EP3831592A1 - Method for manufacturing a cell structure, cell structure and its use - Google Patents

Abstract

The invention relates to a method for producing a cell structure (10, 10 ″, 20) and the cell structure itself, which has at least one structure layer (50) comprising cell layers (31), the cell layers (31) forming cell walls (34, 36) and all cell walls (34, 36) rest against one another in the structural layer (50), and can be expanded from a flat state in an expansion direction (12), perpendicular to the widthwise expansion of the structural layer (50), in such a way that the intermediate webs are (36) erect opposite the longitudinal webs (34). According to the invention, the method comprises the steps a) forming several endless cell layers (31) as webs (122, 122 ') and / or strips (132, 132 are fed one above the other, b) in the area of joining zones (38), the webs (122, 122 ') and / or strips (132, 132') are connected to one another in such a way that a joint (37) is directly connected to the joining zones (38) and c) by the cell layers (31) connected to the joining zones (38) are St structural layers (50) cut off, the length of the sections of the structural layers (50) corresponding to a wall height of the cell structure (10, 10 ', 10 ", 20, 20'). The invention further relates to the use of a cell structure as a packaging or sandwich core.

Description

The invention relates to a method for producing an expandable cell structure which has at least one structural layer comprising cell layers and at least one first boundary layer, the cell layers forming cell walls of the cell structure in the expanded state, the cell walls being longitudinal webs and being located between two adjacent ones at every stage of expansion parallel extending longitudinal webs comprise intermediate webs, and wherein in the at least one structural layer all cell layers lie against one another, the at least one structural layer in an expansion direction, perpendicular to the extension of the at least one structural layer in width, in the manner from a planar state to a structural layer in the Expanded state is expandable that the intermediate webs stand up against the longitudinal webs. The flat, unexpanded, non-erect state of the cell structure also represents the transport and storage state, for example before the cells are filled. The cell layers lie against one another in the flat state and are joined to one another at the joints required to form the cell structure. By later erecting and thus reshaping the cell layers from the flat state, the cells ultimately result in the desired and desired shape and form. A structural layer is the smallest unit that independently represents a cell structure, but can also be combined with other structural layers to form a larger cell structure.

The invention also relates to a cell structure which has at least one structure layer comprising cell layers and at least one first boundary layer, the cell layers forming cell walls of the cell structure in the expanded state, the cell walls being longitudinal webs and extending between two adjacent longitudinal webs that run parallel in each stage of expansion Include intermediate webs, and wherein in the at least one structural layer all cell layers lie against one another, the at least one structural layer in an expansion direction, perpendicular to the extension of the at least one structural layer in width, in the manner of a non-expanded state, subsequently as a planar state in the sense referred to as "flat", it is expandable that the intermediate webs are erected with respect to the longitudinal webs. The cell layers are flat layers of material and are supplied, for example, as webs or strips to produce a structural layer. The invention further relates to the use of a cell structure which forms a compartment comprising cell walls. In contrast to the natural honeycomb, the cell structure, to which or, in particular, the production of which the present invention relates, is not necessarily hexagonal, but can also have a different number of corners, for example square.

In the packaging industry, the subdivision of packing rooms is often carried out with the help of compartments. Conventional compartments are crossed, nested, individual cardboard or cardboard strips. They are used to separate packaged goods and thus have a sorting, but mostly also a protective function. A great advantage of common compartments is the possibility of transporting and storing them in a non-expanded, planar form with little space requirement.

Compartments require a comparatively complex manufacturing process. This is because the individual elements, the cardboard strips that make up compartments, are first punched out of sheets. The slots that are required for the later assembly by plugging together are also made. The free spaces required for plugging lead to voltage peaks when the compartment is loaded, which leads to a reduction in stability. The punched individual parts are then laboriously separated, handled and plugged into one another. In view of the enormous amounts of packaging and thus also compartments, each solution represents a considerable improvement, which enables a comparable function with more cost-effective production.

In addition, the complex production of compartments produced by punching also requires large numbers of items, which is synonymous with a low level of flexibility. Because even compartments with the same cell structure but different heights always require a new punching tool.

Hexagonal honeycomb cores that do not require complex handling of individual components are easier to manufacture. However, conventional hexagonal honeycomb cores have disadvantages which, depending on the application, exclude or severely restrict their use as a compartment. For example, a hexagonal honeycomb core tapers when expanding in the direction transverse to the direction of expansion. This prevents, for example, the use of effective packaging solutions in which the non-expanded core is glued directly to the packaging and only erected at the user. In this case, very uneven, sometimes unusable cells would result. Their use is limited to very special cases, such as B. for the packaging of eggs, as in the document DE 858 224 B described.

From the pamphlet GB 1 001 804 A a packaging unit is known which is also based on an expandable cell structure. The resulting cell structure, which is used as a compartment, only has hexagonal cells of the same size, which severely restricts the possible uses and, moreover, results in unusable cells at the edge of the packaging.

