Semi-open Honeycomb Structure via Integral Sheet Folding
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Solution Overview
Problem
Conventional honeycomb structure fabrication processes are costly and result in structures with poor stability and conductivity due to complex handling and bonding of separate sheets, leading to potential collapse and reduced shielding effectiveness in applications like EMC shielding.
Innovation Solution
A semi-open honeycomb structure formed from a single integral sheet of corrugated material, where slots are created and the material is folded to define tubular cells, eliminating the need for separate interconnections and enhancing stability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If separate sheets or strips are bonded together to form honeycomb structures, then the structure can be formed with open cells, but the adhesive bond strength is insufficient and the structure may collapse
Solution Approach 1:
The patent merges multiple separate sheets into a single integral sheet with continuous corrugations that extend across the entire structure. The sheet sections are interconnected through folded portions that form integral connections, eliminating the need for separate adhesive bonds between discrete components. This integral construction ensures structural stability without relying on potentially weak adhesive joints.
2Ease of manufacture
If resin adhesives are used to bond metal strips, then production costs are reduced, but electric conductivity between strips is lost and shielding capacity becomes irregular
Solution Approach 1:
The patent extracts the adhesive bonding step entirely from the manufacturing process. Instead of using resin adhesives that would insulate adjacent metal strips, the invention creates direct mechanical and electrical connections through folded portions of the continuous sheet. The sheet sections are joined by folding and interlocking, maintaining electric conductivity pathways without requiring any adhesive material that would disrupt electrical continuity.
3Reliability
If soldering is used to bond metal strips, then electric conductivity and shielding properties are improved, but production costs and material costs become extremely high
Solution Approach 1:
The patent replaces the thermal/mechanical soldering process with a purely mechanical folding and interlocking system. The continuous sheet is folded at specific locations to create connections between sheet sections, forming mechanical joints that simultaneously provide both structural support and electrical conductivity. This mechanical folding approach eliminates the need for expensive soldering materials and complex soldering operations while maintaining reliable electric conductivity pathways.
4Ease of manufacture
If multiple separate sheets are handled and bonded, then honeycomb structures can be formed, but the fabrication process becomes complex and costly
Solution Approach 1:
The patent combines multiple separate sheet handling operations into a single continuous sheet processing operation. The entire honeycomb structure is formed from one integral sheet with continuous corrugations, eliminating the need to stack, align, and bond multiple separate sheets. This single-sheet approach dramatically simplifies the fabrication process, reduces material waste, and eliminates the complexity of managing multiple discrete components.
Data Source
Figure 1A~1B
Figure 2A~4B
Figure 5
AI summary
In an at least partially semi-open structure having adjoining, generally tubular open cells, and consisting of sheet material delimiting each of the tubular open cells, having a width (W), a length (L) and a thickness (T) and having multiple spaced corrugations (2, 3) extending in generally parallel first directions (DL or DW) across the sheet material, all of the tubular open cells of the structure are delimited by foldable sheet material of one integral sheet (1) folded onto or towards itself along folding lines (10, 11) extending at predetermined positions in the sheet material and in second directions (DW or DL) being generally transversal to the corrugations. In a method of fabricating such a structure, the sheet is repeatedly folded towards or onto itself, in alternating opposite directions along at least some of sets (10, 11) of mutually aligned and spaced slots (10A, HA) forming said folding lines.