GB2475248A

GB2475248A - Reinforced cellular structure

Info

Publication number: GB2475248A
Application number: GB0919651A
Authority: GB
Inventors: Yue Hang Eric Tong
Original assignee: ERA Ltd
Current assignee: ERA Ltd
Priority date: 2009-11-10
Filing date: 2009-11-10
Publication date: 2011-05-18
Also published as: GB2489618A; GB201210136D0; WO2011058348A1; CN102781282B; GB0919651D0; GB2489618B; HK1177879A1; CN102781282A

Abstract

A reinforced cellular structure comprises one or more cellular structures (020) adapted to receive at least one structural support (100) wherein the least one structural support (100) installed within said one or more cellular structures whereby improving the rigidity of the cellular structure and/or the load bearing capacity.

Description

Reinforced Cellular Structure

Field of the Invention

The present invention relates to a construction material in particular but not exclusively reinforced ceular structure; a method of reinforcing a cellular structure; a structural support for reinforcing a honeycomb structure; and a honeycomb structure modified to receive a structural support to achieve omni-directional rigidity and/or improved load bearing capacity.

Background of Invention

A cellular structure such as honeycomb can be manufactured by bonding together strips of material such as paper, metal, or plastic in lines at regular intervals and in a staggered pattern from strip to strip, of which the distance between the lines of bond defines the cell size. This produces an unexpanded cellular structure pad. This pad may then be cut lengthwise into smaller sections before being mechanically expanded in a direction perpendicular to the face of the strips of material. The cellular structure has the greatest strength and stiffness in the direction along the length of the bonded strips, and is substantially flexible in the direction perpendicular thereto.

There are many of uses for cellular structures but one common use is as a core substrate for a panel; these panels may be widely used in different industries as a substitute for solid or laminated boards such as wood, plywood, or fiberboard panels due to its excellent strength to weight ratio. The panel can be manufactured by bonding an expanded cellular structure between two sheets of material to form a rigid panel; this has many limitations in relation to manufacturing and construction.

It is common for honeycomb panels to be manufactured in standard and limited sizes, when one or more of these panels are joined to construct a larger panel. This creates weak points in the panel, To overcome this problem process of joining panels often requires additional components to be used to overlay the joints having the effect that a joint is more pronounced than desired.

The fabrication of curved honeycomb panels requires tooling which is expensive in addition the method of construction is often complex and inefficient.

The process of manufacturing a preformed ceular structure panel demands high precision and accuracy as alteration or modification of its shape later is often difficult if not impossible.

Summary of invention

It is an objective of the present invention to overcome or mitigate the aforementioned problems of the prior art. It is desirable to provide a means of achieving substantial omni-directional rigidity in a cellular structure by introducing a system of structural support that can be installed into the cellular structure; which cellular structure is adapted to accommodate one or more of these structural members. The structural members extend through the cellular structure transversely perpendicular to the face of the strips of material and optionally may be secured in position by means of component members connecting the honeycomb structures to the structural members.

It is a further objective of the present invention to propose that the aforementioned system of structural support may serve as a jig for about which the cellular structure may be formed which cellular structure may then be laminated with sheet material to produce a panel, the system of structural support may then be removed from the panels and reused to form a subsequent panel.

It is yet a further objective of the present invention to provide a system of structural support which may serve as permanent substructure for honeycomb panels which panels may be laminated with sheet material for example to further improvements in strength and stiffness or to add an impermeable member to protect the ceUular structure, or to improve its appearance.

According to a first aspect of the invention there is provided a reinforced cellular structure comprising one or more cellular structures adapted to receive at least one structural support wherein the least one structural support is instaed within said one or more ceular structures whereby improving the rigidity of the cellular structure and/or the bad bearing capacity.

Preferably, the structural support is removable from the cellular structure.

Preferably, the structural support is re-useable.

Preferably, the cellular structure is a honeycomb having hexagonal cells.

Preferably, the structural supports are formed from a rigid material.

Preferably, the reinforced cellular structure comprises an inter-connection mechanism for coupling two or more structural supports together.

Preferably, the reinforced cellular structure comprises a coupling mechanism for coupling one or more structural supports to one or more cellular structures.

Preferably, the reinforced cellular structure comprises a termination mechanism for terminating an end of a structural support.

Preferably, at least one structural support is extendable. More preferably, the structural support is telescopic.

Preferably, the structural support may be secured in an external or retracted position.