The pamphlets DE 10 2014 117 146 A1 and DE 361 66 32 A1 describe manufacturing processes based on complex cutting processes such as punching or lasers. The pamphlets WO 00/012393 A1 and KR200481315 Y1 reveal nested compartments that do not allow continuous, efficient production. The pamphlets CN 102673889 A , U.S. 5,875,608 A and JP 09187875 A also have an inserted compartment, in which hexagonal structures are also formed, the subject.

Further known solutions with a hexagonal, undefined expanding honeycomb structure can be found in the publications DD 35 395 A1 , DE 198 45 991 A1 , DE 195 07 563 A1 , DE 1 152 520 A and US 2007/0 051 661 A1 known. With the print US 2007/0 051 661 A1 the actually undefined hexagonal honeycomb structure can be forced to a partially defined expansion by a frame.

When a conventional hexagonal honeycomb core is expanded, the width of the honeycomb core changes over the entire length of the core. If this were to be freely clamped, the result would be a strand with a width that is uniformly reduced towards the center. However, this is usually not the case with conventional expansion. The core is pulled from the non-expanded shape into the expanded shape, a characteristic shape being established for the entire expansion area.

The reduction in width and the associated characteristic shape can be attributed to the restraint during the expansion process in combination with the elastic behavior of the material. While, viewed along the machine direction (MLR), the cells are converted from an ideally flat shape to an ideally hexagonal shape, each individual cell has a different, asymmetrical shape deviating from the regular hexagon with increasing distance from the plane of symmetry. The smaller the cell width and the longer the expansion range, the less influence the expansion has on the cell geometry of an individual cell.

This changes, however, if the required core comprises only a few cells, as is the case, for example, when used as a compartment replacement. If a honeycomb core comprising only a few cells is expanded and its end faces are clamped in, a very irregular shape is created.

The object of the present invention is therefore to offer an expandable cell structure and a production method for the cell structure that offers high productivity and flexibility in the arrangement and design of the cell structure of the individual cells, enables a right-angled cell structure and at the same time a defined deformation when expanding having.

The object is achieved by a method for producing a cell structure which has at least one structural layer comprising cell layers. The cell structure is separated from a subsequent cell structure by at least a first boundary layer, while the lower web or a second boundary layer delimit the preceding cell structure. A web or a section of the web without an adhesive application can also be considered as the first limit position.

The cell layers form cell walls, especially longitudinal webs and intermediate webs that extend between two adjacent longitudinal webs that run parallel in every stage of expansion. The cell layers are created when sheets and strips are fed in. In the planar structural layer, all cell walls lie against one another, since the webs and strips are fed in as planar materials. The at least one structural layer can be expanded from a planar state in an expansion direction, perpendicular to the expansion of the at least one structural layer, in such a way that the intermediate webs stand up in relation to the longitudinal webs.

For this purpose, according to the invention, in a first process step, several endless cell layers are fed as webs to the continuous cell layers over the width of the first boundary layer, connected to the longitudinal webs in the region of at least one joining zone, for the formation of the intermediate webs. As an alternative or in addition, strips are provided which only take up part of the width of the web, in particular the width of the intermediate webs, and which additionally comprise a connecting tab on both sides for joining in the joining zone. The tracks and, if any, the strips are fed in layers on top of each other so that several layers can be formed at once. This is a first step in the process.

In a second process step, the layers are connected to one another in lanes or strips in the area of joining zones and continuously by joining in such a way that a joint is directly connected to each of the joining zones. The latter results from the bending away of the two bonded webs during expansion. Preparing the bending points is particularly advantageous with stronger, rigid materials.

In a third process step, structural layers that are present as a strand and are connected at the joining zones are separated into sections, so that the originally planar cell structure that was completed after the last process step is formed after the expansion. The length of the sections of the structural layers corresponds to a wall height of the cell structure. The structural layer is the smallest unit that independently represents a cell structure, but can also be combined with other structural layers to form a larger cell structure. The joining takes place until a boundary layer prevents this and enables a new cell structure.

Several endless or quasi-endless cell layers are thus fed one on top of the other and connected to one another in the area of the joining zones to form a quasi-continuous strand of the structural layers. Subsequently, the strand is divided into structural layers in the required length by cutting, so that after the subsequent expansion, the cell structure is formed with a height that corresponds to the length of the severed sections.

1. 1. Zuführen von Streifen oder Bahnen für die verschiedenen Zelllagen;
2. 2. Vorbereiten der späteren Gelenkstellen durch Rillen, Ritzen oder Perforieren;
3. 3. streifenförmiger Klebstoffauftrag auf die Bahnen oder Streifen und
4. 4. Verpressen dieser zum Strang von Strukturlagen;
5. 5. diskontinuierliches Zuführen und Abtrennen der ersten, oberen Grenzlage als Abschluss einer Zellstruktur;
6. 6. Abtrennen der nicht expandierten, verklebten Strukturlagen in einen Schacht, wobei für den Fall, dass mehrere Strukturlagen zur Zellstruktur zu verkleben sind, diese durch den vorherrschende Druck im entsprechend gestalteten Schacht miteinander verbunden werden;
7. 7. eine plane, nicht expandierte Zellstruktur liegt beim Austritt aus dem Schacht fertig vor.

