JP2001138043A - Sandwich panel manufacturing method, and sandwich panel obtained thereby - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technology to favorably manufacture a thin and lightweight sandwich panel in a sound brazed condition without degradation in productivity or economy. SOLUTION: An aluminum corrugated core 16 showing a continuous corrugation directed in one direction is held between two aluminum face plates 12 and 14, and the corrugated core 16 and two face plates 12 and 14 are integratedly brazed by an Al-Si brazing filler metal alloy having the composition consisting of, by weight, 6-9% silicon(Si) and the balance Al with inevitable impurities and containing substantially no magnesium(Mg).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a sandwich panel and a sandwich panel obtained by the method.
The present invention relates to a novel method of manufacturing a sandwich panel sandwiched between two face plates and brazed integrally to the face plates, and a characteristic sandwich panel obtained by the method.

[0002]

BACKGROUND ART In recent years, sandwich panels have been developed in which a core made of aluminum is sandwiched between two face plates made of aluminum, and the two face plates and the core are integrally brazed. Focusing on strength properties, they are used in a wide range of applications, such as for structural materials, design materials, heat insulating materials, and soundproofing materials. And among such sandwich panels, in particular, the core sandwiched between two face plates is constituted by a honeycomb core having a large number of honeycomb-shaped cells. Since the two face plates are supported vertically in the cell height direction, the compression strength and bending strength are high, and the rigid anisotropy is low. It has been suitably used as a material or a strength member.

However, in the honeycomb panel having such a structure, there is an inherent problem that the thickness (height) of the entire panel is inevitably increased (increased) due to manufacturing reasons and the like. Was to do.

That is, in the conventional honeycomb panel, generally, a plurality of strip-shaped honeycomb forming materials obtained by corrugating a flat plate made of aluminum by, for example, continuously bending and deforming the flat plate are formed in each width direction. A honeycomb core is formed between the two face plates and arranged between the two face plates so that a large number of honeycomb cells are formed. Then, the honeycomb core and the two face plates are integrally formed. Manufactured by brazing. When such a manufacturing method is adopted, if a honeycomb forming material having a small width is used, the core thickness can be reduced, and thus the entire panel can be reduced in thickness. However, since the narrow honeycomb forming material has no rigidity, it is not only easily deformed but also twisted and warped,
It is not easy to arrange such a narrow honeycomb-forming material in such a manner that a large number of honeycomb-shaped cells are formed in a uniform shape between two face plates, which requires considerable time and effort. As a result, a reduction in the productivity of the target honeycomb panel and an increase in manufacturing cost due to the reduction are caused. Therefore, actually, when manufacturing a honeycomb panel by the conventional method as described above, a honeycomb forming material having a narrow width is not used, and therefore, the core thickness of the manufactured honeycomb panel and the overall panel thickness are not used. The thickness was inevitably thicker.

Moreover, even if a thin honeycomb core is formed using such a narrow honeycomb forming material, the thin honeycomb core and two face plates are integrally formed according to a conventionally known method. When the target honeycomb panel is manufactured by brazing, when the honeycomb core and the two face plates are joined by brazing, the core may be deformed or collapsed or collapsed. is there.

As described above, in a sandwich panel such as a honeycomb panel, it is extremely difficult to reduce the thickness of the entire panel. Therefore, it is difficult to further reduce the weight, and accordingly, it is difficult. For example, it is hardly applied to thin and light plate materials such as a general desk top plate, a door face plate, a shelf plate, or a side plate or a bottom plate of a packaging material composed of a predetermined housing, and its use is rare. At present, the thickness is limited to relatively heavy materials and members.

[0007]

The object of the present invention is to provide a sandwich panel in which the thickness of the core is reduced, the thickness of the entire panel is reduced, and the weight is further reduced. It can be manufactured industrially advantageously without any decrease in productivity and economic efficiency, and in a thin sandwich panel obtained in this manner, deformation, collapse or collapse of the core can be prevented. It is an object of the present invention to provide a method that can easily secure a sound brazing condition. Further, in the present invention, it is also possible to provide a sandwich panel having a novel structure that can be easily thinned and lightened as a whole panel, and thus can be advantageously applied as a thin and light plate material. It is to be solved.

