Honeycomb Panel Production via Laser Cutting and Strip Joining
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Solution Overview
Problem
The production of honeycomb panels in existing technologies requires a mechanical separation process and a subsequent drying step, which is inefficient and costly, and often results in damaged structures and tool wear due to mechanical cutting processes.
Innovation Solution
A method and device that uses non-mechanical cutting processes, such as laser cutting, to produce honeycomb panels by separating and joining honeycomb strips without an intermediate block, eliminating the need for mechanical separation and drying, and ensuring precise alignment for improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical separation processes are used to produce honeycomb panels, then the production process can be completed, but the honeycomb structures are crushed and burrs occur in the separation zones
Solution Approach 1:
The patent replaces mechanical cutting processes with laser cutting technology. The laser beam cuts the honeycomb panel through thermal energy rather than mechanical force, eliminating the crushing and burr formation caused by mechanical contact between cutting tools and the honeycomb structure.
Solution Approach 2:
The patent changes the cutting method from mechanical to thermal by using laser energy. This parameter change in the cutting mechanism allows for precise cutting without the physical contact that causes damage to the honeycomb structure.
2Ease of manufacture
If mechanical cutting processes are used, then separation can be achieved, but cutting surfaces have burrs and structures are damaged
Solution Approach 1:
The patent substitutes mechanical cutting with laser cutting, where a focused laser beam melts and vaporizes the material along the cut path. This non-contact method produces clean cut surfaces without burrs while maintaining the separation capability.
3Productivity
If conventional production methods with intermediate blocks are used, then honeycomb panels can be produced, but material waste increases and production costs rise
Solution Approach 1:
The patent extracts and eliminates the intermediate block production step from the conventional process. By cutting honeycomb strips directly from the starting material and joining them immediately, the method removes the unnecessary material that would be wasted in creating and then cutting apart intermediate blocks.
Solution Approach 2:
The patent performs the cutting action before joining, creating honeycomb strips in advance and then assembling them. This preliminary cutting allows for precise material utilization and eliminates the need to produce excess material for intermediate blocks that would later be discarded.
4Ease of manufacture
If mechanical separation processes are used, then honeycomb panels can be manufactured, but tool wear occurs and production costs increase
Solution Approach 1:
The patent replaces mechanical cutting tools with a laser cutting system. The laser beam, focused through a lens or mirror, cuts the material through thermal energy without physical contact, eliminating tool wear and the associated maintenance requirements while maintaining manufacturing capability.
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
This approach reduces material waste, minimizes tool wear, and enhances the mechanical properties of the honeycomb panels by allowing for burr-free cut surfaces and improved alignment of strips, thus optimizing the production process and reducing costs.
Implementation Method 1
the cutting process is to be carried out using a laser beam
Data Source
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AI summary
The invention relates to a method for producing honeycomb panels (5) wherein a honeycomb-structured starting material (2) is transported in a transport plane (T), subsequently separated along a separation plane (t), the resulting honeycomb strip (4) serves as a base strip for generating the honeycomb structure (1) and at least one further honeycomb strip (4) is joined to the base strip and stacked in a stacking plane (S) and is available as a new base strip for a subsequent expansion step, wherein the transport (T) and stacking plane (S) run almost parallel and both are oriented almost perpendicular to the separation plane (t) characterized in that the material thickness produced by the separation process before the joining process corresponds to the final thickness of the honeycomb panel (5) to be produced.The invention further relates to a device for carrying out a previously described method consisting of: a transport device comprising a push and/or pull unit (12), a pressure unit (10), a separating unit (6), a joining unit (9), a guide unit (15) characterized in that the pressure unit (10) consists of at least two rigidly connected guide elements (8).