BRIEF DESCRIPTION OF THE DRAWINGS
The objectives and features of the present invention will become more readily apparent when the following detailed description of the drawings is taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a roll of web material being unrolled and openings created in the web;
FIG. 2 is a perspective view of an unrolled portion of the web of FIG. 1 having been plastically deformed;
FIG. 3 is a perspective view of a portion of the plastically deformed web of FIG. 2 being folded to create rows of cells;
FIG. 4 is a perspective view of a portion of the plastically deformed web of FIG. 3 being further folded to create rows of cells of a honeycomb product;
FIG. 5 is a perspective view of a row of cells;
FIG. 6 is a perspective view of a roll of web material being unrolled according to another aspect of this invention;
FIG. 7 is a perspective view of an unrolled portion of the web of FIG. 6 having been plastically deformed;
FIG. 8 is a perspective view of a portion of the plastically deformed web of FIG. 7 being treated to create a plurality of openings in the plastically deformed web;
FIG. 9 is a perspective view of a portion of the plastically deformed web of FIG. 8 being further folded to create rows of cells;
FIG. 10 is a perspective view of a roll of web material being unrolled then having been plastically deformed and punched simultaneously according to another aspect of this invention; and
FIG. 11 is a perspective view of a portion of the plastically deformed web of FIG. 10 being folded to create rows of cells.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring to FIG. 4, a portion of a honeycomb product 10 according to one embodiment of this invention is shown. The honeycomb product 10 may be made using numerous processes including those described herein and others within the scope of the claims. FIG. 4 shows a portion of a honeycomb product 10 comprising a plurality of rows 12 of identical cells 14 made from one flexible web or sheet of material. FIG. 5 illustrates one such row 12 of cells 14. Referring to FIG. 4, the honeycomb product 10 has a generally planar upper surface 16 in a generally horizontal plane P1 and a generally planar lower surface 18 in a generally horizontal plane P2, the distance between which defines the height H of the honeycomb product 10. The height H of the honeycomb product 10 may be any desired distance and is not intended to be limited to the height of the illustrated portion of the honeycomb product.
As shown in FIGS. 3 and 4, each row 12 of cells 14 is made by bringing two adjacent hinged row walls 20 together in an accordion-like manner. Each row wall 20 has alternating planar and non-planar regions or areas 22, 24, respectively. During the process of making the honeycomb product 10, adjacent row walls 20 are brought together so that the planar regions 22 of adjacent row walls 20 at least partially contact each other and the non-planar regions 24 of row walls 20 define sides or side walls 74,76 of cells 14.
In certain applications, such as for example when a web of plastic material is heated at some stage in the manufacture of the honeycomb product 10, the planar regions 22 of adjacent rows walls 20 may be bonded, welded or secured to each other without any additional material. Alternatively, adhesive may be used to secure adjacent rows walls 20 together to complete the rows 12 of cells 14. The non-planar regions 24 of adjacent row walls 20 are spaced apart and define the shape or configuration of the cells 14 after the manufacturing process has been completed. Outermost portions or sides 74 of adjacent cells 14 in different rows 12 may contact each other and may be secured to each other in certain applications of this invention.
Although the drawings illustrate each non-planar region 24 of each row wall 20 having a cross-sectional configuration of a half-hexagon, the non-planar regions of the row walls may have any desired cross-sectional configuration, such as for example a curved or arcuate or sinuous cross-sectional configuration. The creation of the side walls or sides 74,76 of the cells 14 is described in more detail below. Depending upon the application, the cells 14 may be any desired shape or size.
As best illustrated in FIG. 5, each cell 14 has a top 28 and a bottom 30 of a predetermined size and/or shape. As shown in FIG. 5, the tops 28 of the cells 14 are located in plane P1 and make up the upper surface 16 of the honeycomb product 10. Likewise, the bottoms 30 of the cells 14 are located in plane P2 and make up part of the lower surface 18 of the honeycomb product 10. The top 28, bottom 30 and sides 28 of the cell 14 define a cell interior 32.
In the illustrated embodiment, each cell top 28 and bottom 30 is a polygon and more particularly a hexagon. However, if the non-planar regions of the row walls were in the shape of half a cylinder then the tops and bottoms of the cells would be circular or oval and the cells would have a cylindrical interior.
In order to reduce the weight of the honeycomb product 10 while maintaining the strength of the honeycomb product 10, a plurality of openings 34 are created in the web of material used to make the honeycomb product 10. Consequently, at least some of the cells 14 have at least one opening 34 of a predefined or predetermined size or shape. FIG. 5 shows every other one of the openings 34 being in the tops and bottoms 28, 30 of the cells 14.