[0008]

In order to solve the above-mentioned problem, the present inventors first deform, collapse, or crush the core at the time of brazing and joining a thin honeycomb core and two face plates. Various investigations were repeated on the cause. As a result, the following conclusions were obtained.

That is, for example, when a desired honeycomb panel is obtained according to a general brazing method using a flux, Si is generally used in an amount of about 10% by weight as a brazing alloy for brazing a honeycomb core and a face plate. Al-Si-based brazing alloys containing a relatively large amount of Al-Si brazing alloys are used. In addition, when brazing them, a tunnel-type continuous heating furnace or the like is usually used for the purpose of improving productivity and the like. . However, according to the study of the present inventors, when an Al-Si brazing alloy containing a relatively large amount of Si is used for heating brazing of a member made of aluminum, the brazing alloy has a melting point higher than the melting point. When heated and melted at a high temperature of about 30 ° C. or higher, the aluminum component in the aluminum material to be joined excessively melts into the molten brazing alloy, so-called erosion occurs. That became clear. In addition, since the tunnel-type continuous heating furnace cannot partially control the temperature inside the furnace due to its structure, when heated to the melting temperature of the Al-Si-based brazing alloy, the temperature difference of the panel increases. But inevitably 30 ° C
It was also found that the degree reached.

[0010] From these facts, when a desired honeycomb panel is obtained according to a general brazing method using a flux, when the honeycomb core and the face plate are brazed, a tunnel-type continuous heating furnace is used. It was concluded that erosion occurred at the joint between the honeycomb core and the face plate located in the high-temperature region, which caused deformation or collapse or collapse of the thin honeycomb core at the portion where such erosion occurred. is there.

For example, when a desired honeycomb panel is obtained according to a vacuum brazing method that does not use a flux, as well known, a brazing alloy for brazing a honeycomb core and a face plate is used. Generally, an Al-Si brazing alloy containing about 1.2 to 1.5% by weight of Mg is used, and a honeycomb core and two face plates are brazed and heated in a vacuum heating furnace. As a result, the Al-Si-based brazing alloy containing Mg is melted, and Mg is evaporated from the brazing alloy. At this time, the oxidation formed on the mutual bonding surface between the honeycomb core and the two face plates is performed. The coating is destroyed, and the re-oxidation of the bonding surface is prevented. However, according to the study of the present inventors, a thin honeycomb core is used and the
When placed between two face plates, the interval between the two face plates becomes narrower, and the space between the two face plates becomes a narrow and substantially closed space. Therefore, brazing of the honeycomb core and the two face plates is performed. At the time of heating, the Mg in the brazing alloy evaporates only slightly, and the narrow substantially closed space between the two face plates is filled with the vapor of Mg. It remains in the brazing alloy without evaporation, and as a result,
It has been found that the melting point of the brazing alloy is substantially reduced.

Accordingly, when the honeycomb core and the face plate are integrally brazed by a conventional vacuum brazing method to obtain a desired honeycomb panel, the honeycomb core and the face plate are vacuum-heated. In a furnace, when heated at a temperature near the melting point of the brazing alloy, at the bonding site between the honeycomb core and the face plate, the brazing alloy whose melting point has been substantially reduced by the residual Mg is excessively melted,
As a result, it was concluded that erosion was generated, and as a result, the thin honeycomb core was deformed or collapsed or collapsed at the portion where the erosion was generated.

The present invention has been completed as a result of further intensive studies based on the above conclusions.
By brazing and joining an assembled body formed by sandwiching at least an aluminum core between two face plates,
When manufacturing a sandwich panel in which at least the two face plates and the core are integrally brazed, the core has a corrugated shape having a corrugated shape formed continuously in one direction. Using a core,
After the corrugated core is sandwiched between the face plates in the height direction of the corrugated shape to form the assembly, silicon (Si) is contained at a ratio of 6 to 9% by weight, and the remainder is aluminum. A method for manufacturing a sandwich panel, characterized in that the assembled body is brazed and joined with an Al-Si-based brazing alloy substantially free of magnesium (Mg), comprising (Al) and unavoidable impurities.