Preferab'y, the reinforced c&luar structure is aminated with at east one sheet of materiaL Preferab'y, the structura' supports pass through apertures in opposing was or celk forming the ceUuar structure.

According to a second aspect of the invention there is provided a method of manufacturing a pan& comprising a reinforced celuar structure including the steps of providing an ceUuar structure comprising ces and having apertures in opposing wads of said c&ls; inserting a structural support into the celuar structure by passing the structura' support through said apertures.

Preferab'y, the method further comprises the step of securing the ceuar structure to the structural support.

Preferab'y, the method further comprises the step of aminating the cduar structure with sheet materiaL Preferab'y, the method further comprises the step of securing a second reinforced ceuar structure to the first ceuar structure by inter-connection mechanism coup'ing structural supports in the first celuar structure to structura' supports in the second celuar structure.

Preferab'y, the method further comprises p'acing a first part of a securing member into an endmost ceo, passing a second part of a securing member through an outer waU of said endmost ceH and securing said outer wai between said first and second part.

Preferab'y, the method further comprises the step of engaging the securing member to the structural support.

Preferably, the method further comprises the step of removing the structural support or securing member to modify the cellular structure.

Preferably, the method further comprises the step of removing the structural support after the cellular structure has been laminated.

According to a third aspect of the invention there is provided a structural support system comprising at least one structural member coupleabe to a cellular structure and/or to another structural member by connection assemblies whereby securing a cellular structure in an expanded state and providing structural integrity to the cellular structure.

A fourth aspect of the present invention provides use of the hereinbefore described structural support system according as a forming jig to create cellular structures.

According to a fifth aspect of the invention there is provided a honeycomb substructure system comprising a system of structural support that can be installed into a honeycomb structure that is modified to accommodate the said system in order to achieve substantia' omni-directional rigidity in the said honeycomb structure in order to bear load in excess of normal circumstance; and the said system of structural support that can also be uninstalled from the said honeycomb structure to reverse therefrom.

Preferably, the modified honeycomb structure comprises one or more through holes that bore through the said honeycomb structure transversely perpendicular to the face of the honeycomb strips.

Preferably, the said system of structural support comprises at least one structural member comprising a substantially rigid and elongated piece with cross-sectional dimension and shape that correspond to that of the said through hole, with an axial connection means at each of its distal ends.

Brief Description of the Drawings

Exemplary embodiments of the present invention wi now be described with reference to the accompanying drawings, in which: Figure la shows a perspective view of an unexpanded honeycomb structure as known in the

prior art;

Figure lb shows a perspective view of an expanded honeycomb structure as known in the

prior art;

Figure 2a shows a perspective view of an unexpanded honeycomb structure according to a first embodiment of the present invention; Figure 2b shows a perspective view of the expanded honeycomb structure of Fig 2a in an expanded condition; Figure 3 shows an exploded perspective view of a substructure system in accordance with a first embodiment of the present invention; Figure 4 shows an exploded perspective view of the embodiment of Figure 5; Figure 5 shows a perspective view of a honeycomb structure instaed with a substructure system in accordance with a first embodiment of the present invention; Figure 6 shows a perspective view of a honeycomb structure instaed with a substructure system in accordance with a second embodiment of the present invention; Figure 7 shows a exploded perspective view of a connection assembly between the dista' end of a structural member and a honeycomb structure; Figure 8 shows an exploded perspective view of a connection assembly between the dista' ends of two structural members and two honeycomb structures; Figure 9 shows an exploded perspective view of a connection assembly between the dista' ends of two structural members; Figure 10 shows an exploded perspective view of the embodiment of Figure 11; Figure 11 shows a perspective view of a substructure system in accordance with a third embodiment of the present invention; Figure 12 shows a perspective view of a honeycomb structure installed with substructure system in accordance with a third embodiment of the present invention; Figure 13 shows a p'an view of the embodiment of Figure 12; Figure 14 shows a cross sectiona' view of the embodiment of Figurel2 taken a'ong sine S-S'; Figure 15 shows an end view of the embodiment of Figure 12; Figure 16 shows an exp'oded perspective view of the embodiment of Figure 17; Figure 17 shows a perspective view of a substructure system in accordance with a fourth embodiment of the present invention; Figure 18 shows a perspective view of a substructure system in accordance with a fifth embodiment of the present invention; Figure 19 shows a perspective view of a honeycomb structure instaUed with a substructure system in the embodiment of Fig 18.; Figure 20 shows a part exp'oded perspective view of the embodiment of Figure 21; Figure 21 shows a perspective view of a substructure system comprising in accordance with a sixth embodiment of the present invention; Figure 22 shows a perspective view of a substructure system in accordance with a sixth embodiment of the present invention; Figure 23 shows a perspective view of a honeycomb structure instaUed with a substructure system in the embodiment of Figure 22; Figure 24 shows a part exp'oded perspective view of the embodiment of Figure 25; Figure 25 shows a perspective view of a substructure system in accordance with a seventh embodiment of the present invention; Figure 26 shows a perspective view of a substructure system in accordance with an eighth embodiment of the present invention; and Figure 27 shows a perspective view of a honeycomb structure instaed with a substructure system in the embodiment of Fig 26; Detai'ed Description of Exemplary Embodiments of the Present Invention Figure la iUustrates a honeycomb structure 010 as known in the prior art in an unexpanded form, and Figure lb illustrates the honeycomb structure 010 of Fig la in an expanded state.