FIGS. 1-4 illustrate a method or process of making honeycomb product 10 which may be used alone or in a multi-layered material or product, or in any desired manner. FIG. 1 illustrates a flexible web of material 40 wound into a roll 42 about a core 44. The web 40 is illustrated as being unrolled in a clockwise direction. However, it may be unrolled in the opposite direction and supported or mounted in any desired manner known in the art. The unrolled portion 41 of the web 40 travels in a direction indicated by arrow 43 and has a pair of opposed side edges 45, the linear distance between which defines the width or transverse dimension of the web 40. The web 40 may be any desired material of any desired thickness and/or width. Although the web 40 is illustrated as being a solid material, it may have holes or voids therein, such as for example a metallic screen, a microporous plastic material or other similar material. As shown in FIG. 2, the unrolled portion 41 of the web 40 may be generally planar and located generally in a plane P3.
FIG. 1 illustrates a movable tool 46 in the form of a punch press which is used to remove material 48 from an unrolled portion 41 of the web 40 in predetermined or preselected locations. In FIG. 1, the punch press or tool 46 has a plurality of spaced punchers 50 aligned in rows 52 and mounted on a plate 54 to create a plurality of circular openings 34 through an unrolled portion of the web 40. These openings 34 become the openings in the honeycomb product 10 described above. The openings 34 may be any desired shape or size and strategically located or created at any predetermined or desired location on the web.
Although a punch press is illustrated, any other tool, such as a laser cutter, may be used to create the openings 34 through the unrolled portion 41 of the web 40 to lighten the unrolled portion 41 of the web of material 40 so that when this portion of the web 40 is formed into a honeycomb product 10, the resultant honeycomb product 10 has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the honeycomb product. Although the tool 46 is illustrated beneath the unrolled portion 41 of web 40, tool 46 may be located above the unrolled portion 41 of web 40 or at any desired location. More than one tool 46 may be used if desired, and combinations of tools may also be used. The term tool is not intended to be limiting and may include any tool known in the art including for example, lasers.
After the openings 34 have been created through an unrolled portion 41 of the web 40, the unrolled portion 41 of the web 40 may be heated by any desired method. Such heating is illustrated schematically by arrows 38. This method step is optional and may be used in certain applications only. In other applications it may be omitted partially or entirely. Although it is shown schematically after the openings 34 have been created and prior to plastically deforming the unrolled portion 41 of the web 40, this heating step may occur any time during the manufacturing process including prior to creating the openings 34.
FIG. 2 illustrates another step in this process of making honeycomb product 10 comprising plastically deforming at least portions of the unrolled portion 41 of the web 40 to create a plastically deformed web 36. This plastic deformation may include using a movable tool 56 such as shown in FIG. 2 to create a plurality of corrugated regions or areas 58 comprising a plurality of corrugations 60 extending in a first direction generally parallel the direction of travel 43 of the web 40 or longitudinally, and a plurality of flattened areas or regions 62, 63 each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 58, 62 and 63 may vary depending upon the desired size or shape of the cells 14 of the honeycomb product 10.
Although the tool 56 is illustrated beneath the unrolled portion 41 of web 40, tool 56 may be located above the unrolled portion 41 of web 40 or at any desired location. More than one tool 56 may be used if desired and combinations of tools may also be used. Again, the term tool is not intended to be limiting and may include any tool known in the art.
As seen in FIG. 2, the corrugations 60 may comprise coplanar flattened peaks 64 located generally in a horizontal plane P4 above the plane P3 of the unrolled portion 41 of the web 40 and flattened valleys 66 in the plane P3 of the unrolled portion 41 of the web 40 with generally rectangular flat connecting portions 68 extending therebetween. The planes P3 and P4 are illustrated as being parallel, the distance therebetween defining the height of the corrugations 60. Lastly, each corrugation 60 may have an end portion 69 which extends between a peak 64 and a valley 66. These end portions 69 are illustrated as each being in the shape of a trapezoid but may be other shapes, depending upon the shape of the corrugations.
As best illustrated in FIG. 2, each generally rectangular, transversely extending flat or flattened area 62 is located in the plane P3 of the unrolled portion 41 of the web 40. Each generally rectangular, transversely extending flat or flattened area 63 is located in plane P4 above the plane P3 of the unrolled portion 41 of the web 40 and coplanar with the plane of the flattened peaks 64 of corrugations 60. Flattened areas 62 and 63 alternate between corrugated areas 58. Due to the shape of the tool 56, each flat or flattened area 63 has side walls 70 extending from the outer edges of the flat 63 to the flattened valleys 66 in the corrugated regions 58. These side walls 70 are illustrated as each being in the shape of a trapezoid but may be other shapes, depending upon the shape of the corrugations. Although not shown, the corrugations may have a semi-circular, sinuous, curved or other cross sectional configuration.