In the method for manufacturing a sandwich panel according to the present invention, the corrugated core having the corrugated shape continuously formed in one direction is formed by two face plates in the height direction of the corrugated shape. Since the core is sandwiched between the cores, the core (thickness),
As a result, the thickness (height) of the entire panel can be easily reduced (lowered), whereby the weight of the finally obtained sandwich panel can be effectively reduced.

In the method of the present invention, the corrugated core used as the core sandwiched between the two face plates has an integrated structure having a corrugated plate shape. The time and effort required to form the assembled body by sandwiching it does not depend on the height of the corrugated shape in the corrugated core, that is, the difference in the core thickness, and therefore, the corrugated core having a large thickness In the case where a panel is manufactured using a corrugated core having a small thickness as compared with a case where a panel is manufactured using Due to such a difference in panel productivity, there is no difference in panel manufacturing cost between using a thick corrugated core and using a thin corrugated core.

Moreover, in the method of the present invention, 2
Al-Si, which is made of silicon (Si), aluminum (Al), and unavoidable impurities, and substantially does not contain magnesium (Mg), as a brazing alloy for brazing an assembled body composed of two face plates and a corrugated core Since the brazing alloy is used, even if the corrugated core is thinned and the distance between the two face plates sandwiching the corrugated core is reduced, for example, such two face plates are formed by a vacuum brazing method. When brazing the brazing core with the corrugated core, the Mg remaining in the brazing alloy without evaporating does not cause the melting point of the brazing alloy to be substantially reduced. Even if the face plate is heated at a temperature near the melting point of the brazing alloy, the brazing alloy is excessively melted at the joint between the corrugated core and each face plate, and erosion does not occur at all. It is. As a result, when the corrugated core is brazed to each face plate, deformation of the thin corrugated core, collapse or collapse of the corrugated core, and the like can be effectively avoided.

In the method of the present invention, the Al-
Since the Si content of the Si-based brazing alloy is suppressed to a relatively low ratio of 9% by weight or less, for example, the corrugated core and the two face plates are brazed by a general flux brazing method. In doing so, even when the brazing alloy is heated at a temperature about 30 ° C. higher than its melting point, it is possible to advantageously prevent erosion from occurring,
Thus, the deformation, collapse or collapse of the corrugated core can be effectively prevented. In addition, since the content of Si in the Al-Si-based brazing alloy is limited to 6% by weight or more, the amount of Si is too small, and the amount of Si is too small during the heating brazing of the corrugated core and the two face plates. Insufficient melting or fluidity of the brazing alloy occurs,
The occurrence of poor bonding can also be reliably prevented.

Therefore, according to the sandwich panel manufacturing method according to the present invention, the thickness of the core is reduced and the thickness of the entire panel is also reduced, whereby the weight is effectively reduced. Panels can be manufactured industrially advantageously without any loss in productivity and economy. Then, the two face plates and the corrugated core constituting the thin sandwich panel obtained in this manner are free from joint failure, deformation of the core, collapse or collapse, regardless of the method of brazing them. It can be easily and reliably brazed with no sound brazing state, and as a result, in such a thin sandwich panel, excellent quality and high surface accuracy can be extremely effectively secured. It becomes.

According to the method for manufacturing a sandwich panel according to the present invention, a thin sandwich panel having excellent quality and high surface accuracy can be obtained. Applicable to thin plate materials that could not be applied to sandwich panels such as conventional honeycomb panels, such as top plates, door face plates, shelf plates, and side plates and bottom plates of packaging materials consisting of a predetermined housing. A possible sandwich panel can be provided, whereby the expansion of the scope of the sandwich panel can be achieved very advantageously, and by such an expansion, a more robust desk or door can be obtained. , Shelves, packaging materials, etc. can be obtained.

Further, in the method for manufacturing a sandwich panel according to the present invention, since the face plate and the corrugated core used as the components of the panel, and the brazing alloy for brazing and joining them are all made of aluminum material, It has excellent characteristics in strength, durability, heat resistance (fire resistance), chemical resistance, and workability, and can be easily recycled. There are advantages that can be obtained.