A preferred process flow is divided into the following sub-steps:

1. 1. Supply of strips or sheets for the different cell layers;
2. 2. Prepare the later joint points by creasing, scoring or perforating;
3. 3. Strip-shaped adhesive application on the webs or strips and
4. 4. Compression of these to form a strand of structural layers;
5. 5. discontinuous supply and separation of the first, upper limit layer as a termination of a cell structure;
6. 6. Separation of the non-expanded, bonded structural layers into a shaft, whereby in the event that several structural layers are to be bonded to form the cell structure, these are connected to one another by the prevailing pressure in the correspondingly designed shaft;
7. 7. A flat, non-expanded cell structure is ready when it emerges from the shaft.

The beginning of a new cell structure is formed in each case by a first, lower web of the first structure layer, but can also be fed in discontinuously as a separate second boundary layer.

This manufacturing process is used to produce the cell structure according to the invention. If the number of cell layers, the number of bonded structural layers, the bond location or its width are varied, different cell structures according to the invention result. The length of the sections of the structural layer separated from the strand gives the height of the cell structure. The height can also be varied by using a non-linear cut to create advantageous cell structures with cell walls of different heights.

Quasi-endless cell layers for several cell structures are preferably supplied at the same time. The beginning and end of a new cell structure are formed by the boundary layer without joining zones, in particular without application of adhesive, on the side facing away from the structural layer, that is to say the outside of the individual cell structure.

The difference between the cell structure according to the invention and the conventional manufacture of honeycomb cores is not least that cell layers, for example paper webs and / or paper strips, can be specifically arranged and glued in a defined manner, depending on the required cell structure. The structure achieved then not only serves as the core structure for sandwich components, but also offers the possibility of subdividing packing rooms according to the application. All packaging materials that can be produced in this way use the kinematic properties of combined slider crank and parallel crank drives when they expand.

Preferably, the joining takes place during production by means of a strip-shaped application of adhesive. However, other joining methods can also be used, such as B. heat sealing a correspondingly suitable material web or the use of a material provided with an appropriately activatable adhesive strip. The Activation can be done by heat, but also in other ways depending on the type of adhesive.

With the non-linear separation of the sections, different height profiles of the web walls can be generated. A correspondingly designed separating or cutting device is required for this.

According to the method according to the invention described above, some of the variability in the size of the compartments of the cell structure is possible through simple parameter setting. Furthermore, products with improved mechanical properties, in which, for example, no stress peaks arise as a result of the required punching clearances for joining slots, as well as simplified handling are made possible. In the field of lightweight construction, especially in the so-called sandwich construction, a so-called expandable hexagonal honeycomb core is often used as the cell structure as a core layer between cover layers. An advantage in the production of such cores according to the method according to the invention is the very productive method with which expandable cell structures can be produced just as inexpensively, while at the same time avoiding the disadvantages of conventional hexagonal honeycomb cores.

Another aspect of the invention relates to an expandable cell structure which has at least one structure layer comprising cell layers, initially planar in an initial state, which is pulled apart in an expansion direction during expansion. The cell layers, the layers arranged on top of one another and partially connected to one another, form cell walls, which as such only come into effect when the cell structure is expanded and the cell walls are erected. In the structural layer, all of the cell walls, which comprise longitudinal webs and intermediate webs which extend between two adjacent longitudinal webs which run parallel in each stage of expansion, rest against one another. The structural layer can be expanded in an expansion direction, perpendicular to the expansion of the structural layer, in such a way that the intermediate webs are erected with respect to the longitudinal webs and thereby free spaces, for example the packing spaces for a compartment. While in the non-expanded, planar state of the structural layers, the intermediate webs are essentially parallel to the longitudinal webs and assume an angle of approximately 0 ° to one another, the angle in a joint increases to up to 90 ° when erecting. As soon as the joints assume an angle of almost 90 °, the cells of the cell structure are almost rectangular.

According to the invention, the at least one structural layer comprises a first and a second boundary layer, one of which is usually already formed by the lower web. The other boundary layer, usually the upper or last in the respective cell layer, which is separated and conveyed into the shaft, is preferably formed by a section of a non-glued web. The boundary layers form the upper and lower ends of a cell structure. The cell walls also form a parallel kinematic cell geometry. In general, in a parallel kinematic multi-axis system, all actuators act on a common platform. This means that the dynamic properties of the axes can be designed identically. The cell walls in the present invention follow the kinematic properties of combined slider crank and parallel crank drives, hereinafter referred to as parallel kinematic cell geometry. It also follows from this that all intermediate webs must be the same in length.

According to a first embodiment, cell layers that are continuous over the width and are connected to the longitudinal webs in the region of at least one joining zone are provided for the formation of the intermediate webs. The width of the longitudinal webs, in the non-expanded and in the expanded state, can extend beyond the intermediate webs or no intermediate webs have to form an outer, laterally closed edge area in the expanded state. According to a second embodiment, cell layers are provided for the formation of the intermediate webs, which are provided as strips that only cover the width of the intermediate web and on each side a connecting tab for joining in the joining zone. This arrangement advantageously prevents an undefined reduction in the width of the cell structure associated with the expansion during the expansion of the at least one structural layer.

