurality of honeycombs.

[0035] In operation, the method is carried out by providing a honeycomb panel 1 comprising a pair of plates 2 having disposed therebetween an alveolar structure 3 defined by a plurality of honeycombs.

[0036] Said honeycomb panel 1 may comprise or be made using one or more of the following materials, by way of example only: glass, marble, aluminum (or in any case any metal material or metal alloy), aluminum-wood (or any metal or metal alloy in combination with wood), polymer, composite material, cement mixture, resin or ceramic material, and the pair of plates 2 may have one or more surface finishes or coating surface layers, which may be made, for example, from leather, wood, marble, metal or composite material, woven fabric, non-woven fabric, etc., as appropriate.

[0037] Structurally, the panels may be generally flat or may have a predetermined radius of curvature.

[0038] More particularly, the panel may comprise at least one non-planar plate 2. This means that the two plates 2 between which the alveolar structure 3 is enclosed do not have to be parallel to each other.

[0039] Overall, the honeycomb panel may be curved with a radius of curvature to thickness ratio of, for example, 17:1 to 23:1.

[0040] Advantageously, the alveolar structure 3 may be at least partially made of auxetic material or may feature a honeycomb shape based on a geometric shape and / or cross-sectional profile having auxetic properties.

[0041] Auxetic materials are unusual in that they are characterized by a negative Poisson number, as well as what is known as an "auxetic topology", a topology for filling a volume that leaves regions within the volume itself where the Poisson number of the stressed volume is negative overall. Materials and structures with a negative Poisson number tend to expand transversely to the direction of stress when subjected to tensile stress, and to contract transversely to the direction of stress when compressed. At the same time, "auxetic lattices", or structures with auxetic morphology at any rate, have a behavior of geometric reconfiguration, so that any mechanical stress applied to them with the aim of obtaining a compression or expansion in one direction or orientation implies a compression or expansion in the other direction or orientation as well, perpendicular to the direction or orientation of application of the mechanical stress itself (as opposed to "isotropic" structures, where a given stress in one direction or orientation determines an equivalent deformation geometric reconfiguration in two mutually orthogonal directions, rather than undergoing opposite deformation geometric reconfigurations along two orthogonal directions).

[0042] According to a particular aspect of the invention, the preparation of the honeycomb panel 1 is carried out by molding at least the alveolar structure 3, preferably by means of an additive manufacturing process (or by overmolding, if appropriate).

[0043] In other words, using an additive manufacturing (or overmolding) process, it is possible to prepare an existing plate 2 by creating the alveolar structure 3 by molding a suitable material, for example by selecting a material from the group of materials listed above.

[0044] More specifically, a first plate 2 may be provided that serves as a working surface for the additive manufacturing process, after which a material may be molded thereon that defines the alveolar structure 3. A second plate 2 may then be bonded to the alveolar structure 3, thereby defining the honeycomb panel 1.

[0045] By way of example only, the alveolar structure 3 may include a plurality of spherical honeycombs, ie, spherical, hemispherical, or substantially spherical in shape.

[0046] This means that the panel preparation process can be carried out to produce a honeycomb panel 1 comprising an alveolar structure 3 having a plurality of spherical honeycombs.

[0047] Alternatively or additionally, the preparation of the honeycomb panel 1 may also be carried out by manufacturing at least one plate 2 of the pair of plates 2, preferably both plates 2.

[0048] Advantageously, the manufacture of the at least one plate 2 can also be carried out by an additive manufacturing process.

[0049] It therefore appears that, in general, the preparation of the honeycomb panel 1 may be carried out by manufacturing and / or assembling one or more of its components, namely the pair of plates 2 and the alveolar structure 3.

[0050] Regardless of the particular mode leading to the preparation of the honeycomb panel 1, the honeycomb panel 1 is carved to form a deposition path "P" having a predetermined depth (and, in terms of the interior volume of the panel, an "interception function" of the cavities already present in the panel itself).

[0051] The term "carving" is intended to encompass all operations and processes aimed at forming and defining a recess of a predetermined depth, i.e. a deposition path "P", in the honeycomb panel 1. The deposition path "P" realizable by the present invention may then have any path relative to the surface of the honeycomb panel 1 and may develop into any geometric shape starting from any point of the panel and reaching any other point of the panel (defining, for example, an open path, a closed path, a single path or multiple branch paths, etc., depending on the needs at the time).