According to a preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, the face plate and the corrugated core are each made of Al—Mg—Si.
It is composed of an aluminum compact formed using a 6000 series aluminum alloy. In the case of adopting such a configuration, since the two face plates and the corrugated core are formed of an Al-Mg-Si-based 6000 series aluminum alloy having excellent strength, the corrugated core is made thin. Then, when obtaining a sandwich panel in which the thickness of the entire panel is reduced, the strength of the obtained sandwich panel can be secured as much as possible. As the face plate and the corrugated core, those having the same characteristics in terms of thermal properties such as the coefficient of thermal expansion are used. It is possible to advantageously prevent deformation or the like due to differences in physical properties.

According to one advantageous aspect of the method for manufacturing a sandwich panel according to the present invention, at least one of the face plate and the corrugated core has one or both surfaces of a plate material made of aluminum or an alloy thereof. To
It is composed of an aluminum compact formed using a brazing sheet clad with the Al-Si-based brazing alloy. Accordingly, the work of brazing the face plate and the corrugated core can be performed more efficiently.

Further, according to a preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, aluminum or an alloy thereof is provided between at least one of the two face plates and the corrugated core. A brazing sheet in which the Al-Si brazing alloy is clad on one or both sides of a plate material made of
Further sandwiching a sheet or plate made of an i-based brazing alloy,
The assembly will be formed. According to such a configuration, a brazing sheet sandwiched between the face plate and the corrugated core, or a sheet or plate material made of the Al-Si-based brazing alloy can be used as a reinforcing member. It is possible to impart more excellent strength characteristics to the sandwich panel obtained in terms of bending strength, compressive strength and the like.

Further, according to another preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, a plurality of the corrugated cores are used, and the plurality of corrugated cores are arranged in a height direction of a corrugated shape in each of the corrugated cores. And the adjacent ones are arranged such that the directions of forming the corrugated shapes are orthogonal to each other, and the plurality of corrugated cores to be laminated are sandwiched between the two face plates in the laminating direction. Thus, the assembly is formed. by this,
A sandwich panel in which the anisotropy of flexural rigidity and flexural strength is effectively eliminated or reduced can be easily obtained.

According to another advantageous aspect of the method for manufacturing a sandwich panel according to the present invention, the plurality of corrugated cores and at least one intermediate plate made of aluminum material are used to form the plurality of corrugated cores. Are laminated in the height direction of the corrugated shape in each of the components, the at least one intermediate plate is positioned between the plurality of corrugated cores to be laminated, and further laminated with the intermediate plate interposed therebetween. The plurality of corrugated cores are sandwiched between the two face plates in the laminating direction to form the assembly, and then the assembly is brazed and joined to form the two face plates. And the plurality of corrugated cores and the at least one intermediate plate are integrally brazed together.

According to such a method of the present invention, the intermediate plate sandwiched between the corrugated cores to be laminated can be used as a reinforcing member, whereby the finally obtained sandwich panel can be used. On the other hand, more excellent bending strength and compression strength can be provided. Also, here, an aluminum intermediate plate is used,
There is also a feature that the advantage as described above obtained by using the all-aluminum face plate, the corrugated core and the brazing alloy can be advantageously prevented from being impaired by the provision of the intermediate plate. In particular, a plurality of corrugated cores are stacked such that the directions of forming the corrugated shapes are mutually orthogonal between the adjacent corrugated cores, and the intermediate plate is sandwiched between the laminated corrugated cores and the corrugated cores. In this case, since any of the laminated corrugated cores is brought into line contact with the intermediate plate, the bonding strength between the laminated corrugated cores can be effectively increased. It becomes possible.

Further, according to another preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, the plurality of corrugated cores and at least one intermediate plate made of aluminum are used to form the plurality of corrugated cores. , Are arranged in the height direction of the corrugated shape in each of them, and are arranged so that the directions in which the corrugated shapes are formed coincide with each other, and the at least one intermediate plate, Between the corrugated cores of
Further, the plurality of corrugated cores laminated with the intermediate plate interposed therebetween are sandwiched between the two face plates in the laminating direction to form the assembled body, and then, the crimped core having a predetermined curved surface shape is formed. Using a pair of forming jigs having a pressing surface, the formed assembly is sandwiched between the pair of forming jigs, and brazed and joined under a state of being pressed by the pair of forming jigs. Thereby, the face plate, the plurality of corrugated cores, and the at least one intermediate plate are brazed integrally with each other, and they are formed into a curved surface shape corresponding to the pressing surface.