Several structural layers strung together, e.g. B. glued together, form a cell structure, but it is sufficient according to the invention, a single structural layer. The number of cell layers and thus the number of expandable rows of cells depends on the number of webs and strips that can be fed in at the same time.

The main difference between the present invention and the prior art is that according to the invention, cell structures are created which, in terms of their cell geometry, are based exclusively on four-link linkages, instead of exclusively on six-link linkages, as is the case with conventional ones Honeycomb core. The four-link chains that are lined up and connected to one another have only one degree of freedom. An additional constraint creates a precisely defined cell geometry and, as a result, the cell structure according to the invention with its advantageous properties.

According to an advantageous embodiment, a further cell layer must be applied for each compartment to the side of a central six-link coupling gear. According to a first embodiment, which provides for the feeding of webs, this leads to multiple layers of cells arranged one above the other and joined together. This results in a higher stability, but also a higher weight and a higher cost of materials.

As an alternative to this or alternately with the continuous cell layers, which are supplied as webs to form the longitudinal and possibly also the intermediate webs, a second embodiment provides that the non-expanded cell structure comprises other cell layers for the formation of the intermediate webs. These cell layers are designed as strips that only encompass the width of the intermediate web plus a connecting tab on each side for joining in the joining zone. As a result, strips that are separated in sections across the width and preferably joined to the separately provided connecting straps are used, so that unnecessary duplication or multiple overlapping of material is avoided.

According to an advantageous development, the cell walls together form the parallel kinematic cell geometry by flanking at least one six-link coupling gear in the at least one structural layer by two rows arranged one behind the other in the expansion direction, each with at least one four-link coupling gear. The six-link coupling mechanism extends between two tracks that form its longitudinal webs. The two four-link linkage flank the six-link linkage on at least one side, which is each formed by two adjacent intermediate webs. Each of the four-link linkage is connected to one of the intermediate webs of the six-link linkage.

According to one embodiment, each structural layer is constructed symmetrically and the central six-link linkage is flanked on both sides by the same number of four-link linkage. It continues to be beneficial Further, a different cell geometry with different cell sizes and / or wall heights is provided in each structural layer.

According to an advantageous embodiment of the present invention, the non-expanded cell structure comprises cell layers that are continuous over the width and are connected to the longitudinal webs in the region of at least one joining zone for the formation of the intermediate webs. Joining is preferably carried out by gluing by means of previously applied adhesive, in particular strip-shaped areas, alternatively by a separate application of adhesive, a pressure-sensitive adhesive or in another suitable manner, such as, for. B. a sealing process. The joining zone does not have to be completely glued; one glued area at the edges of the joining zone is sufficient.

It has proven to be advantageous to use different materials, such as e.g. B. to combine corrugated and cardboard layers. Furthermore, it has proven to be advantageous to prepare the later kinks before joining the tracks and strips to form the strand of the unexpanded, planar structural layer by means of grooves, scratches or perforations along a kink line.

Another aspect of the invention relates to a use of a cell structure which forms a compartment comprising cell walls. A variable-length cell structure with a defined change in width is used as a packaging material. The packaging means, based on an expandable cell structure, forms the compartment comprising a partition, in particular for arrangement in a folding box. An expandable cell structure according to the invention is provided as compartments. The web walls advantageously run in the fully expanded state of the compartment when the joints between the longitudinal and intermediate webs assume an angle of almost 90 °, at right angles to one another and parallel to the outer edges of the packaging. A particular advantage of the present invention arises accordingly when the compartment is used as an interior device for folding boxes. The compartment can also be designed with compartments of different sizes and web height profiles. In addition, the cell structure does not necessarily have to be overexpanded by 90 °, but rather installed at other angles, for example 45 °.

It is also provided that the expandable cell structure described above can also be used as a variable-length product with a defined change in width, such as, for. B. in the furniture industry or as a pressure-resistant sandwich core, is advantageously used. This is also possible, for example, with locally varying wearing properties, in particular by changing the cell size locally, e.g. B. according to the expected load is varied. The locally varied cell structures result in sandwich core materials with partially different wearing properties.

The invention offers a modification of the manufacturing method for conventional honeycomb structures so that such erectable cell structures can be manufactured very effectively with this method. The manufacturing method according to the invention offers significant advantages over the prior art, e.g. B. by other, above all flexible adhesive patterns depending on the intended cell structure, the possible use of strips instead of webs and the fact that there is no endless cell structure, but rather individual products are formed despite quasi-continuous production due to the uncoated, adhesive-free boundary layer. Cell structures, in particular with a repeating pattern, can be produced in a simple manner by lining up and gluing structural layers.