Figure 2a iUustrates a honeycomb structure 020 according to a first embodiment of the present invention, the honeycomb structure 020 is in an unexpanded state. Holes 021 are provided in the honeycomb structure 020, the ho'es are provided in the strips of material forming the honeycomb structure 020 and form a through ho'e 021. Figure 2b iUustrates the honeycomb structure 020 in an expanded state. It is envisaged that the hoses 021 wi be created in the honeycomb structure 020 in an unexpanded states, however it is a'so envisaged that in an afternative embodiment the ho'es 021 wHI be provided in the strips of materia' prior to assemb'e of the unexpanded honeycomb structure 020. n a preferred embodiment the through ho'e 021 is axiay a'igned to a notiona' tine passing through the centre of a co'umn of ces. The through ho'e 021 may be of any dimension and shape and wiU be adapted to accommodate the cross-sectiona' dimension and shape of a reinforcing member such as structural member 100 as iHustrated in Fig 3. Preferab'y, the through ho'e 021 is dimensioned such that it is sufficiently smaUer than the height of the strips of material forming the honeycomb structure 020; this ensures that the honeycomb structure 020 retains sufficient structura' integrity about the through hole 021. Furthermore it is envisaged that the cross-sectiona' dimension of the through ho'e O2lis a'so equa' or less than the width of a ce'l wa of the honeycomb structure 020; this ensures that the cross-sectiona' shape of the through ho'e 021 is not distorted when the honeycomb structure 020 is expanded.

Preferab'y the number of through ho'es 021 provided wi correspond to the number of structural members 100 to be inserted. Preferab'y, the two, three or more through hoies 021 are provided in order to achieve the desired structura' stabi'ity and strength. Preferably the through ho'es 021 wi be equidistance from one another when more than two through hoses 021 are provided.

Figure 3 Wustrates an exp'oded view of a first embodiment of a substructure system for incorporation into a honeycomb structure 020. Figure 4 iUustrates an exp'oded view of the embodiment of Figure 5 which ifiustrates a honeycomb structure 020 into which the substructure system of Figure 3 is instaed. There is shown in Figure 4 a pair of structural members 100 extending through the through holes 021. The honeycomb structure 020 in an expanded state or condition; the ength of the expanded honeycomb structure 020 is equa' to the length of the structura' members 100. It will be appreciated that in some embodiments of the present invention the honeycomb structure 020 need not be expanded to its full capacity but may only be partially expanded. Each structural member 100 comprises a substantially rigid and elongated element such as a tube or rod. The structura' member 100 comprises a female connecting section 101 that is recessed axially at each end thereof. In a preferred embodiment it is envisaged that the recess comprises a screw thread on the internal bore of the recess for engagement with a comp'ementary threaded bar or bolt. The through hole 021 should be sized such that it is in proxim& contact with the engaging structural members 100. The end strips 022 of the honeycomb structure 020 are connected to the distal ends of the structural members 100 by end connection assemblies 1, The end connection assembly 1 comprises an end connector member 200, a disk member 400 and optionally a bracing member 600.