According to the method of the present invention, the thickness of each core can be reduced, and the thickness of the entire panel is also reduced, whereby the weight of the sandwich panel is advantageously reduced. In particular, a so-called curved panel having a curved surface as a whole is industrially advantageously manufactured with a uniform brazing state without causing any reduction in productivity and economic efficiency and with no variation in bonding strength. You can do it.

When the above-mentioned intermediate plate is used, it is advantageous that the intermediate plate is provided on one or both sides of a plate made of aluminum or its alloy.
It is composed of an aluminum compact formed using a brazing sheet clad with a Si-based brazing alloy.
Thereby, the brazing operation of the laminated corrugated core and the intermediate plate can be performed more efficiently.

According to still another preferred aspect of the method for manufacturing a sandwich panel according to the present invention, a frame material made of aluminum is used, and the frame material is formed so as to surround the corrugated core. At the same time, the frame material and the corrugated core are sandwiched between the two face plates in the height direction of the corrugated shape of the corrugated core, and the assembled body is formed. By brazing, the face plate, the corrugated core, and the frame are brazed integrally with each other. By adopting such a configuration, not only a sandwich panel in which the anisotropy of bending rigidity and bending strength is eliminated or relaxed can be easily obtained, but also the outer surface of the frame material is used as a joining surface for welding or the like. By doing so, independent panels can be welded to each other, so that a large-sized large panel or the like can be easily manufactured. In addition, if a hollow material is used as the frame material, the inside of the hollow portion of the frame material can be used, for example, as a refrigerant distribution route or an electrical wiring route in a manufactured sandwich panel. Becomes

According to the present invention, in order to solve the problem relating to the sandwich panel, a sandwich panel obtained by the manufacturing method as described above, wherein at least an aluminum material is provided between two aluminum face plates. Cores are sandwiched and arranged, and at least,
In the one in which the two face plates and the core are integrally brazed, the core is constituted by a corrugated core having a corrugated shape in which a corrugated shape is continuously formed in one direction, Further, the corrugated core contains silicon (Si) at a ratio of 6 to 9% by weight in a state of being sandwiched between the two face plates in the height direction of the corrugated shape, and the remainder is made of aluminum (Al). ) And an unavoidable impurity, which are brazed integrally to the two face plates by an Al-Si-based brazing alloy substantially free of magnesium (Mg). Is also the gist of this.

In the sandwich panel according to the present invention, which is obtained by the characteristic manufacturing method as described above, the corrugated core made of a corrugated plate-shaped integral body is formed in the height direction of the corrugated shape. In this case, the corrugated core, and thus the entire panel, can be easily made thin without any troublesome labor simply by configuring the corrugated shape to be low, since it is sandwiched between two face plates. In addition, such a corrugated core and two face plates are brazed with an Al-Si-based brazing alloy substantially free of Mg and having a low upper limit of the content of Si. Therefore, it is possible to advantageously prevent poor connection between the two face plates and the corrugated core and deformation, collapse, or collapse of the corrugated core.

Therefore, in the sandwich panel according to the present invention, the overall thickness of the panel can be easily reduced without lowering the quality and surface accuracy, and a further reduction in weight can be effectively achieved. You get. And, by that, it could not be applied at all in a sandwich panel such as a conventional honeycomb panel such as a general desk top plate, a door face plate, a shelf plate, or a side plate or a bottom plate of a packing material formed of a predetermined housing. The present invention can be sufficiently applied to a thin and light plate material or the like, so that the applicable range can be effectively expanded.

[0034]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, in order to clarify the present invention more specifically, a method of manufacturing a brazed sandwich panel according to the present invention and a configuration of a sandwich panel obtained by the method will be described with reference to the drawings. It will be described in detail.

First, FIG. 1 is an exploded view of an example of a brazed sandwich panel having a structure according to the present invention, and FIG. 2 is a sectional view of such a sandwich panel. I have. As is clear from those figures, the sandwich panel 10 has an upper surface plate 12 and a lower surface plate 14 which are arranged to face each other in the vertical direction. And, between the upper surface plate 12 and the lower surface plate 14,
The corrugated core 16 having a corrugated shape is sandwiched and arranged, and is brazed and joined to the upper and lower plates 12 and 14 respectively.