• das erfindungsgemäße Verfahren basiert auf und ist angelehnt an ein industriell erprobtes Verfahren zur Herstellung bekannter Hexagonalwabenkerne als Zellstruktur;
• nur wenige Verfahrensschritte - dafür aber mehrfach wiederholt bzw. parallel ausgeführt - werden benötigt, was zu einem überschaubaren Prozess und Produktionssicherheit führt;
• hohe Produktivität durch kontinuierliche Verarbeitung von Bahnen oder Streifen;
• kostengünstige Herstellung von Produkten;
• sehr variables Verfahren in Bezug auf die Produkthöhe und die Mehrfachanordnung eines Musters bzw. einer Strukturlage in einer Zellstruktur;
• hohe Ausbringung bei kostengünstiger Produktion;
• Verarbeitung verschiedenster Materialien möglich, auch innerhalb eines Packmittels (z. B. auch Wellpappe).

Further essential advantages of the present invention lie in the arrangement of web elements for the formation of kinematic structures, which during expansion result, for example, in a packaging material tailored to a task. The method according to the invention also offers the following advantages:

• the method according to the invention is based on and is based on an industrially proven method for producing known hexagonal honeycomb cores as a cell structure;
• only a few process steps - but repeated several times or carried out in parallel - are required, which leads to a manageable process and production reliability;
• high productivity through continuous processing of webs or strips;
• inexpensive manufacture of products;
• very variable process with regard to the product height and the multiple arrangement of a pattern or a structural layer in a cell structure;
• high output with inexpensive production;
• Processing of a wide variety of materials is possible, even within one packaging (e.g. also corrugated cardboard).

• Form und Geometrie sehr flexibel für einzelne Anwendungen bzw. zu verpackende Gegenstände gestaltbar;
• anpassbar durch verschiedene Zellgrößen, -formen und -kombinationen sowie Materialien, die in einer Einheit realisierbar sind;
• expandierbar bzw. auffaltbar, dadurch geringe Lager- und Transportkosten;
• Produkte mit variabler Höhe können hergestellt werden;
• definierte Breitenreduktion der Zellstruktur bei der Expansion, so dass die typische Breitenreduktion herkömmlicher Hexagonalwabenkerne vermieden wird;
• Schwachstellen, wie beispielsweise Stanzfreiräume von Gefachen, werden vermieden, wodurch eine Schwächung der Struktur, vor allem durch konstruktionsbedingten Spannungsspitzen unter Belastung, entfällt;
• Mehrfachwände mit nahezu beliebigem Abstand können als Schutzfunktion bzw. zur Verstärkung geschaffen werden.

The use according to the invention as a packaging means offers, depending on the embodiment, the following advantageous properties:

• Shape and geometry can be designed very flexibly for individual applications or items to be packaged;
• adaptable through different cell sizes, shapes and combinations as well as materials that can be realized in one unit;
• expandable or foldable, thus low storage and transport costs;
• Variable height products can be made;
• Defined reduction in the width of the cell structure during expansion, so that the typical reduction in width of conventional hexagonal honeycomb cores is avoided;
• Weak points, such as spaces for punching compartments, are avoided, which means that there is no weakening of the structure, especially due to construction-related stress peaks under load;
• Multiple walls with almost any distance can be created as a protective function or for reinforcement.

The packaging industry is only an exemplary application for the cell structure according to the invention. Thus, other objects of variable length, for example for the furniture industry, could also be produced according to the principle according to the invention. Cell structures produced in this way can also be used as special core layers for sandwich composites.

• Fig. 1: eine Draufsicht auf einen Wabenkern nach dem Stand der Technik;
• Fig. 2: Draufsichten auf drei exemplarische Zwischenzustände eines Wabenkerns nach dem Stand der Technik während der Expansion in einen überexpandierten Zustand;
• Fig. 3: eine perspektivische Ansicht eines Gefaches nach dem Stand der Technik;
• Fig. 4: eine schematische Draufsicht auf drei exemplarische Zwischenzustände einer Ausführungsform der erfindungsgemäßen Zellstruktur während der Expansion;
• Fig. 5: eine schematische perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Zellstruktur mit unterschiedlichen Wandhöhen nach der Expansion;
• Fig. 6: eine schematische Draufsicht einer Ausführungsform des erfindungsgemäßen Zellstruktur, gefügt aus Materialbahnen;
• Fig. 7: eine schematische Draufsicht einer Ausführungsform einer erfindungsgemäßen Zellstruktur, optimiert hinsichtlich Materialausnutzung, gefügt aus Materialbahnen und -streifen;
• Fig. 8: eine schematische perspektivische Ansicht einer Ausführungsform einer Vorrichtung zur Herstellung einer erfindungsgemäßen Zellstruktur;
• Fig. 9: eine schematische perspektivische Ansicht einer Ausführungsform einer Zellstruktur in drei Stufen der Aufrichtung und
• Fig. 10: eine schematische perspektivische Ansicht eines Packmittels, verwandt als Inneneinrichtung einer Faltschachtel.

