JP3183790B2 - Brazed honeycomb panel unit and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a brazed honeycomb panel unit for a structure, and more particularly to a brazed honeycomb panel unit suitable for forming a vehicle structure and a method of manufacturing the same.

[0002]

2. Description of the Related Art Vehicle structures such as passenger trains and monorails include side structures forming a vehicle side wall, a roof structure forming a roof,
The main frame and underframe constituting the vehicle end are manufactured as unit panels, and are formed by joining these unit panels.

[0003] In recent years, from the viewpoint of vehicle weight reduction, aluminum brazed honeycomb panels have attracted attention as components of a vehicle structure, and various improvements have been made for application to the vehicle structure. As shown in FIG. 6, a brazed honeycomb panel made of aluminum (including aluminum and an aluminum alloy; the same applies hereinafter) forms a honeycomb core 6 by brazing and joining a number of aluminum brazing sheets 16 to each other. 6 is formed by brazing aluminum face plates (not shown in FIG. 6) to both upper and lower surfaces.

Conventionally, in order to manufacture a unit panel of a vehicle structure using an aluminum brazed honeycomb panel, first, as shown in FIG. 7, a number of vertical frame members (S frames) are used.
19, peripheral horizontal frame material 17, intermediate horizontal frame material 17a (W frame)
Is temporarily fixed and welded at a point w to form a frame 1. A honeycomb core 6 is arranged at the opening of the frame 1 so as to be flush with the upper and lower surfaces of the frame, and aluminum plates are provided on both upper and lower surfaces. Thereafter, heating and brazing are performed to form a brazed honeycomb panel unit, and this unit is joined to form a unit panel for a vehicle structure. The reason why the temporary fixing welding is used to form the frame body is that the brazing body is given a degree of freedom of deformation at the time of heating by brazing, which suppresses the occurrence of distortion of the panel unit integrated with brazing, and may be caused by the distortion. This is for preventing the occurrence of mounting failure. Also, the provision of the intermediate horizontal frame material is for imparting strength.

FIG. 8 shows a frame for forming a vehicle structure having a curved surface. Similarly, a number of vertical frame members 19 (S frames), a peripheral horizontal frame member 18 having a predetermined curvature, and an intermediate horizontal frame member are shown. 18a
(R frame) is formed by temporarily welding at point w.
An aluminum honeycomb core 6 is mounted on the frame 1,
Aluminum face plates are arranged on both upper and lower surfaces, heated and brazed together to form a brazed honeycomb panel unit, and the unit is joined to form a vehicle structural unit panel used for a curved surface portion.

However, in the production of a conventional panel unit, as shown in FIGS. 7 and 8, the frame is formed only by temporarily welding a large number of short framed vertical frame members and horizontal frame members. In this case, sufficient rigidity cannot be ensured, and deformation occurs when the honeycomb core is mounted and the face plate is disposed and heated and brazed, thereby affecting the dimensional accuracy of the manufactured panel unit. In particular, during heating, brazing, and during straightening after brazing, the joint between the temporarily-welded vertical frame member and the horizontal frame member is easily opened, and the thickness of the face plate in this portion is reduced. There is a possibility that the face plate may be cracked.

In addition, since a large number of vertical frame members are used, the number of temporary fixing welding points is increased, and the dimensional accuracy in the vertical direction is often deteriorated and the dimensional tolerance is deviated. However, there is also a disadvantage that an extremely large number of restraining jigs are required at the time of temporary fixing welding. When the frame 1 is formed by combining the vertical frame member 20 having a cross-sectional shape as shown in FIG. 9 with the horizontal frame member 21, the protruding portion 22 of the horizontal frame member 21 must be cut off after brazing. There are many things that must be done.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems in the brazed honeycomb panel unit. Temporary welding of the frame without any problems in accuracy, no heating at the joints between the vertical frame material and the horizontal frame material, and no gaps during brazing or straightening after brazing A brazing honeycomb panel unit for a structure that can easily perform work, particularly a brazing honeycomb panel unit suitable for a vehicle structure,
And a method for manufacturing the same.

[0009]

Means for Solving the Problems To achieve the above object, a honeycomb panel unit according to the present invention has a honeycomb core mounted on a frame composed of a vertical frame material and a horizontal frame material, and is provided on the frame body and the honeycomb core. A brazed honeycomb panel unit having a face plate disposed on a lower surface and integrated with brazing, and configured as follows.