More specifically, both the upper plate 12 and the lower plate 14 constituting the sandwich panel 10 are made of an aluminum material made of an Al-Mg-Si 6000 series aluminum alloy exhibiting excellent strength. It is composed of things. They have a rectangular flat plate shape with a relatively thin thickness of about 0.8 mm, and have the same size.

On the other hand, the corrugated core 16 is made of
A rectangular plate made of a 6000 series aluminum alloy and having a thickness of about 0.2 mm, which is thinner than the upper and lower plates 12 and 14, has a substantially same size as the upper and lower plates 12 and 14. It is formed into a plate shape and is made. That is, the corrugated core 16 has a rectangular corrugated plate shape in which a corrugated shape or a corrugated shape in which concavo-convex portions (valley portions and peak portions) are alternately formed is formed continuously in one direction. It is composed of an integral body of the aluminum molded body. In the corrugated core 16, each of the convex portions (peak portions) and concave portions (valley portions) that give the corrugated shape or corrugated shape has a substantially triangular shape in which a vertex portion has a curved surface shape. In addition, the distance between the apexes of the concave and convex portions, that is, the height of the waveform shape is about 2.6 mm.

Thus, the corrugated core 16 having such a low wavy shape, in other words, the thin corrugated shape, is provided between the upper surface plate 12 and the lower surface plate 14 in the height direction of the corrugated shape. Under such an arrangement state, the upper and lower ends of the corrugated core 16 (the respective apexes of the concave and convex portions in the corrugated shape) are positioned under the upper and lower plate 1.
2 and 14 are integrally brazed to respective opposing surfaces. Thereby, the sandwich panel 10
It consists of upper and lower two face plates 12, 14 and a corrugated core 16,
It is configured as an integral product made of an Al-Mg-Si-based 6000 series aluminum alloy having a hollow sandwich structure with a small thickness as a whole.

The thickness of the upper and lower plates 12 and 14 constituting the sandwich panel 10 and the thickness of the corrugated core 16
The thickness of the plate material and the height of the corrugated shape, which give the above, are not limited to the dimensions described above. In addition, the shape of the uneven portion of the corrugated core 16 is not particularly limited, and may be, for example, a triangular shape, a rectangular shape, a polygonal shape such as a trapezoidal shape, or the like.
Alternatively, the shape may be a U-shape or the like. Further, the corrugated core 16 and the upper and lower plates 12, 14
Aluminum alloy and pure aluminum are also appropriately selected and used, but they can be used, but they prevent deformation under high temperature during brazing or prevent undesired reaction with flux. Above,
As a constituent material thereof, Al-Mg-Si based 60
Al-Mn 300 other than the 00 aluminum alloy
A zero-based aluminum alloy is preferably used.

Here, in particular, the brazing alloy for brazing the upper and lower plates 12 and 14 and the corrugated core 16 integrally is different from the generally used Al-Si brazing alloy, Al-containing a relatively low proportion, such as 6-9% by weight, with the balance being Al and unavoidable impurities, substantially free of magnesium Mg.
It is composed of a Si-based brazing alloy.

By the way, the sandwich panel 10 having such a structure is manufactured, for example, according to the following method.

That is, first, the upper and lower two face plates 12,
14 and the corrugated core 16 are prepared. Here, as the upper and lower plates 12, 14, a thickness of about 0.8 mm made of an Al-Mg-Si-based 6000 series aluminum alloy having excellent strength. Each formed from a rectangular flat plate is used.