[0052] The depth of the deposition path "P" is understood as the distance between the base or bottom of the engraving and the surface of the plate 2 on which the engraving is carried out.

[0053] According to a possible aspect of the invention, the engraving step is carried out at least in part by a milling process.

[0054] In other words, the deposition path "P" is realised by milling the plates 2 and alveolar structures 3 of the honeycomb panel 1 such that material removal occurs according to a precise predefined pattern down to a specific depth in the honeycomb panel 1 itself.

[0055] This type of machining is particularly efficient when the machining path unfolds along straight sections.

[0056] Alternatively or additionally, the engraving phase is carried out at least in part using a drilling or boring process.

[0057] In other words, the deposition path "P" may be defined by one or more holes (not necessarily through holes) formed in the honeycomb panel 1 according to a precise predefined pattern.

[0058] This type of processing is particularly efficient when the deposition path "P" is defined by a plurality of substantially distinct and separate points.

[0059] Depending on the characteristics of the object to be manufactured and the needs of the particular construction, it is also possible to use a combination of the possible types of processing described above to carve the honeycomb panel 1 to define a deposition path "P" that includes a combination of linear and dotted sections.

[0060] Further details regarding deposition path "P" are provided below.

[0061] The width and depth of the groove, which is proportional to the distance between a pair of plates (i.e. the thickness of the panel), depends on the viscosity of the deposited material, its resistance to shear and its ability to adhere to the materials that make up the plates and the honeycomb.

[0062] Once the deposition path "P" has been defined, a filling material 4 can be applied to it, which may be polymeric or another, depending on the needs at the time, so as to at least partially, and preferably completely, fill the deposition path "P".

[0063] In other words, the grooves formed by carving the honeycomb panel 1 define tracks along which the filler material 4 can be applied, inserted, deposited, molded or extruded, after which the grooves created in the carving phase are filled.

[0064] Furthermore, the filler material 4 is bound to the honeycomb panel 1 in a deposition path "P" and starting from this bonding zone, it may be applied so as to define a more or less complex structure capable of defining a part of an object.

[0065] Advantageously, the application of the filling material 4 is carried out by an additive manufacturing process.

[0066] In particular, it is possible to carry out the additive manufacturing process according to a first phase in which the filler material 4 is applied by forming a bonded portion defined by the filler material 4 arranged in the deposition path "P", and a second phase in which the bonded portion operatively performs basic functions and working surfaces for the continuation of the additive manufacturing process to form a more or less complex predefined structure extending preferably away from the honeycomb plate.

[0067] In this regard, the honeycomb panel 1 in effect defines the supporting base of the structure defined by the infill material 4 .

[0068] By way of example only, all steps described herein, and generally all procedures shown herein that can be performed by additive manufacturing processes, can be realized using a 3D molding machine equipped with an extrusion head through which the fill material 4 is processed and deposited on a work surface.

[0069] More specifically, the extrusion head may be movable along a precise trajectory, specifically to follow the path of the deposition path "P".

[0070] Advantageously, the work surface may also be movable and may be designated, for example, by a conveyor belt.

[0071] In this way, during the manufacture of one or more components of the honeycomb panel 1 and / or during the application of the filler material 4 within the deposition path "P", the object being manufactured can be gradually moved away from the extrusion head, making it possible to manufacture articles of infinite length at least along a direction coinciding with the forward advancement direction of the conveyor belt.

[0072] To facilitate the step of applying the filling material 4, the method is further carried out by temperature conditioning at least a portion of the honeycomb panel 1 while the filling material 4 is inserted into the deposition path "P".

[0073] For example, if the filling material 4 is or comprises a thermoplastic filling material 4, it is possible to heat the honeycomb panel 1, and in particular the deposition path "P", at least in the part where said thermoplastic filling material 4 has been applied, for any period of time and then cool it in a controlled manner so as to determine the cooling gradient and, therefore, the final level of crystallinity and the resulting mechanical and, more generally, physico-chemical properties (on the other hand, if the material is of the thermosetting type, the same volume or surface is cooled and then heated to crosslink the deposited material).

[0074] Heating the honeycomb panel 1 facilitates fluidization of the thermoplastic filler material 4 by facilitating its entry into the deposition path "P" and thus its accurate bonding with the honeycomb panel 1.

