| JPH03248835A | 1991-11-06 | |||
| JP2001179843A | 2001-07-03 | |||
| KR20040026068A | 2004-03-27 | |||
| KR20020084660A | 2002-11-09 | |||
| US4284457A | 1981-08-18 | |||
| US4971746A | 1990-11-20 |
| 1. | A method of producing honeycomb structure using a press or a vacuum forming machine with a mold to form a honeycomb structure from either two plastic plates that have hexagonal pegs which are placed at a certain distance from each other and then these two formed plates are joined together by facing the protruding sides to each other, or from a plastic plate in which the hexagonal pegs are crowded very closely and then those pegs are joined together. |
| 2. | The method of claim 1, wherein the pegs have different polygonal shapes such as triangular, square, and octagonal or even circular. AMENDED CLAIMS [received by the International Bureau on 24 February 2005 (24.02. 2005); original claims 12 replaced by amended claims 12 (1 page)] 1 (amended) A method of making honeycomb structure which comprises shaping hexagonal celled plastic plates consisting of hexagonal pegs having a predetermined distance from each other by using press forming or vacuum forming process, interlocking these two plastic plates facing the protruded side to each other whereby hexagonal pegs from on plate are inserted between the hexagonal pegs from the other plate, and thus hexagonal pegs are continuously joined, or in case of dense hexagonal protruded pegs, only one plastic plate can be used and its hexagonal pegs are joined together continuously. 2 (amended) The method according to claim 1, wherein the pegs have different polygonal shapes such as triangular, square, and octagonal or have circular shape. Statement under Article 19 (1) Claim 1 of the present application relates to making honeycomb structure which comprises preparing hexagonal celled plastic plates by press forming or vacuum forming process whereby forming hexagonal pegs placed at a certain distance from each other and interlocking these two plastic plates facing the protruded side to each other whereby hexagonal pegs from one plate are inserted between the hexagonal pegs from the other plate and thus hexagonal pegs are continuously joined. In case of dense hexagonal protruded pegs, only one plastic plate can be used and those hexagonal pegs from a plate are joined together. D1 (JP03248835) is concerned with making a injection mold which consist of the upper part of the mold having honeycombformed protrusions and the lower part of the mold which fit over the honeycombformed protrusions from upper mold. Honeycomb core can be formed using this mold whereby inserting synthetic resin into the gap between this two parts of the mold. Then, a film is laminated to an opening part side of the honeycomb core through an adhesive agent, sealed and molded integrally. According to claim 1 of the present application, it is possible to fabricate a honeycomb structure by interlocking two hexagonal celled plastic plates from each other toward the protruded hexagonal peg, in which hexagonal pegs are continuously joined. In case of dense hexagonal protruded pegs, these pegs from a plastic plate are joined together continuously to fabricate a honeycomb structure. On the contrary, D1 is merely to provide an injection mold which can produce honeycomb core having only one side opened and the other side closed. In the above reasons, the subject matter of claim 1 has an inventive step under PCT Article 33 (3). |
Description of Drawings FIG 1 is the position of hexagonal cells on the plastic plate A; FIG 2 is the position of hexagonal cells on the plastic plate B ; FIG 3 shows position of hexagonal cells on the plastic plate A and B combined together ; FIG 4 is the plastic plate A with hexagonal pegs formed by a press or vacuum forming machine.
FIG 5 is the plastic plate B with hexagonal pegs formed by a press or vacuum forming machine.
FIG 6 is the honeycomb structured block in which plastic formed plates A and B are joined together.
FIG 7 is showing a method of extending the total size of the core block by joining the honeycomb blocks in a zigzag manner.
FIG 8 is showing a method of making honeycomb sandwich panel attaching non- woven fabric and face sheets on a core.
FIG 9 is showing the plastic plate with hexagonal pegs, which are very close together, formed by vacuum forming machine.
FIG 10 is showing the method of bonding the formed hexagonal pegs to each other on plastic plate from FIG 9.
<Description of the numbers on drawing> 2. Plastic plate A 4. Position of the hexagonal cells on Plastic plate A 6. Plastic plate B 8. Position of the hexagonal cells on Plastic plate B 10 Plastic plate A + B 12 Position of the hexagonal cells that are made automatically 14 Hexagonal peg 16 Hexagonal cell 18 Hexagonal cells that are made automatically 20 Honeycomb block A 22 Honeycomb block B 24 Non-woven fabric 26 Face Sheet 28 Bonding area on hexagonal pegs Technical Problems Unlike the existing methods of making plastic honeycomb structure, the present invention is using a press or a vacuum forming machine to produce the high quality product and perform easier process.
Technical Solutions In the present invention, a mold is needed to be built for the making of hexagonal cells of the honeycomb structure. The mold is designed and the hexagonal cells on the mold are placed at a certain distance from each other as shown in FIG 1 and FIG2, so that when the cell positions from those two FIGs are overlapping, the result is a perfect honeycomb shape as shown in FIG 3. A press or vacuum forming machine with this mold are used to change the shape of two thin plastic plates (2,6), shown in FIG 1 and FIG 2, into two formed plastic plates which have hexagonal pegs (14) protruding out as shown in FIG 4 and FIG 5. And then, in order to make a shape of honeycomb structure, these two formed plastic plates are joined together into a block, like in FIG 6, by facing the protruding sides to each other and inserting one plate's pegs (14) into the spaces among the other plate's pegs (14). In order to have physical properties of honeycomb structure from the block described above, the hexagonal pegs (14) have to be bonded to each other strongly using a plastic joining method, such as solvent bonding, fusion bonding, or ultrasonic welding.
FIG 7 shows the method of extending the size of the block by joining the honeycomb blocks (20,22) in a zigzag manner.
FIG 8 shows the making of a honeycomb sandwich panel. Face sheets (26) and adhesive are added to the top and bottom of the block. The face sheets can be made out of many different materials. Non-woven fabric (24) can be used with the adhesive to create a better bond between the sheets (26) and the block. In the existing method of making honeycomb panels, because the edge of the cells on a honeycomb core is attached to the face sheet, detachment of the face sheet from the core can happen more easily. In the present invention, however, the bonding area between the honeycomb block and the face sheet is much larger so that detachment is harder.
FIG 9 shows a plastic plate with hexagonal pegs that are crowded very close to each other. This plate is formed by a vacuum forming machine and there are some spaces between the pegs. Because it already has the honeycomb shape, when the pegs are attached together as shown in FIG 10, it becomes a honeycomb structure.
Advantageous Effects In the present invention, the process of producing plastic honeycomb structure is simplified by using a press or a vacuum forming machine and by using fusion bonding or ultrasonic welding. Also, honeycomb structure can be formed using many different types of plastic material.
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