[0010] An aluminum extruded profile having a cross-section in which welding grooves are formed vertically by superposing in the opposite directions is used as a vertical frame, and a notch provided on a side surface of the vertical frame has an aluminum profile. A frame member is formed by fitting a horizontal frame member made of and temporarily welding, a honeycomb core is mounted on the frame member, and face plates are disposed on the upper and lower sides to be integrally brazed.

In the formed honeycomb panel unit, the vertical frame members are welded through the welding grooves formed by superimposing the vertical frame members in opposite directions, and the honeycomb panel units are connected to each other to form a vehicle structure or the like. The unit panel is applied as

A method for manufacturing a brazed honeycomb panel unit according to the present invention is characterized in that the upper surface comprises a first horizontal surface portion, a second horizontal surface portion connected to the first horizontal surface portion and an inclined surface portion, and located above the first horizontal surface portion. The aluminum hollow extruded profile formed in parallel with the upper surface is used as a vertical frame, and a horizontal frame composed of an aluminum extruded profile is fitted into a cutout provided in the vertical frame, and temporarily fixed and welded to form a frame. After the honeycomb core is mounted on the frame body, face plates are disposed on the upper and lower surfaces of the frame body and the honeycomb core, and brazing is performed integrally. After that, trimming is performed diagonally from the first horizontal surface portion to the lower surface of the frame body. It is characterized by doing.

In the present invention, as shown in FIG. 1, the frame of the brazed honeycomb panel unit is provided with a notch 5 in the vertical frame member 3, and the notch 5 has a horizontal frame member such as an intermediate horizontal frame member 4a. 4 is fitted and temporarily welded.
It is desirable that the size of the notch 5 is as equal as possible to the cross-sectional dimension of the intermediate horizontal frame member 4a to be fitted. If the width of the cutout portion is smaller than the width of the horizontal frame material to be fitted, the contact portion between the vertical frame material and the horizontal frame material rises at the time of fitting, and there is a possibility that brazing failure around the cutout portion is induced. It is preferable that the depth of the notch be slightly larger in order to correct the distortion of the horizontal frame material to be fitted and absorb dimensional errors. In addition, it is preferable to provide a notch at the end portion of the vertical frame material and fit and temporarily weld the peripheral frame material. However, the peripheral horizontal frame material is provided in a butt state as before. You may.

As the vertical frame member and the horizontal frame member, for example, extruded aluminum members having various cross-sectional shapes having a width of 20 to 50 mm and a height of 20 to 100 mm can be used, and formed as described above. For example, an aluminum honeycomb core 6 having a cell size of 5 to 50 mm is mounted on the frame body 1, and an aluminum face plate made of, for example, a brazing sheet is provided on both upper and lower surfaces of the frame body 1 and the honeycomb core 6, and brazing is performed. Heat to temperature and braze together.

In this case, as the honeycomb core to be mounted on the frame, a honeycomb core previously assembled by brazing can be used, but a corrugated aluminum brazing sheet is formed in the frame so as to have a honeycomb core shape. And brazing honeycomb panel units can be formed by arranging face plates made of aluminum brazing sheets on the upper and lower surfaces and heating and brazing all at once. Further, the honeycomb core may be formed by brazing and joining a bare material. The molded panel unit can be applied as various structural materials.

The vertical frame members are overlapped and welded together.
When the brazed honeycomb panel units are joined to each other to form a unit panel for a structure such as a vehicle structure, as shown in FIG.
And a second horizontal surface portion 11 connected to the first horizontal surface portion 10 and the inclined surface portion 12 and located above the first horizontal surface portion 10,
An aluminum hollow extruded profile having a lower surface 13 formed in parallel with the upper surface is used as a vertical frame member 3, a notch 5 is provided in the vertical frame member 3, and an intermediate horizontal frame member 4 a made of an extruded aluminum material is provided in the notch portion 5. At the same time, the peripheral frame member is arranged at the end of the vertical frame member, and these are temporarily fixed and welded to produce the frame 1.
The notch 5 is formed so as to have a depth up to the end of the second horizontal surface portion 11 and not to extend over the inclined surface portion 12. Various shapes can be adopted for the side surfaces 14 and 15 of the vertical frame member 3 depending on the panel unit to be manufactured.