[0075] Thus, in general, the temperature conditioning phase of the honeycomb panel 1 is carried out with the purpose of promoting fluidization of the filler material 4 to improve and facilitate bonding to the honeycomb panel 1 when the filler material 4 is applied to the deposition path "P".

[0076] It should be noted that, generally, since multiple honeycombs of the alveolar structure 3 are exposed during the carving phase, the application phase of the filling material 4 is actually carried out by applying the filling material 4 within these interconnected volumes between the carved grooves and the honeycombs.

[0077] In other words, the engraving of the honeycomb panel 1 exposes one or more honeycombs of the alveolar structure 3 to the external environment, allowing the filling material 4 to enter them during the deposition phase of the filling material 4 itself.

[0078] Therefore, in order to optimize the precise application of the filler material 4, including ensuring precise bonding with the honeycomb panel 1, the length of time of the application phase of the filler material 4 is preferably determined as a function of the depth of the filler material 4 by setting a length of time proportional to the depth of the deposition path "P", its morphology, the fluidity of the material and its properties determining its interaction with the surrounding surfaces.

[0079] In other words, when the deposition path "P" is considered to be superficial, i.e. having a limited volume resulting from connections between the volumes of the honeycomb, the overall duration of the application process of the filling material 4 may be shorter since the amount of material applied and the volume of the deposition path "P" to be filled are smaller, whereas in the case of deeper deposition paths "P", or deposition paths "P" that have connected with existing honeycombs to produce a larger volume, or when a larger solid volume is inserted to increase the resistance of the introduced volume, it is advantageous to extend the duration of the application process of the filling material 4.

[0080] In particular, the amount of honeycombs that are exposed and accessible to the fill material 4 is directly proportional to the depth of the deposition path "P" because as the depth increases, the number of honeycombs that become accessible along the sidewalls of the deposition path "P" also increases proportionally, and therefore it is advantageous to extend the duration of the application process of the fill material 4 so as to accurately fill the deposition path "P".

[0081] More specifically, engraving of the honeycomb panel 1 is performed to expose a plurality of honeycombs that define undercuts with the bottom wall of the deposition path "P".

[0082] This means that the engraving makes accessible a number of honeycombs, at least one of which (preferably all) facilitates the entry of the filling material 4 by means of through holes, the through holes having a surface area that is smaller than the corresponding internal surface area of ​​the chamber defined by the honeycomb and in which the through hole is defined.

[0083] In this manner, as the filler material 4 is applied to the deposition path "P" and enters the exposed honeycomb, it adheres to the undercuts, making the bond between the honeycomb panel 1 and the filler material 4 particularly resistant to tensile stresses.

[0084] This aspect is particularly important when the object to be manufactured is, contains or contributes to the definition of a frame or structural element which must withstand stresses of this kind.

[0085] Advantageously, the particular form of the deposition path "P" may be defined as a function of the purpose for which the method is carried out or as a function of the structural characteristics of the object to be produced.

[0086] In particular, according to the first embodiment, the deposition path "P" may develop along the honeycomb panel 1, at least partially along its edge.

[0087] This particular configuration of the deposition path "P" is particularly useful for obtaining objects the manufacture of which requires the joining of a number of honeycomb panels 1.

[0088] In fact, it is possible to carve the edges of each of several honeycomb panels 1, abut them and apply a filler material 4 across each deposition path "P", bonding them to both panels and in fact acting as a part / bonding element between the two panels 1 and tightly joining them together.

[0089] In particular, the method may be carried out by preparing at least two honeycomb panels 1 according to any of the methods described above, followed by carving the respective parts of the edges that will be abutted.

[0090] It is possible to carve the panels individually and assemble them only at a later stage by abutting the panels, or it is possible to abut the panels so that the deposition path "P" can be realised with a single carving step carried out by straddling the abutted edges of the honeycomb panels 1.

[0091] The filler material 4 is then applied in the manner described above to connect the engraved edges of the honeycomb panels 1 and firmly bond the honeycomb panels 1 together.

[0092] Alternatively or additionally, according to a further embodiment, the deposition path "P" extends along at least one fold line 5 and the method is further carried out by folding the panel around the at least one fold line 5 prior to applying the filling material 4.

[0093] In other words, the honeycomb panel 1 is scored along said fold line 5 and folded around it by exerting a force in a direction notably such as to widen the deposition path "P".

[0094] Once the desired shape is obtained, the filler material 4 can be applied.