As shown in FIG. 3, the plastically deformed web portion 36 is then folded along transversely extending fold lines 72 located generally on the edges of the flats 62, 63. Such fold lines 72 may be optionally scored or perforated at any step in the manufacturing process with cuts 71 to assist folding. See FIG. 2. Such scoring may be made by a separate tool or tools. As shown in FIGS. 3 and 5, after the plastically deformed web portion 36 is folded along transversely extending fold lines 72, side walls 70 lay underneath and may contact the raised flat 63, and end walls 69 of corrugations 60 rest on and contact flats 62.
As shown in FIGS. 2-5, the strategic locations of the openings 34 may be such that some of the openings 34 are located along the flats 62, 63 of the plastically deformed web portion 36 and others are located along fold lines 72 such that material is removed or missing from parts of end portions 69 of the corrugations 60 and parts of side walls 70 of the flats 62, 63 in addition to portions of flats 62, 63. Each opening 34 is illustrated as being generally circular but may be any preselected shape or size. As shown in FIGS. 4 and 5, when adjacent row walls 20 are compressed or otherwise brought together every cell 14 has a hole 34 through the top 28 of the cell 14 and another hole 34 through the bottom 30 of the cell 14.
As best illustrated in FIGS. 4 and 5, side walls 70 abut and are underneath portions of the raised flats 63. These two ply areas comprise approximately half of the tops 28 of some of the cells 14. In such cells the bottom 30 of the cell 14 is a single ply having a hole 34 which was formed in the flat 62 before folding. As shown in FIG. 5, end walls 69 abut and are above portions of the flats 62 to form approximately half of the bottoms 30 of other cells 14. In such cells the top 28 of the cell 14 is a single ply having a hole 34 which was formed in the flat 63 prior to folding. Thus, in one row 12 of cells 14, each cell 14 has a single ply top 28 and a double ply bottom 30. In adjacent rows of cells 14 to row 12, each cell 14 has a double ply top 28 and a single ply bottom 30.
As shown in FIGS. 4 and 5, after the plastically deformed web portion 36 is folded along transversely extending fold lines 72, the corrugations 60 or non-planar regions 24 of the row walls 20 become the side walls 74,76 of the cells 14. More particularly, the generally planar peaks 64 of corrugations 60 become the outmost side walls 74 of the cells 14 and the generally planar connecting portions 68 of corrugations 60 become additional side walls 76 of the cells 14. See FIG. 5. As shown in FIG. 5, within a row 12 of cells 14, the planar portions 22 of row walls 20 come together to create flattened two-ply portions 77 of row 12. Side walls 74, 76 along with the top 28 and bottom 30 of each cell 14 define a cell interior 32 which may be accessed by openings or holes 34. See FIG. 5.
The last step in the process is to cut the unrolled portion 41 of web 40 at any desired location. FIG. 3 illustrates a cutter 78 at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10 of a desired length.
FIGS. 6-9 illustrate another method or process of making a honeycomb product which may be used alone or in a multi-layered material or product. FIG. 6 illustrates a flexible web of material 40a wound into a roll 42a about a core 44a. The web of material 40a is illustrated as being unrolled in a clockwise direction. However, it may be unrolled in the opposite direction and supported or mounted in any desired manner known in the art. The unrolled portion 41a of the web 40a travels in a direction indicated by arrow 43a and has a pair of opposed side edges 45a, the linear distance between which defined the width or transverse dimension of the web 40a. The web 40a may be any desired material of any desired thickness and/or width. The unrolled portion 41a of the web 40a may be generally planar and located generally in a plane P5.
After a portion 41a of the web 40a has been unrolled, the unrolled portion 41a of the web 40a may be heated by any desired method. Such heating is illustrated schematically by arrows 38a. This method step is optional and may be used in certain applications only. In other applications any portion of web 40a may be omitted partially or entirely. Although it is shown schematically prior to plastically deforming an unrolled portion 41a of the web 40a, this heating step may occur any time during this manufacturing process.