The invention is explained in more detail below on the basis of the description of exemplary embodiments and their representation in the associated drawings. Show it:

• Fig. 1 : a plan view of a honeycomb core according to the prior art;
• Fig. 2 : Top views of three exemplary intermediate states of a honeycomb core according to the prior art during the expansion into an overexpanded state;
• Fig. 3 : a perspective view of a compartment according to the prior art;
• Fig. 4 : a schematic plan view of three exemplary intermediate states of an embodiment of the cell structure according to the invention during expansion;
• Fig. 5 : a schematic perspective view of an embodiment of a cell structure according to the invention with different wall heights after expansion;
• Fig. 6 : a schematic plan view of an embodiment of the cell structure according to the invention, assembled from material webs;
• Fig. 7 : a schematic top view of an embodiment of a cell structure according to the invention, optimized with regard to material utilization, assembled from material webs and strips;
• Fig. 8 : a schematic perspective view of an embodiment of a device for producing a cell structure according to the invention;
• Fig. 9 : a schematic perspective view of an embodiment of a cell structure in three stages of erection and
• Fig. 10 : a schematic perspective view of a packaging, used as the interior of a folding box.

Fig. 1 shows a top view of a honeycomb core 1 according to the prior art, which is joined with two parallel planes and then expanded and in which the individual honeycombs are formed by cell separators 2. The change between single and double bars is characteristic, which results from the bonding of individual cell layers. It can be seen that the entire structure constricts in the middle area and decreases in width. This common reduction in width shows the behavior of a conventional honeycomb core, which is disadvantageous for many applications, and which is overcome with the present invention.

Fig. 2 shows further top views of three exemplary intermediate states of a honeycomb core 1 according to the prior art during the expansion, wherein also initially completely unexpanded honeycomb cores and thus present in the delivery state are erected and brought into a hexagonal honeycomb shape. An arrow pointing upwards indicates the direction of expansion in which the honeycomb core 1 is pulled apart. The cells are then stretched further until they are almost rectangular in shape. Here, too, it can be seen that the width of the honeycomb core 1 decreases unevenly during expansion.

Fig. 3 shows a perspective view of a compartment 6 according to the prior art, the individual cells being formed by four compartment walls 7. These have a fixed length so that a mechanism based on the principle of parallel crank drives works when they are folded up and unfolded. However, the complex manufacture of such compartments is disadvantageous, since the required blanks are comparatively complex to manufacture and to be inserted into one another. The for The punched slots that are required to fit into one another also reduce the stability and strength and promote the formation and growth of cracks in the material.

Fig. 4 shows a schematic plan view of three exemplary intermediate states of an embodiment of a cell structure 20 according to the invention, comprising a structure layer 50 including boundary layer 32 during the expansion. After the flat, unexpanded state under letter a), the erection begins in the direction of the arrow, the expansion direction 12. Under letter b), the partially erected cell structure 20 is shown, the embodiment consisting of several rectangular cells, which in the direction of expansion are equal to the conditions of cranks long crank and coupling lengths as well as in the transverse direction the conditions of parallel cranks with cranks of the same length. The exemplary arrangement also results in a hexagonal cell that approximates a rectangle when it is maximally erected. Letter c) shows the fully erect cell structure 20 '.

The cells of the cell layer 31, the structural layer 50 or the cell structure 20 ′ are formed by longitudinal webs 34 and intermediate webs 36. The delimitation to the outside, to a further cell structure 20, takes place in each case by a boundary layer 32 which, as a web, also forms the longitudinal web 34. The longitudinal webs 34 are connected to the intermediate webs 36 via joints 37.

Fig. 5 shows a schematic perspective view of an embodiment of a cell structure 10 "according to the invention with different wall heights. This is achieved in that the cell structure 10" is not cut in a straight line when separating the structural layer, here only on one side, the top. Instead, the desired height profile is taken into account by choosing a cutting line for the cut.

Fig. 6 shows a schematic view from above of an embodiment of a cell structure 20 'according to the invention, in which both for the formation of the longitudinal webs 34, as well as for the intermediate webs 36, continuous webs 122, 122' encompassing the full width (see also FIG Fig. 8 ) as cell layers 31 to form a strand of the structure layer 50 (shown here already expanded to form the structure layer 50 ') one above the other.

As a result, in the area of one or more joining zones 38 or in partial areas of the longitudinal webs 34, several layers of material lie one on top of the other. The consequences are a higher material consumption and a higher weight, but also a higher stability in the relevant areas and thus the entire cell structure 20 '. A joint 37, via which the cell structure 20 ′ can be erected, adjoins the joining zone 38.

Fig. 7 shows a schematic view from above of a further embodiment of a cell structure 10 'according to the invention, the cell layers 31 of which are made up of webs 122, 122', but also of strips 132 (see also FIG Fig. 8 ) consists. In the exemplary embodiment shown, the webs 122, 122 ′ are used for the longitudinal webs 34 and are connected to a plurality of intermediate webs 36 in a respective joining zone 38 via connecting tabs 39. The intermediate webs 36 are formed from the strips 132, 132 ′, which have the width of the intermediate web 36 plus connecting tabs 39. The joint 37 is formed between the intermediate web 36 and the connecting strap 39. This is the case in the structural layer 50 ′ and likewise immediately following the joining zone 38.

