Cell-like structure manufacturing method, cell-like structure, and corresponding equipment

Abstract

Method for manufacturing a cell-like honeycomb structure, formed from a plurality of thermoplastic sheets ( 101 ) attached to each other, wherein contoured areas ( 2 a and 3 a ) are provided in each sheet, and each free sheet ( 101 b ) is attached to an adjacent sheet ( 101 a ) of an intermediate block ( 21 ) formed by the different sheets previously attached therebetween, welding at least some of the flat areas ( 3 a and 2 b ) contacting this free sheet and this adjacent sheet with a laser source along a continuous line (L) parallel to the contour axis.

1 .- 17 . (canceled) 
     
     
         18 . A method for manufacturing a cell-like honeycomb structure formed with several sheets of a thermoplastic material assembled together, a method in which areas provided with embossments are made in each sheet, and each free sheet is assembled with an adjacent sheet of an intermediate block formed by different sheets assembled together beforehand, by welding by conduction at least certain of the planar areas in contact of this free sheet and of this adjacent sheet with a laser source, along a continuous line parallel to an axis of the embossments. 
     
     
         19 . The method according to  claim 18 , wherein a laser source emitting from visible light to middle infrared is used. 
     
     
         20 . The method according to  claim 19 , wherein a set of emitters for which the wavelength is comprised between 800 and 1,200 nanometers is used as the laser source. 
     
     
         21 . The method according to  claim 19 , wherein the electromagnetic radiation from the laser source is transmitted through optical fibers. 
     
     
         22 . The method according to  claim 19 , wherein a laser beam is generated from the laser source, this laser beam is transformed into a laser segment, a width of which is substantially close to a diameter of the beam, and a length of which is much greater than the diameter and this laser segment is moved along said continuous line. 
     
     
         23 . The method according to  claim 22 , wherein the laser beam is directed towards a mirror provided with facets and performing a movement of rotation, so as to generate said segment. 
     
     
         24 . The method according to  claim 18 , wherein areas provided with embossments are made by compressively marking lines alternately on a first face and on an opposite face of the sheet, and then by exerting on either side of these folding lines, pressure forces so as to cause folding of this sheet. 
     
     
         25 . The method according to  claim 24 , wherein lines parallel to a width of the sheet equidistant from each other are compressively marked, and then pressure forces are exerted on either side of these folding lines in opposite directions so as to cause the folding of the sheet in the longitudinal direction according to a semi-hexagonal pattern and then this strip is cut out in order to form different sheets. 
     
     
         26 . The method according to  claim 18 , wherein each free sheet is heated up, before welding it to the adjacent sheet of the intermediate block. 
     
     
         27 . The method according to  claim 18 , wherein each free sheet is pressed against the adjacent sheet, during the laser welding step and immediately after this step along said continuous line. 
     
     
         28 . The method according to  claim 18 , wherein the cell-like honeycomb structure has a density of less than 80 kg/m 3  with cells for which a largest transverse dimension is less than 12 mm. 
     
     
         29 . The method according to  claim 18 , wherein the sheets are monolayer sheets in 100% recycled material containing carbon black. 
     
     
         30 . An installation for applying the method according to  claim 18 , comprising:
 means for forming embossments in each sheet;   means for setting into place each free sheet, in a vicinity of the adjacent sheet of the intermediate block;   means for laser-welding by conduction this free sheet with the adjacent sheet;   means for applying pressure to each free sheet with this adjacent sheet.   
     
     
         31 . The installation according to  claim 30 , wherein the welding means comprise a laser source, capable of generating a laser beam, as well as means for transforming this beam into a laser segment, with a length much greater than the diameter of this laser beam. 
     
     
         32 . The installation according to  claim 30 , wherein the pressure means comprise first pressure members, capable of putting the intermediate block into contact with the free sheet, as well as an additional pressure member capable of penetrating into the cells of said intermediate block and of increasing the pressure between the free sheet and the adjacent sheet along said continuous line.