As the corrugated core 16, an aluminum molded body obtained by molding a plate material having the same material as the upper and lower plates 12 and 14 and having a thickness of about 0.2 mm into a corrugated plate is used. Used. That is, the waveform core 16 is made of Al
A thin plate made of a Mg-Si-based 6000-series aluminum alloy is formed into a substantially triangular shape having a curved top at a vertex portion by a predetermined forming operation such as press forming, for example, to have a wave shape of 2.6 mm. It can be obtained by forming into a corrugated sheet shape formed continuously in one direction with a certain height. Of course, as shown in the above example, each shape of the convex portions (peaks) giving the waveform shape is a polygonal shape such as a triangular shape, a rectangular shape, a trapezoidal shape, or a U shape.
In the case where the plate material has a shape such as a character shape, the plate material is formed into a corrugated plate by a predetermined forming operation as described above so that a corrugated shape having a desired shape is obtained. It will be.

At least one of a flat plate of an aluminum alloy that provides the upper and lower plates 12 and 14 and a thin plate of an aluminum alloy that provides the corrugated core 16 are:
Advantageously, the brazing sheet is made of an Al-Mg-Si 6000 series aluminum alloy brazing sheet clad on one or both sides with a brazing material. Thereby,
Brazing bonding of an assembled body in which the upper and lower plates 12, 14 and the corrugated core 16, which will be described later, are assembled to each other can be efficiently performed.

Next, the corrugated core 16 is placed on the upper and lower sides of the corrugated core 16 so as to sandwich the corrugated core 16 from above and below in the height direction of the corrugated shape, and contact the upper and lower ends of the corrugated core 16. The face plate 12 and the lower plate 14 are arranged and assembled. Thereby, the corrugated core 16 and the upper and lower plate 1
Thus, an assembly 17 composed of the components 2 and 14 is formed (see FIG. 4).

At this time, it is not a brazing sheet,
Upper and lower plate 1 made of simple aluminum alloy
When the assembled body 17 is formed by using the corrugated cores 2 and 14 and the corrugated core 16, as shown in FIG. A brazing sheet 19 made of an aluminum alloy having a brazing alloy clad on both surfaces or a thin plate 21 of a brazing alloy is interposed and arranged on each of the two. By doing so, the brazing sheet 19 and the brazing alloy thin plate 21 sandwiched between the upper and lower plates 12 and 14 and the corrugated core 16 are formed.
However, an advantage is obtained that the bending strength and the compressive strength of the finally obtained sandwich panel 10 can be advantageously increased by functioning as a reinforcing member. As the brazing alloy or brazing alloy thin plate 21 of the brazing sheet 19 used for forming the assembled body 17 or the brazing sheet brazing alloy for providing the upper and lower plates 12 and 14 and the corrugated core 16 described above, 6-9 Si
A special Al-Si-based brazing alloy containing a low percentage by weight and substantially free of magnesium Mg, with the balance being Al and unavoidable impurities, is used.

Thereafter, as shown in FIG. 4, the assembled body 17 formed as described above is set in a molding device 18 having a known structure. That is, in this step, generally, an upper forming jig 22 having an upper pressing surface 20 corresponding to the upper surface of the target sandwich panel 10 having the planar shape and a lower surface of the sandwich panel 10 having the same planar shape are generally formed. And a lower molding jig 26 having a lower pressurizing surface 24,
used. Then, the assembling body 17 is interposed between the lower pressing surface 24 of the lower forming jig 26 and the upper pressing surface 20 of the upper forming jig 22, so that the assembling is performed in the forming apparatus 18. The attachment 17 is set.

FIG. 4 shows a vacuum heating furnace (not shown).
An example of a method of discontinuously brazing the assembled body 17 by the vacuum brazing method using the method is shown.
Therefore, in this case, for the purpose of improving the productivity and the like, the upper and lower molding jigs 22, 22 of the molding apparatus 18 are stacked in a state where a plurality of the assembled bodies 17 are stacked so as to be overlapped in the vertical direction. 26. And
As described above, when a plurality of the assembled bodies 17 are stacked and set in the molding device 18, it is advantageous that the assembled body 17 located at the uppermost position among the assembled bodies 17 to be laminated is preferably used.
Carbon between the upper and lower jigs 22 and between the assembly 17 and the lower jig 26 located at the lowermost portion thereof, and between the assembly 17 to be stacked. The release material 28 made of a sheet or the like is sandwiched and positioned. Thereby, in the brazing process described later,
The brazing of the plurality of assembled bodies 17 can be performed at once, and the assembled bodies 17 and the assembled body 17 and the upper and lower forming jigs 22 and 26 are hot-pressed or brazed. That they are joined to each other due to
It can be advantageously prevented.

