Half Closed Thermoplastic Honeycomb Plastic Deformation
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Solution Overview
Problem
Existing methods for producing folded honeycombs require cuts, which can be economically inefficient and limit the attachment quality to covering layers.
Innovation Solution
A process and equipment that form folded honeycombs from a substantially uncut flat body by plastic deformation to create 3D structures and connection areas, allowing cells to be bridged without cuts, enabling good attachment to covering layers with minimal material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cuts are used to produce folded honeycombs, then the production process can be simplified, but the attachment quality to covering layers deteriorates and material usage increases
Solution Approach 1:
The patent changes the physical state and geometric parameters of the material by introducing 3D structures through plastic deformation. The flat body is transformed into a three-dimensional form with cells having lateral walls and covering-layer planes, enabling structural integrity and attachment capability without cuts. This parameter change allows the material to achieve both ease of manufacture and high attachment quality.
2Ease of manufacture
If cuts are used to produce folded honeycombs, then the production process can be simplified, but material usage increases
Solution Approach 1:
The invention transforms the flat body into a 3D structure through plastic deformation, creating a honeycomb configuration that efficiently utilizes the material. The 3D structures with lateral cell walls and covering-layer planes allow the material to achieve the desired honeycomb form without requiring additional material from cuts, thus reducing material loss while maintaining production simplicity.
3Reliability
If vacuum forming is applied to the flat body, then good attachment to covering layers can be achieved, but the formation of 3D structures without cuts becomes challenging
Solution Approach 1:
The patent applies preliminary plastic deformation to the flat body to create 3D structures with lateral cell walls and covering-layer planes before the vacuum forming process. This preliminary action prepares the material geometry in advance, enabling subsequent vacuum forming to achieve good attachment to covering layers without requiring complex process steps for 3D structure formation during vacuum forming.
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 efficient vacuum forming and strong attachment to covering layers with minimal material usage, facilitating the production of high-quality folded honeycombs without the need for cuts.
Implementation Method 1
a folded honeycomb structure, formed from a plurality of cells arranged in rows, comprising: cells have lateral cell walls which adjoin one another in the form of a ring and are bounded toward two opening sides of each cell by covering-layer planes whereby the cells are each bridged partially or completely in one or other of the covering-layer planes; the folded honeycomb being formed from a substantially uncut flat body; the folded honeycomb having a plurality of 3D-structures (1 and 2) formed by plastic deformation and connecting areas (3 and 4) produced by the plastic deformation
Implementation Method 2
An advantage of the present invention is that it enables vacuum forming and a good attachment to the covering layers
Data Source
AI summary
A half closed thermoplastic folded honeycomb structure is described which is produced from a continuous web of material by plastic deformation perpendicular to the plane of the material to thereby form half-hexagonal cell walls and small connecting areas. By folding in the direction of conveyance the cell walls meet to thereby form the honeycomb structure.