Figure 7 illustrates an exploded view of an end connection assembly 1. An end connection assembly 1 comprises an end connector member 200 fastened to the distal end of a structural member 100. Disk member 400 is coupled to end connector 200; a bracing member 600 and preferably the end strip 022 of a honeycomb structure 020 are fastened therebetween. The end connector member 200 is formed of a substantially rigid materia' arranged as a rod or tube, with a cross-sectional dimension and shape corresponding to that of the structura' member 100. The end connector member 200 comprises a male connecting section 201 substantially equal to the internal diameter of the structural member 100 at a first end thereof. The end connector member 200 also comprises a disk section 202 at a second end opposing said first end. The disk member 202 extends radiaUy outward from the end connector member 200. The male connecting section 201 is complementary with the female connecting sections 101 of the structural members 100 such that they can be fastened together with a fastening means, for example, but not limited to, mechanica' threading. Alternatively, the male and female sections may each comprise an aperture or through hole arranged to be in registry with one another, through which aperture a fastening means may be placed to prevent separation of the structural member from the end connection member. Such fastening means may for example comprise a lynch pin, split pin, hair pin, cotter pin or R-pin. In the preferred embodiment the structural member 100 comprises a circular cross section however in alternative embodiments the structural member may have alternative cross-sectional shape, it will be further appreciated that the end connector 200 wfll be adapted to have cross-sectional shape corresponding to the structural member 100.

A disk member 400 formed of a substantially rigid material and having overaU dimension and shape corresponding to that of the disk section 202 of the end connector member 200. The disk member 400 comprises an aperture 401 and forms an 0-ring. The aperture 401 is adapted to receive the end connector member 200 and is optionaUy in mechanical engagement therewith. The disk member 400 is axially aligned to the through hole 021. The internal surface of the end strip 022 of the honeycomb structure 020 is engaged by the disk member 400 and the external surface of the end strip 022 is engaged by the end connector member 200. The aperture 401 engages with the end connector member 200, for example but not limited to, magnetic attachment or mechanical attachment such as a screw thread.

In alternative embodiments the disk member 400 is adapted to engage male connecting section 101, It is envisaged that in alternative embodiments the disk member 400 may be replaced with a circlip receivable in a circumferential groove formed in the end connector member 200.

A bracing member 600 formed of a substantially rigid material preferably formed as a flat plate and comprises an aperture 601 dimensioned and arranged to correspond to the through hole 021 of the honeycomb structure 020. The aperture 601 is axially aligned with the through hole 021. The end strip 022 of the honeycomb structure 020 and the bracing member 600 are fastened in position between mating surfaces of the disk section 202 of the end connector member 200 and the disk member 400 respectively.

Figure 6 illustrates a second embodiment of a substructure system for incorporating into a honeycomb structure 020. In this embodiment a third structural member 100 is instaUed equidistance between the first and second structural members 100.

Figure 10 iUustrates an exploded view of Figure 11 which illustrates a third embodiment of a substructure system for incorporation into a honeycomb structure 020.

Figure 12 illustrates a honeycomb structure 020 into which the third embodiment of the substructure system is instaed. Figs. 13-15 ifiustrate a plan view, cross-sectional view through lines S-S', and end view of the embodiment of Figure 12 respectively. The third embodiment comprises second structural members 110 which are connected at one distal end to the structural members 100 of the previous embodiments. The second structural members 110 are each coupled to the end of the structural member 100 by mid connection assembly 2 at one end and terminated by the end connection assemblyl at the other.

Preferably, the honeycomb structures 020 are engaged by the second structural members via the mid connection assemblies 2 at one end, and more preferably by the end connection assemblies 1 at the other end. The second structural member 110 is similar to a structural member 100 as described previously; the second structural member 110 is provided with an arcuate section substantially at one end thereof and preferably said arcuate section provides a substantially 90° bend having a radius of curvature, although other angles and other shape and configuration are enviaged. A mid connection assembly 2 comprising a mid connector member 300, a disk member 400, and a bracing member 600, is provided for coupling the structural member 100 to the structural member 110, Figure 8 illustrates an exploded view of a mid connection assembly 2. The mid connection assembly 2 comprises a mid connector member 300 axially fastenable between distal ends of a pair structural member 100, or afternative structural members such as second structur& member 110, or any combination thereof. Disk member 400 is coupled to mid connector member 300, a bracing member 600 and preferably the end strips 022 of two honeycomb structures 020 are fastened therebetween. The mid connector member 300 is formed of a substantially rigid material and may be arranged as a rod or tube with cross-sectiona' dimension and shape corresponding to that of the structural member 100. The mid connector member 300 comprises a male connecting sections 301 at both ends and a disk section 302 therebetween; the disk section 302 extends radially outward from a notiona' axia' line, The mid connector member 300 is axially aligned with the through hole 021 and passes through the end strip 022 of honeycomb structure 020. The disk section 302 engages with an internal face of the end strip 022 of a first honeycomb structure 022. A disk member 400 is axia'ly aligned with the through hole 021 and engages with an internal surface of the end strip 022 of a second honeycomb structure 020. The male connecting sections 301 are complementary to the female connecting sections 101 of the structural members 100, or alternative structural members of similar nature, such that they can be fastened together by a fastening means, for example but not limited to, mechanical threading. The disk member 400 is engaged by the mid connector member 300 when the aperture 401 receives an end of connector member 300. Preferably the disk member 400 is in magnetic attachment with the mid connector member 300. The end strips 022 of each of the two honeycomb structures 020 and the bracing member 600 are fastened in position contiguously between the mating surfaces of the disk section 302 of the mid connector member 300 and the disk member 400 when assembled.

