Device for the production of cellular materials

Abstract

A system and method for the production of cellular materials. Several geometries such as honeycomb, chiral, auxetic are described. The pre-formation of the cellular structure is by penetration of a reinforcement fabric by means of punches properly structured. Punches housed on one of the matrices of the device allow obtaining several geometries without need of complex fabric pre-formations operations or of manual placement of the fabric in the interstices of the mold.

What is claimed is: 
     
         1 . A mold for the production of a perforated material, comprising:
 a matrix comprising a specific perforation pattern, said matrix being configured to perforate a fabric sheet, and   a vessel configured to house said matrix and to receive a resin to impregnate a fabric sheet,   wherein said matrix comprises a base portion and a structured portion comprising the specific perforation pattern, wherein the base portion is removable from said matrix.   
     
     
         2 . A mold according to  claim 1 , wherein the specific perforation pattern comprises a structure selected from the group consisting of a honeycomb structure and a chiral structure. 
     
     
         3 . A mold according to  claim 1 , further comprising a second matrix adapted to drive the specific perforation pattern. 
     
     
         4 . A mold according to  claim 1 , further comprising a frame adapted to laterally close said mold. 
     
     
         5 . A mold according to  claim 4 , wherein said frame comprises an injection line suitable for the injection of resin. 
     
     
         6 . A mold according to  claim 1 , wherein said vessel comprises at least one air relief hole. 
     
     
         7 . A mold according to  claim 1  wherein the mold is utilized in a process comprising the steps of:
 perforation of a first fabric sheet by means of a matrix comprising a specific perforation pattern adapted to penetrate the first fabric sheet; 
 impregnation of the perforated first fabric sheet with a resin, said step of impregnation being performed in the presence of the specific perforation pattern penetrating the first fabric sheet; 
 wherein the matrix comprises a base portion and a structured portion comprising the specific perforation pattern adapted to penetrate the first fabric sheet, the first fabric sheet having an upper base and a lower base; 
 removal of at least the base portion of the matrix; 
 placement of a second fabric sheet on at least one of the upper base or the lower base of the first fabric sheet; and 
 impregnation of the perforated first fabric sheet and of the second fabric sheet, said step of impregnation being performed in the presence of at least one not removed portion of the structured portion of the matrix penetrating the first fabric sheet. 
 
     
     
         8 . A device used for forming cellular material structures having cells comprising:
 a frame;   a vessel held by said frame;   a driving matrix having a plurality of holes adjacent said vessel, each of said plurality of holes having a shape of one of the cells;   a support matrix positioned opposing said driving matrix, said support matrix having a plurality of seats; and   a plurality of punches removably placed in the plurality of seats, wherein said plurality of punches are removable from said support matrix, said plurality of punches extending towards said driving matrix and arranged in a geometry to mate with the plurality of holes,   whereby a fabric placed between said driving matrix and said support matrix is preformed and perforated by said plurality of punches and a resin may be injected into the device forming cells and a cellular material structure with said plurality of punches remaining upon removal of said support matrix.   
     
     
         9 . A device used for forming cellular material structures having cells as in  claim 8  wherein:
 said plurality of punches are removed from said support matrix and remain thrust within the cellular material structure. 
 
     
     
         10 . A cellular material structure made in accordance with the following process:
 perforation of a first fabric sheet by means of a matrix comprising a specific perforation pattern adapted to penetrate the first fabric sheet;   impregnation of the perforated first fabric sheet with a resin, said step of impregnation being performed in the presence of the specific perforation pattern penetrating the first fabric sheet;   wherein the matrix comprises a base portion and a structured portion comprising the specific perforation pattern adapted to penetrate the first fabric sheet, the first fabric sheet having an upper base and a lower base;   removal of at least the base portion of the matrix;   placement of a second fabric sheet on at least one of the upper base or the lower base of the first fabric sheet; and   impregnation of the perforated first fabric sheet and of the second fabric sheet, said step of impregnation being performed in the presence of at least one not removed portion of the structured portion of the matrix penetrating the first fabric sheet.