The principle when erecting the two design variants is the same, creating the desired spaces, cavities or cells. When using webs in combination with strips, however, an advantageous, resource-saving cell structure 10 ', 10 "can be produced.

Fig. 8 shows a schematic perspective view of an embodiment of a device 110 for producing a cell structure 10 according to the invention. The erection to form the cell structure 10 ', already shown here, advantageously takes place later, in particular immediately before use. Not only tracks 122, 122 ', but also strips 132, 132' are used here. In combination with the strip-shaped adhesive application, which is applied in a targeted manner in accordance with the intended cell structure, this leads to a cell structure 10, from which the cell structure 10 ′ according to FIG Fig. 7 results.

In addition to the webs 122, 122 ', which are removed from web rolls 120, 120', there are also strips 132, 132 'for forming cell layers 31 (cf. Fig. 4 , 6th and 7th ) intended. These are present in the device as strip rolls 130, 130 '. To produce the joining zones, devices for applying adhesive are designed as application devices 144, 144 'is provided. Furthermore, an application device 144 ″ is provided and designed in such a way that an intermittent application of adhesive can take place. When the adhesive application is interrupted, a boundary layer 32 is formed from the web 122, which separates one cell structure 10 from the next one, since the structure layers 50 of the two adjacent one another Do not stick the following cell structures 10 for lack of adhesive.

There is also a pressing of the webs 122, 122 'and strips 132, 132' in the formed strand of the structure layers 50 by means of pressure rollers 142 to form a strand of structure layers 50, followed by the cutting of the individual sections of structure layers 50 by means of cutting device 146 and pressing in a chute 150. Finally, a section of the web 122 without adhesive is conveyed as a boundary layer 32 into the cutting device 146, a section is separated from this and pressed in the chute 150 with the structural layers 50 already present there. The cell structure 10 discharged from the shaft 150 can then or later be erected.

Fig. 9 shows a schematic perspective view of an embodiment of a cell structure 10 in three stages of erection.

The illustrated cell structure 10 comprises a single structure layer 50 with cell layers 31 which have been supplied as webs 122 and strips 132. The longitudinal webs 34 protrude beyond the outer joining zones 38 at which the intermediate webs 32 are connected to the longitudinal webs 34. The position of the intermediate webs 32 is freely selectable and adjustable via the feeding of the strips 132 and their position over the working width. The border layer 32 forms the end. The cell structure 10 does not have a hexagonal structure.

Fig. 10 shows a schematic perspective view of a packaging means, used as the interior of a folding box 60, comprising an embodiment of a cell structure 10 according to the invention, and its erection in steps a) to g).

The boundary layers 32 here consist of, for example, silicone-coated release paper, which is later removed again so that the subsequent gluing with a folding box blank 62 can be ensured. The cell structure 10 was joined with pressure-sensitive adhesive according to the method according to the invention. This is illustrated in steps a) and b).

In the next step (illustration b), the boundary layer 32, the release paper, is removed and the cell structure 10 with exposed adhesive areas (illustration c) is joined to a corresponding folding box blank 62 (illustration d).

When the folding box 60 is erected in steps e) to g), the cell structure 10 'is also erected, and the finished packaging material is produced. In this case, the folding box 60 with the walls of the folding box blank 62 replaces both boundary layers 32, which were only used temporarily as separating paper during manufacture.

List of reference symbols

1

Honeycomb core (state of the art)

2

Cell separator (state of the art)

6th

Compartments (state of the art)

7th

Partition wall (state of the art)

10

Cell structure (with stripes)

10 '

Cell structure (with stripes, erect)

10 "

Cell structure (with stripes, erect, height varying)

12th

Direction of expansion

20th

Cell structure (without stripes)

20 '

Cell structure (without stripes, erect)

30th

six-link coupling gear

31

Cell location

32

Border location

34

Longitudinal web

36

Intermediate bridge

37

joint

38

Joining zone

39

Connecting tab

40

four-link coupling gear

50

Structural position of a cell structure

50 '

Structural position of a cell structure (erect)

60

Folding box

62

Folding box cut

110

Device (webs and strips)

120.120 '

upper, lower web roll

122.122 '

upper, lower track

130.130 '

upper, lower strip roll

132.132 '

upper, lower stripe

142

Pressure rollers

144.144 '

upper, lower applicator

144 "

Application device (for boundary layer formation)

146

Cutting device

150

Manhole

Claims (13)