FIG. 7 illustrates another step in this process of making honeycomb product boa comprising plastically deforming at least portions of the unrolled web 41a to create a plastically deformed web portion 36a. This plaster deformation may include using a movable tool 56a such as shown in FIG. 7 to create a plurality of corrugated regions or areas 58a comprising a plurality of corrugations 60a extending in a first direction generally parallel the direction of travel 43a of the web 40a or longitudinally, and a plurality of flattened areas or regions 62a, 63a each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 58a, 62a and 63a may vary depending upon the desired size or shape of the cells 14a of the honeycomb product 10a.
Although the tool 56a is illustrated beneath the unrolled portion 41a of web 40a, tool 56a may be located above the unrolled portion 41a of web 40a or at any desired location. More than one tool 56a may be used if desired, and combinations of tools may also be used. Again, the term tool is not intended to be limiting and may include any tool known in the art.
As seen in FIG. 7, the corrugations 60a may comprise coplanar flattened peaks 64a in a plane P6 above the plane P5 of the unrolled portion 41a of the web 40a and flattened valleys 66a in the plane P5 of the unrolled portion 41a of the web 40a with generally rectangular flat connecting portions 68a extending therebetween. Lastly, each corrugation 60a may have a end portion 69a which extends between a peak 64a and a valley 66a. These end portions 69a are illustrated as each being in the shape of a trapezoid but may be other shapes, depending upon the shape of the corrugations.
As best illustrated in FIG. 7, each generally rectangular, transversely extending flat or flattened area 62a is located in the plane P5 of the unrolled portion 41a of the web 40a. Therefore, each generally rectangular, transversely extending flat or flattened area 63a is located in plane P6 above the plane P5 of the unrolled portion 41a of the web 40a and coplanar with the flattened peaks 64a of corrugations 60a. Flattened areas 62a and 63a alternate between corrugated areas 58a. Due to the shape of the tool 56a, each corrugation 60a has side walls 70a extending from the outer edges of the flat 63a to the flattened valleys 66a in the corrugated regions 58a. These side walls 70a are illustrated as each being in the shape of a trapezoid but may be other shapes, depending upon the shape of the corrugations. Although not shown, the corrugations may have a semi-circular, sinuous, curved or other cross sectional configuration.
FIG. 8 illustrates a movable tool 46a in the form of a punch press which is used to remove material 48a from plastically deformed web portion 36a in predetermined or preselected locations. In FIG. 8, the punch press or tool 46a has a plurality of punchers 50a aligned in rows 52a and mounted on a plate 54a at preselected or predetermined locations or positions to create a plurality of rectangular openings 34a through predetermined or preselected portions of the plastically deformed web 36a. These openings 34a become the openings in the honeycomb product boa described above. Although illustrated as being rectangular, the openings 34a may be of any desired size or shape and strategically located at any desired location on a portion of unrolled web. For example, the holes or openings 34a may be created at the same locations shown in FIGS. 2-5 and be any predetermined or predefined size or shape.
Although a punch press is illustrated, any other tool, such as a laser cutter, may be used to create the openings 34a through any portion of the unrolled plastically deformed portion 36a of the web so that the resultant honeycomb product 10a has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the honeycomb product.
Although the tool 46a is illustrated beneath the plastically deformed portion 36a of the web 40a, tool 46a may be located above the plastically deformed portion 36a of the web 40a or at any desired location. More than one tool 46a may be used if desired.
As shown in FIGS. 8-9, the strategic locations of the openings 34 are such that the openings 34a are located along the flats 62a, 63a of the plastically deformed web of material 36a, along the flattened peaks 64a of the corrugations 60a and along connecting portions 68a of corrugations 60. As shown in FIG. 8 each opening 34a is illustrated as being generally rectangular but may be any predefined or preselected shape or size. As shown in FIGS. 8 and 9, some of the holes 34a in flats 62a, 63a extend through the bottoms 30a and tops 28a of cells 14a. Likewise, holes 34a through the flattened peaks 64a of the corrugations 60a extend through the side walls 74a of cells 14a.
As shown in FIG. 8, after the openings 34a have been bored, punched or otherwise made, the plastically deformed web portion 36a is then folded along transversely extending fold lines 72a located generally on the edges of the flats 62a, 63a. As shown in FIGS. 8 and 9, after the plastically deformed web 36a is folded along transversely extending fold lines 72a, side walls 70a lay underneath the raised flats 63a and end walls 69a of corrugations 60a rest on flats 62a.
The last step in the process is to cut the unrolled portion 41a of web 40a at any desired location. FIG. 8 illustrates a cutter 78a at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10a of a desired length.