Figure 16 illustrates an exploded view of the embodiment of Figure 17 which illustrates a fourth embodiment of a substructure system for incorporation into a honeycomb structure 020.

Figure 18 illustrates a fifth embodiment of a substructure system. Figure 19 illustrates a honeycomb structure 020 into which the fifth embodiment of the substructure system is instaUed. The fourth embodiment differs from the third embodiment in that the structural members 100 and second structura' members 110 have been replaced with first modu'ar structural members 120 and second modular structural member 122. The modular structural members 120 and/or second modular structural members 122 are coupled to one another by means of inter-connection assemblies 3. The two honeycomb structures 020 are each coupled to the modular structural members 120; at one end by the mid connection assembly 2 and at the other end by the end connection assemblies 1. The modular structural member is simi'ar to the structural members 100 and the modu'ar structural member 122 is similar to the structural members 110 as described previously; this allows for reconfiguration of a substructure system by means of rearranging the components parts. The fifth embodiment shows an examp'e of this reconfiguration.

Figure 9 illustrates an exploded view of an inter-connection assembly 3. The inter-connection assemb'y 3 is i'lustrated coup'ed between the dista' ends of two structura' members 100, but it is envisaged that it could be coupled between second structural members 110, or modular structural members 120, or members of similar nature or any combination thereof. The inter-connection assemb'y comprises an inter-connector member 500 which is formed of a substantially rigid material and may be arranged as a rod, or tube with cross-sectional dimension and shape corresponding to that of the structural member 100 to which it is to be coupled. The interconnector member 500 comprises mate connecting sections 501 at both ends and extending axially therefrom. The male connecting sections 501 are complementary to female connecting sections 101 of the respective structural members 100. The inter-connector member 500 is axial'y a'igned between the modu'ar structural members 120 and may be engaged thereto by fastening means for example, but not limited to, mechanical threading.

Figure 20 illustrates a partially exploded view of the embodiment of Figure 21 which illustrates a sixth embodiment of a substructure system for incorporation into a honeycomb structure 020.

Figure 22 il'ustrates a sixth embodiment of a substructure system with te'escopic sections in an extended state. Figure 23 i'lustrates a honeycomb structure 020 into which the sixth embodiment of the substructure system is instaUed. The sixth embodiment differs from the third embodiment whereby each of the aforementioned second structural members 110 are rep'aced with a te'escopic structura' members 130. The honeycomb structures 020 are coup'ed to the tdescopic structural member 130 by the mid connection assemb'y 2 at one end and by the end connection assemb'ies 1 at the other end. The honeycomb structure 020 may be further expanded subsequent to engagement with the respective connection assemb'y 1, 2, such that its ength may be increased by extension of the extended t&escopic structural members 130. Aternativ&y, the t&escopic structura' members 130 may be extended prior to their engagement and/or insertion into the honeycomb structure 020. The te'escopic structura' member 130 is similar to the structura' member 100 as described previous'y; it may be of any axia' ength and shape providing a te'escopic property aUowing for a change of ength by means of extension and retraction 132 of one or more t&escopic sections, The te'escopic section may then be secured in the desired extended or retracted state for examp'e, but not limited to, a twist-sock mechanism integrated into the t&escopic structural member 130, afternativeiy a mechanica' threading may be used. The sixth embodiment shows an examp'e of use of the te'escopic structura' members 130 in which the t&escopic structura' members 130 are extended.