Next, as shown in FIG. 2, a honeycomb core 6 is attached to the opening of the manufactured frame 1, and face plates 7 and 8 made of aluminum brazing sheets are provided on both upper and lower surfaces of the frame 1 and the honeycomb core 6. Is arranged. The end of the face plate 7 arranged on the upper surface is made to coincide with the end of the vertical frame member 3 on the inclined surface portion 12 side of the second horizontal surface portion 11, and is heated to a brazing temperature to be integrally brazed.

After brazing, as shown in FIG. 2, from the first horizontal plane portion 10 to the lower surface 13 of the frame body, the frame is trimmed diagonally along the line XX to form a brazed honeycomb panel unit 2 shown in FIG. I do. As shown in FIG. 2, first, a frame body 1 is formed using a vertical frame material 3 made of an aluminum hollow profile, and after brazing, is formed into a vertical frame material having an open end as shown in FIG. 3 by trimming. In this case, the strength of the open end of the vertical frame member 9 can be kept sufficiently high. on the other hand,
When the frame is formed from the beginning by using the vertical frame member 9 having the open end as shown in FIG. 3, the strength of the open end is reduced at the time of brazing heating, and the rigidity of the vertical frame member is inferior.

As shown in FIG. 5, the manufactured brazed honeycomb panel unit 2 is formed by welding the vertical frame members 9 in opposite directions to form welding grooves K on the upper and lower surfaces and performing welding. The panel unit 2 is joined to form a structural material such as a vehicle structure. In the structural material thus formed, the horizontal frame members are joined to each other and extended to form a strong bone. In addition, when the strength is not so required, the frame body need only be temporarily fixed and welded to the vertical frame material and the horizontal frame material. However, in the case of an application that requires sufficient strength such as a vehicle structure, As shown in FIG. 4, it is preferable to form a fillet weld W at the fitting portion between the vertical frame member 9 and the intermediate horizontal frame member 4a to reinforce the fitting portion.

[0020]

According to the present invention, there is provided a brazed honeycomb panel unit in which a honeycomb core is mounted on a frame composed of a vertical frame material and a horizontal frame material, and face plates are disposed on upper and lower surfaces to be integrally brazed. The notch is provided, and the frame is formed by fitting the horizontal frame into the notch, so it is not necessary to use a large number of divided vertical frames, and the rigidity of the vertical frame is improved, Good dimensional accuracy such as the length accuracy of the frame material, and the joint between the vertical frame material and the horizontal frame material is opened during brazing and the thickness of the face plate is reduced, and inconvenience such as cracking of the face plate occurs There is no. Such an effect can be exerted at least by applying it to the intermediate horizontal frame material. For the peripheral horizontal frame material, a conventional butting method may be used, but it is more effective when applied to the peripheral horizontal frame material. Further, the present invention can be applied to a frame body having only the peripheral frame material in which the intermediate horizontal frame material is omitted, and the dimensional accuracy can be improved as compared with the conventional butting method.

Further, a frame body is formed by using an aluminum hollow extruded shape having a cross-sectional shape as shown in FIG. 2 as a vertical frame material, and a honeycomb core and a face plate are arranged and brazed integrally. By trimming the frame material and forming it into a vertical frame material 9 having an open end as shown in FIG. 3, if it is formed into a brazed honeycomb panel unit 2, a panel unit having sufficient strength characteristics can be obtained. By welding the vertical frame members 9 in opposite directions to form a welding groove K and welding, a unit panel that can be used as a structural material for a structure, particularly as a structural material for a railway vehicle structure is manufactured. However, the vertical frame material may be a square or the like.

[0022]

Embodiments of the present invention will be described below. Example 1 An aluminum hollow profile (material: 6063 alloy or 6N01 alloy, dimensions: 50 mm, height from the lower surface to the second horizontal surface 80 mm, wall thickness 5 mm) having a sectional shape as shown in FIG. Aluminum hollow profile (the same material as the vertical frame)
A frame body was configured with a horizontal frame material having a width of 50 mm, a height of 80 mm, and a thickness of 5 mm).

As shown in FIG. 2, a cell size is formed from a 0.2 mm thick aluminum brazing sheet in which a BA4004 alloy is clad on both sides of a 3003 alloy core material, as shown in FIG.
Aluminum brazing sheet with a 20 mm inch honeycomb core and the same material as the core material as the face plate
(Thickness: 1 mm), and heated and brazed to 600 ° C. in a vacuum brazing furnace.