[0095] In this way, the filler material 4 contributes to maintaining the form assumed by the honeycomb panel 1, since its presence prevents the honeycomb panel 1 from returning to the deformation applied.

[0096] Advantageously, the invention achieves the proposed objective by overcoming the drawbacks associated with the known technology by making available to the user a method for manufacturing an object comprising at least one honeycomb panel 1, which makes it possible to manufacture complex structures, for example by deforming and / or bonding the honeycomb panel 1 or by making use of the properties and advantages offered in particular by additive manufacturing processes (or, as already mentioned several times above, by the possible use of overmolding processes) to manufacture predefined structures in said honeycomb panel 1.

Claims

1. A method for manufacturing an object comprising at least one honeycomb panel (1), comprising the steps of: - providing at least one honeycomb panel (1) comprising a pair of plates (2) and a honeycomb structure (3) arranged between said pair of plates (2); - engraving said honeycomb panel (1) to form a deposition path (P) having a predetermined depth; applying, by an additive manufacturing process, a filling material (4) along said deposition path (P) so as to at least partially fill said deposition path (P).

2. 2. The method of claim 1, comprising the step of thermoregulating at least a portion of the honeycomb panel (1) during the step of applying the infill material (4).

3. 3. The method according to claim 1 or 2, wherein the duration of the step of applying the filling material (4) is determined depending on the depth of the deposition path (P), preferably said duration being proportional to the depth of the deposition path (P).

4. The method of claim 1 or 2, wherein the engraving step is performed at least in part using a milling, laser cutting, water cutting or plasma cutting process.

5. The method of claim 1 or 2, wherein the engraving step is performed at least in part using a drilling or boring process or by a stamping process.

6. 3. The method according to claim 1 or 2, wherein the engraving step is carried out so as to form a deposition path (P) that at least partially follows the edge of the honeycomb panel (1).

7. 3. The method according to claim 1 or 2, wherein the engraving step is performed to form a deposition path (P) extending along at least one fold line (5), the method comprising a step of folding the honeycomb panel (1) around the fold line (5), the folding step being performed between the engraving step and the step of applying the filler material (4).

8. 3. The method according to claim 1 or 2, wherein the step of preparing the honeycomb panel (1) is carried out by preparing a honeycomb panel (1) comprising a honeycomb structure (3) made at least in part of an auxetic material and / or having a honeycomb shape based on a cross-sectional profile having a geometric shape and / or auxetic features and / or topology.

9. 3. The method according to claim 1 or 2, wherein the step of providing the honeycomb panel (1) is carried out by providing a pair of plates (2) comprising at least one non-planar plate (2).

10. 3. The method according to claim 1 or 2, wherein the honeycomb panel (1) is non-planar and has a radius of curvature to thickness ratio of 17:1 to 23:

1.

11. 3. The method according to claim 1 or 2, wherein the step of carving the honeycomb panel (1) is carried out to expose a plurality of honeycombs of the honeycomb structure (3) and to allow the ingress of the infill material (4) into the plurality of honeycombs during the deposition step of the infill material (4).

12. The method according to claim 11, wherein the carving step is performed to expose a plurality of honeycombs defining undercuts with a bottom wall of the deposition path (P).

13. 3. The method according to claim 1 or 2, wherein the step of preparing the honeycomb panel (1) is carried out by preparing the pair of plates (2) and manufacturing, preferably by means of an additive manufacturing process, the honeycomb structure (3) to be placed between the pair of plates (2).

14. 14. The method according to claim 13, wherein the step of manufacturing the honeycomb structure (3) is carried out by manufacturing an alveolar structure (3) having a plurality of preferably spherical honeycombs.

15. 3. The method according to claim 1 or 2, wherein the step of preparing the honeycomb panel (1) is carried out to manufacture at least one plate (2) of the pair of plates (2), preferably by means of an additive manufacturing process.

16. - providing at least two honeycomb panels (1); - lining up said at least two honeycomb panels (1) at their edges; - carving said at least two honeycomb panels (1) to form a deposition path (P) extending at least partially along said respective edge portions; - applying said infill material (4) so ​​as to connect said at least two honeycomb panels (1) at their respective edge portions.

17. 3. The method according to claim 1 or 2, wherein the step of applying the filling material (4) is carried out by applying the filling material (4) so ​​as to define a predefined structure extending outside the deposition path (P), preferably extending away from the deposition path (P).

Images