Figure 24 fllustrates a partiaUy exp'oded view of the embodiment of Figure 25 which iUustrates a seventh embodiment of a substructure system for incorporation into a honeycomb structure 020.

Figure 26 il'ustrates an eighth embodiment of a substructure system. Figure 27 fllustrates a honeycomb structure 020 into which the eighth embodiment of a substructure system is instal'ed. The seventh embodiment comprises shaped structura' members 140. The honeycomb structure 020 is coup'ed to the shaped structura' members 140 at both ends by the mid connection assemblies 2. The length of the honeycomb structure 020 when expanded matches the length of the preformed shaped structural members 140. The shaped structural member 140 is similar to the structural members 100 as described previously; it may be of any length and be formable into any desired shape, which shape may be fixed to form a rigid structural support, preferably permanently. The shaped structural member 140 may be preformed into the desired shape by means of bending with tools or machines. The desired shape shall be retained, it is envisaged that the shaped structural member 140 is formed from materials providing strength and stiffness to bear load but may be maeable under certain conditions such as treatment with heat. The eighth embodiment shows the shaped structural members 140 formed into an alternative shape.

It will be appreciated by those skilled in the art that the foregoing embodiments are given by way of example and that various changes can be made with the scope of the present invention. It is envisaged that the present invention may find application in construction of furniture and also as elements for use in construction of buildings.

Additionally, it is envisaged to be within the scope of the present invention that the honeycomb structure 020 need not comprise plurality of contiguously arranged hexagonal cells but may have a different cell shape or different cell arrangement or both.

In alternative embodiments the end connector member 200, mid connector member 300, and disk member 400 may be omitted or alternatively substituted with the inter-connector member 500 ii it is not desirable to couple the honeycomb structure 020 to the structural members 100, second structural members 110, modular structural members 120, telescopic structural members 130, shaped structural members 140, or members of the same type.

Furthermore, The bracing member 600 may be regarded as an optional component, in circumstances and may be omitted if its absence does not compromise structural stability.

It wiU also be appreciated that the features each of the respective exemplary embodiments described and/or illustrated herein may be inter changeable with those of any of the other embodiments.

In yet a further alternative embodiment the disk member 400 may be provided with a screw thread on the internal face of the aperture 401 which is adapted to be complementary to the screw head on the mid connection member 300 or end connection member 200, such that a ce'l wall of the honeycomb structure 020 may be secured between the disk member 400 and the radial protrusion 202 of the either connection member 200 or the radial protrusion 302 of the mid connection member 300. It will be further appreciated that this could also secure brace member 600, The disk member 400 may also be provided with a key mechanism to allow a user to engage the disk member with the mid connection member 300 or end connection member 200 by rotating the disk member 400 about its central axis.

The key mechanism may take the form of at least one pair flat surfaces on the externa' circumferential face of the disk member 400 such as may be engaged by a spanner or wrench.

In this embodiment it will be appreciated that the structure support 100 will abut the disk member 400 rather than pass through the aperture 401, The honeycomb substructure system has a vast array of applications in a vast array of environments, in particular, but not limited to, the manufacturing and construction industries. It exploits the unidirectional strength of the structural honeycomb by providing structural support perpendicular thereto without the necessity of lamination. In manufacturing, be it for the production of single panels or conjoint panels, the system can be used as part of a framework tool for preforming honeycomb structures which may then be laminated over with sheet materials to produce honeycomb panels, of which the system may then be uninstaUed and reused. AdditionaUy or alternatively in construction, furniture or building, the system may be used as permanent substructure for honeycomb structures which may then be laminated with sheet materials thereafter to improve strength and stiffness.

The substructure system has numerous advantages over the conventional honeycomb structures. For example the production of a rigid honeycomb panel is no longer confined to the production environment of a factory as the lamination process may now be carried out in situ when a substructure system is installed into a honeycomb structure. Weak points between prefabricated honeycomb panels may be eliminated by substantially offsetting the joints between the honeycomb structure and those between the overlay sheets during the lamination process.

The present invention eliminates the need for additional components when the joining of panels since weak points can be avoided yet a further benefit being that the aesthetic quality of the honeycomb panels is improved by eliminating pronounced joints.

The present invention provides an inexpensive, simple, and efficient method for preforming and fabricating curved honeycomb panels. The present invention also improves the precision and accuracy for producing honeycomb panels having non-linear geometry, since the shape of the honeycomb structure is wholly dependent on the shape of the substructure system which substructure system may be fine tuned to the desired shape before installation and/or before any lamination process. Furthermore, alteration to the shape of the honeycomb structure in situ s now possible as the substructure system may be readily uninstalled.