After brazing, trimming was performed as shown by the line XX in FIG. 2 to produce a brazed honeycomb panel unit as shown in FIG. As shown in FIG. 4, the fitting portion between the vertical frame member and the horizontal frame member of the frame of the panel unit is reinforced by welding, and then the panel unit is overlapped in the opposite direction as shown in FIG. When the welding groove formed in the overlapped portion was subjected to MIG welding, a unit panel having sufficient strength and good dimensional accuracy without warpage was formed.

[0025]

As described above, according to the present invention, a dimensional change of a vertical frame material is provided in a frame having excellent rigidity and good length accuracy, and in straightening during brazing or after brazing. As a result, a brazed honeycomb panel unit having sufficient strength characteristics without causing any defects in the face plate can be obtained.

[Brief description of the drawings]

FIG. 1 is a partial perspective view showing an arrangement of a vertical frame member and a horizontal frame member in forming a frame of the present invention.

FIG. 2 is a partial perspective view showing an intermediate step of manufacturing a brazed honeycomb panel unit of the present invention.

FIG. 3 is a partially cutaway perspective view showing an embodiment of the brazed honeycomb panel unit of the present invention.

FIG. 4 is a cross-sectional view taken along line AA of FIG. 3 showing a reinforcing welded portion of a fitting portion between the vertical frame member and the horizontal frame member.

FIG. 5 is a partial perspective view showing a joined state of the panel units of FIG. 3;

FIG. 6 is a partial perspective view of a honeycomb core.

FIG. 7 is a perspective view showing a conventional frame.

FIG. 8 is a perspective view showing another example of a conventional frame.

FIG. 9 is a perspective view showing a combination of a conventional vertical frame member and a horizontal frame member.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Frame body 2 Brazing honeycomb panel unit 3 Vertical frame material 4 Horizontal frame material 4a Intermediate horizontal frame material 5 Notch 6 Honeycomb core 7 Face plate 8 Face plate 9 Vertical frame material 10 First horizontal surface portion 11 Second horizontal surface portion 12 Slope surface portion 13 Lower surface 14 Side portion 15 Side portion 16 Brazing sheet 17 Peripheral horizontal frame material 17a Intermediate horizontal frame material 18 Peripheral horizontal frame material 18a Intermediate horizontal frame material 19 Vertical frame material 20 Vertical frame material 21 Horizontal frame material 22 Projection portion K Welding groove W Reinforced weld w Temporary weld

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-8-90114 (JP, A) Japanese Utility Model Application 57-187733 (JP, U) Ministry of Agriculture and Forestry Forestry Experiment Station Wood Industry Handbook Maruzen Co., Ltd. Published by The Japan Society of Materials Processing Technology August 10, 1964 Issued 4th edition P351-354 (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B21D 47/00 E04C 2 / 00-2/52

Claims (2)

(57) [Claims] 1. A brazed honeycomb panel unit in which a honeycomb core is mounted on a frame composed of a vertical frame material and a horizontal frame material, and face plates are disposed on upper and lower surfaces of the frame body and the honeycomb core, and are integrally brazed. An aluminum extruded profile having a cross-section in which welding grooves are formed vertically by superposing in the opposite directions is used as a vertical frame material, and a notch provided on a side surface of the vertical frame material has a horizontal portion formed of an aluminum profile. A frame body is formed by temporarily fixing and welding the frame material, and the vertical frame material is welded through the welding groove formed by superimposing the vertical frame materials in opposite directions, thereby forming a honeycomb panel. A brazed honeycomb panel unit comprising units connected to form a unit panel. 2. An aluminum hollow extrusion having an upper surface composed of a first horizontal surface portion, a second horizontal surface portion connected to the first horizontal surface portion and an inclined surface portion and located above the first horizontal surface portion, and a lower surface formed parallel to the upper surface. The shape material is a vertical frame material, a horizontal frame material made of an extruded aluminum material is fitted into a notch provided in the vertical frame material, and temporarily fixed to form a frame body, and a honeycomb core is formed on the frame body. After mounting, the face plate is disposed on the upper and lower surfaces of the frame body and the honeycomb core, and brazing is performed integrally, and then trimming is performed diagonally from the first horizontal surface portion to the lower surface of the vertical frame member of the frame body. A method for manufacturing an attached honeycomb panel unit.