A method for producing an expandable cell structure (10, 20) which has at least one cell layer (31) comprising structural layer (50) and at least one first boundary layer (32), the at least one cell layer (31) having cell walls of the expanded cell structure (10 ', 10 ", 20 '), the cell walls comprising longitudinal webs (34) and intermediate webs (36) extending between two adjacent longitudinal webs (34) that run parallel in each stage of expansion, and wherein in the at least one non-expanded structural layer (50 ) all cell layers (31) lie next to one another, the at least one structure layer (50) in an expansion direction (12), perpendicular to the extension of the at least one structure layer (50) in width, from a planar state to a structure layer (50) ') in the expanded state is expandable that the intermediate webs (36) stand up relative to the longitudinal webs (34), characterized in that a. In a first process step, several quasi-endless cell layers (31) as webs (122, 122 ') continuous across the width perpendicular to the expansion direction (12) to form the longitudinal webs (34) and the intermediate webs (36) are fed one above the other, the cell layers ( 31) for the formation of the longitudinal webs (34) each in the area of a joining zone (38) are connected to the cell layers (31) for the formation of the intermediate webs (36), and / or as strips (132, 132 ') for the formation of the Intermediate webs (36) are fed one on top of the other, which have only the width of the intermediate webs (32) plus a connecting strap (39) on both sides with which the intermediate webs (32) are connected to the longitudinal webs (34) in the joining zone (38), b. In a second process step in the area of the joining zones (38), the webs (122, 122 ') and / or strips (132, 132') are connected to one another in such a way that a joint (37) is attached to each of the joining zones (38) Intermediate web (36) directly adjoins it, c. In a third process step, structural layers (50) are cut from the cell layers (31) connected to the joining zones (38), the length of the sections of the structural layers (50) being a wall height of the cell structure (10, 10 ', 10 ", 20, 20 ') corresponds to and d. in a fourth method step, the at least first limit layer (32) is supplied and a section is cut off. Method according to claim 1, wherein in a subsequent method step several structural layers (50) are joined in the area of the longitudinal webs (34) and connected to form the cell structure (10, 20) so that the cell structure (10 ', 10 ", 20 '), educates, Method according to Claim 1 or 2, the joining being carried out by means of the application of adhesive. Method according to one of the preceding claims, wherein a non-linear division of the joined structure layers (50) is provided and thus different wall heights of cell walls (34, 36) are generated in the cell structure (10 ", 20 '). Cell structure (10, 20, 10 ', 10 ", 20') which has at least one structural layer (50) comprising cell layers (31) and at least one first boundary layer (32), the cell layers (31) having cell walls of the cell structure (10 ') , 10 ", 20 ') in the expanded state, the cell walls comprising longitudinal webs (34) and intermediate webs (36) extending between two adjacent longitudinal webs (34) extending parallel in each stage of expansion, and wherein in the at least one structural layer (50) all cell layers (31) lie against one another, the at least one structure layer (50) in an expansion direction (12), perpendicular to the width of the at least one structure layer (50), from a planar state to a structure layer (50 ') is expandable in the expanded state that the intermediate webs (36) erect with respect to the longitudinal webs (34), characterized in that the longitudinal webs (34) and the intermediate webs (36) form a parallel kinematic cell geometry with one another According to a first embodiment, several quasi-endless cell layers (31) fed one above the other are provided as webs (122, 122 ') continuous across the width perpendicular to the expansion direction (12) to form the longitudinal webs (34) and the intermediate webs (36) , wherein the cell layers (31) for the formation of the longitudinal webs (34) are each connected in the region of a joining zone (38) with the cell layers (31) for the formation of the intermediate webs (36), and / or, according to a second embodiment, strips fed one above the other (132, 132 ') for the formation of the intermediate webs (36), which only have the width of the intermediate webs (32) plus a connecting strap (39) on both sides with which the intermediate webs (32) in the joining zone (38) with the longitudinal webs (34) are connected. Cell structure according to claim 5, wherein the longitudinal webs (34) and the intermediate webs (36) together form the parallel kinematic cell geometry, in which in the at least one structure layer (50, 50 ') at least one six-element coupling gear (30), which is located between a first and a second longitudinal web (34) of the at least one Structural layer (50) extends, on at least one side, which is formed by two adjacent intermediate webs (36) connected by a joint (37), through two rows arranged one behind the other in the expansion direction (12), each with at least one four-link coupling gear ( 40), each of which is connected to one of the intermediate webs (36) of the six-link linkage (30), is flanked. Cell structure according to claim 6, wherein each structural layer (50, 50 ') is constructed symmetrically and the six-link coupling gear (30) is arranged centrally, the six-link coupling gear (30) being flanked on both sides by the same number of four-link coupling gears (40). Cell structure according to one of Claims 5 to 7, a different cell geometry with different cell sizes and / or wall heights being provided in each structural layer (50, 50 '). Cell structure according to one of Claims 5 to 8, different materials being used in a cell structure (10, 10 ', 10 ", 20, 20'). Cell structure according to one of Claims 5 to 9, the cell structure (10, 10 ', 10 ", 20, 20') being designed as a product of variable length. Use of a cell structure according to one of Claims 5 to 10 as a compartment of a packaging material or as a sandwich core in combination with cover layers. Use according to Claim 11, the cell walls (34, 36) running at right angles to one another and parallel to the outer edges of the packaging in the fully expanded state of the compartment. Use according to claim 11 or 12, the compartment being used as a folding box interior, the compartment being designed with compartments of the same or different sizes and / or compartments with cell walls (34, 36) of the same or different heights.

Images