Claims

Claims 1. A reinforced ceuar structure comprising one or more ceuar structures adapted to receive at east one structural support wherein the least one structural support is instaed within said one or more ceUular structures whereby improving the rigidity of the cellu'ar structure and/or the toad bearing capacity.
2. A reinforced cellular structure according to claim 1 wherein the structura' support is removable from the cellular structure.
3. A reinforced ceuar structure according to daim 1 wherein the structural support is re-useabe.
4. A reinforced cellu'ar structure according to any preceding claim wherein the cellu'ar structure is a honeycomb having hexagona' ce'ls.
5. A reinforced ceUuar structure system according to any preceding daim wherein the structural supports are formed from a rigid materiaL
6. A reinforced celuar structure according to any preceding claim comprising an inter-connection mechanism for coup'ing two or more structural supports together.
7. A reinforced ceUular structure according to any preceding daim comprising a coup'ing mechanism for coup'ing one or more structural supports to one or more ceuar structures.
8. A reinforced ceilular structure according to any preceding claim comprising a termination mechanism for terminating an end of a structural support.
9. A reinforced ceular structure according to any preceding daim wherein said at east one structural support is extendable.
10. A reinforced cellular structure according to claim 9 wherein the structura' support is te'escopic.
11. A reinforced ceilular structure according to claim 10 wherein the structural support may be secured in an external or retracted position.
12. A reinforced ceuar structure according to any preceding daim aminated with at east one sheet of material.
13. A reinforced celuar structure according to any preceding claim wherein the structural supports pass through apertures in opposing was or cel's forming the ceuar structure.
14. A product comprising the reinforced cellular structure of any preceding daim.
15. An item of furniture comprising the reinforced ceular structure of any of daims ito 13.
16. A building material comprising the reinforced cellular structures of any of daims 1 to 13.
17. A method of manufacturing a panel comprising a reinforced ceUular structure induding the steps of providing an cellular structure comprising ces and having apertures in opposing was of said cells; inserting a structural support into the ceular structure by passing the structural support through said apertures.
18. A method according to claim 17 further comprising the step of securing the cellular structure to the structural support.
19. A method according to claim 18 further comprising the step of laminating the cellular structure with sheet material,
20. A method according to any of claims 17 to 19 further comprising the step of securing a second reinforced cellular structure to the first cellular structure by inter-connection mechanism coupling structural supports in the first cellular structure to structural supports in the second cellular structure.
21. A method according to any of claims 18 to 20 further comprising placing a first part of a securing member into an endmost cell, passing a second part of a securing member through an outer wall of said endmost cell and securing said outer wall between said first and second part.
22. A method according to claim 21 comprising the step of engaging the securing member to the structural support.
23. A method according to any of claims 17 to 22 comprising the step of removing the structural support or securing member to modify the cellular structure.
24. A method according to any of claims 17 to 23 comprising the step of removing the structural support after the cellular structure has been laminated.
25. A structural support system comprising at least one structural member coupleable to a cellular structure and/or to another structural member by connection assemblies whereby securing a cellular structure in an expanded state and providing structural integrity to the cellular structure.
26. Use of a structural support system according to daim 25 as a forming jig to create cellular structures.
27. A honeycomb substructure system comprising a system of structura' support that can be installed into a honeycomb structure that is adapted to accommodate the said system in order to achieve substantial omni-directional rigidity in the said honeycomb structure in order to bear load in excess of normal circumstance; and the said system of structura' support that can also be uninstalled from the said honeycomb structure to reverse therefrom.
28. A honeycomb substructure system according to claim 27, wherein the honeycomb structure comprises one or more through holes that bore through the said honeycomb structure transversely perpendicu'ar to the face of the honeycomb strips.
29. A honeycomb substructure system according to claim 28 wherein the said system of structural support comprises at east one structural member comprising a substantially rigid and elongated piece with cross-sectional dimension and shape that correspond to that of the said through ho'e, with an axial connection means at each of its distal ends.
30. A method of producing a reinforced cellular structure substantiaUy as described herein and/or as iUustrated by Figures 2A to 27.
31. A reinforced cellular structure substantially as described herein and/or as illustrated by Figures 2A to 27.
32. A structural support system substantially as described herein and/or as illustrated by Figures 2Ato27.