Folded Pattern Molds for Rapid Complex Cellular Core Forming
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Solution Overview
Problem
Existing methods for forming cellular cores in acoustic panels, particularly those with complex or non-honeycomb configurations, are inefficient and require improvement for rapid production.
Innovation Solution
A method involving folding a sheet of material to create a pattern, depositing mold material to form a mold, and then using this mold to create a cellular core between skins, which is bonded to form a structured panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to form cellular cores, then manufacturing simplicity is maintained, but productivity is low and formation speed is slow
Solution Approach 1:
The method creates a reusable mold with the cellular core pattern in advance. This mold can then be used repeatedly to form multiple cellular cores quickly without repeating the complex folding process each time, thereby increasing productivity while maintaining manageable process complexity
Solution Approach 2:
The invention creates a physical mold that copies the desired cellular core pattern. This mold serves as a template that can be used to reproduce the cellular core structure multiple times rapidly, significantly improving formation speed compared to traditional methods
2Adaptability or versatility
If complex or non-honeycomb core configurations are produced using traditional methods, then design versatility is achieved, but formation time increases and efficiency decreases
Solution Approach 1:
The mold is prepared in advance with the specific complex or non-honeycomb pattern required. Once the mold is created, it enables rapid production of cores with that specific configuration without requiring time-consuming traditional forming processes for each core
Solution Approach 2:
The invention changes the forming approach from direct complex folding to mold-based replication. This parameter change in the forming method allows complex configurations to be produced efficiently through mold replication rather than through complex manual or mechanical folding processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and efficient production of structured panels with complex cellular cores, enhancing sound attenuation capabilities.
Implementation Method 1
a sheet of material is embossed to provide a plurality of fold lines. The sheet of material is folded along the fold lines to provide a pattern
Implementation Method 2
The pattern is separated from the first mold. A cellular core for a structured panel is formed by depositing core material with the first mold
Implementation Method 3
The cellular core may also be formed by consolidating the core material under an elevated pressure and an elevated temperature
Implementation Method 4
The cellular core may also be formed by consolidating the core material under an elevated pressure and an elevated temperature
Implementation Method 5
The cellular core is bonded to the first skin and the second skin to form a structured panel
Data Source
AI summary
A formation method is provided during which a pattern is formed by folding a sheet of material. A first mold is formed by depositing mold material with the pattern. The pattern is separated from the first mold. A cellular core for a structured panel is formed by depositing core material with the first mold.