FIG. 9 shows a portion of the resultant honeycomb product 10a along with skins or layers 80 (shown in phantom) one or both of which may be secured to at least one of the upper and lower surfaces 16a, 18a of honeycomb product 10a to create a multi-layered product for any desired use. Such skins may be incorporated into a product having a honeycomb product made in accordance with any aspect of the present invention including via any method described or contemplated herein.
FIGS. 10-11 illustrate another method or process of making a honeycomb product 10b which may be used alone or in a multi-layered material or product. FIG. 10 illustrates a flexible web of material 40b wound into a roll 42b about a core 44b. The web of material 40b is illustrated as being unrolled in a clockwise direction. However, it may be unrolled in the opposite direction and supported or mounted in any desired manner known in the art. The unrolled portion 41b of the web 40b travels in a direction indicated by arrow 43b and has a pair of opposed side edges 45b, the linear distance between which defined the width or transverse dimension of the web 40b. The web 40b may be any desired material of any desired thickness and/or width. The unrolled portion 41b of the web 40b may be generally planar and located generally in a plane P9.
After a portion 41b of the web 40a has been unrolled, the unrolled portion 41b of the web 40b may be heated by any desired method to facilitate processing. Such heating is illustrated schematically by arrows 38b. This method step is optional and may be used in certain applications only. In other applications it may be omitted partially or entirely. Although it is shown schematically prior to plastically deforming an unrolled portion 41b of the web 40b, this heating step may occur any time during this manufacturing process.
FIG. 10 illustrates another step in this process of making honeycomb product boa comprising plastically deforming at least portions of the unrolled web 41b. Plastic deformation may include using a movable tool 56b such as shown in FIG. 10 to create a plurality of corrugated regions or areas 58b comprising a plurality of corrugations 60b extending in a first direction generally parallel the direction of travel 43b of the web 40b or longitudinally, and a plurality of flattened areas or regions 62b, 63b each extending in a second direction perpendicular to the first direction, transversely or from side-to-side. The size of these regions or areas 58b, 62b and 63b in FIG. 10 may vary depending upon the desired size or shape of the cells 14b of the honeycomb product 10b in FIG. 11.
FIG. 10 illustrates a movable tool 56b which in addition to plastically deforming the unrolled portion 41b of web 40b is also used to remove material 48b from plastically deformed web portion 36a in predetermined or preselected locations. In this embodiment, removal of material 48b occurs simultaneously with the operation of plastically deforming the unrolled portion 41b of web 40b. In FIG. 10, the tool 56b has a plurality of punchers 50b mounted on a plate 54b at preselected or predetermined locations or positions to create a plurality of circular openings 34b through predetermined or preselected portions of the plastically deformed web portion 36b. These openings 34b become the openings in the honeycomb product 10b described above. Although illustrated as circular, the openings 34b may be of any desired shape and strategically located at any desired location on a portion of the unrolled web of material.
Although one configuration of tool 56b is illustrated, any other tool may be used to plastically deform unrolled portions of web 40b and simultaneously create openings 34b through any portion of the unrolled portion of the web to lighten the plastically deformed web portion 36a so that when this portion of the web 36b is folded to create honeycomb product 10b, the resultant honeycomb product 10b has a relatively high strength-to-weight ratio due, at least in part, to the removal of such material during the process of manufacturing the honeycomb product 10b.
Although the tool 56b is illustrated beneath the unrolled portion 41b of web 40b, tool 56b may be located above the unrolled portion 41b of web 40b or at any desired location. More than one tool 56b may be used if desired.
As shown in FIGS. 10 and 11, after the unrolled portion of the web has been plastically deformed and the openings 34b have been created, the plastically deformed web portion 36b is then folded along transversely extending fold lines 72b located generally on the edges of the flats 62b, 63b. As shown in FIGS. 10 and 11, after the plastically deformed web of material 36b is folded along transversely extending fold lines 72b, side walls 70b lay underneath the raised flats 63b and end walls 69b of corrugations 60b rest on flats 62b.
The last step in the process is to cut the unrolled portion 41b of web 40b at any desired location. FIG. 10 illustrates a cutter 78b at one location. However, one or more cutting tools or devices may be used at any desired location to create a honeycomb product 10b of a desired length.
While I have described several preferred embodiments of the present invention, persons skilled in the art will appreciate changes and modifications which may be made without departing from the spirit of the invention. For example, although one configuration of a cell is illustrated and described, the cells of the present invention may be other configurations, such as cylindrical in shape. Therefore, I intend to be limited only by the scope of the following claims and equivalents thereof:
Patent Application
20080075916