In this step, instead of using the release material 28 made of a carbon sheet or the like, each assembly 17
Even if a fine solid lubricant such as graphite powder or boron nitride powder is applied to the surfaces of the upper plate 12 and the lower plate 14, the same effect as that obtained by using the release material 28 can be obtained. Will be done. Further, instead of the brazing method of the assembled body 17 by such a vacuum brazing method, the assembled body 17 is continuously brazed by a general flux brazing method using a tunnel type continuous heating furnace. Of course, it is also possible to adopt a joining method. In that case, one set of the assembled bodies 17 is disposed between the upper and lower molding jigs 22 and 26 of the molding device 18.

Next, the upper molding jig 22 of the molding device 18
With the pressing mass 30 having a predetermined weight placed thereon and the lower molding jig 26 placed on the support tray 32, the molding device 18 and a plurality of assembles set thereto are set. The body 17 is housed in a vacuum heating furnace (not shown). At this time, a pressing force corresponding to the total weight of the upper forming jig 22 and the pressing mass 30 placed on the upper forming jig 22 is applied to the assembled body 17, and a plurality of assembled bodies 17 are fixed. Pressure is applied to each of them.

Then, after the inside of the vacuum heating furnace in which the plurality of assembled bodies 17 are set as described above is evacuated, the inside of the vacuum heating furnace is set to a temperature substantially equal to the melting point of the brazing alloy. And the upper molding jig 22 and the pressing mass 3
0 under constant pressure based on the total weight of
7 is heated and melted, and the upper plate 1
2 and the corrugated core 16 and between the abutment portions of the lower plate 14 and the corrugated core 16.
6 and the upper and lower plates 12 and 14 are integrally brazed. When a general flux brazing method is adopted, the corrugated core 16 and the upper and lower plates 12 and 12 are placed before the assembly 17 is placed in the tunnel-type continuous heating furnace.
For example, after applying a known fluoride-based flux to the joint portion with the soldering material 14, the brazing alloy in the assembly 17 is heated and melted in the continuous heating furnace under the above-mentioned constant pressure to form a corrugated core. 16 and the upper and lower plates 12 and 14 are integrally brazed.

Here, as described above, in the present embodiment, Si is used as a brazing alloy for brazing the corrugated core 16 and the upper and lower plates 12 and 14 integrally with each other.
A special Al-Si-based brazing alloy containing a small percentage by weight of aluminum and the balance consisting of Al and unavoidable impurities and containing substantially no Mg is used. Therefore, in such a brazing step, Mg does not evaporate from the heat-melted brazing alloy, and
The assembly 17 has a narrow gap between the upper and lower plates 12 and 14 sandwiching the thin corrugated core 16 having a corrugated height of about 2.6 mm.
It is possible to prevent the melting point of the brazing alloy from being substantially lowered by Mg remaining in the brazing alloy without being evaporated, despite the fact that the space is narrow and substantially closed. Then, when the corrugated core 16 and the upper and lower plates 12 and 14 are heated at a temperature near the melting point of the brazing alloy, the brazing alloy is formed at the joint between the corrugated core 16 and each of the face plates 12 and 14. Excessive melting and erosion are avoided, so that the corrugated core 16 is not deformed or collapsed or collapsed.

Here, as described above, since the space between the upper and lower plates 12 and 14 is a narrow and substantially closed space, the mutual joint surface between the upper and lower plates 12 and 14 and the corrugated core 16 is formed. Are not easily oxidized, and therefore, it is not necessary to include Mg in the brazing alloy in order to destroy the oxide film formed on the joint surface or to prevent re-oxidation of the joint surface. is there. In other words, in other words, in the present embodiment, when the assembled body 17 is brazed and joined according to the vacuum brazing method using no flux, the brazing alloy causes no brazing failure because the brazing alloy does not contain Mg. There is nothing to be done. In addition, in a portion where the space between the upper and lower plates 12, 14 is an open space, such as an outer peripheral portion of the assembled body 17, an upper and lower plate 12, 1 is provided.
If there is a concern that the brazing property may be reduced due to oxidation of the respective joint surfaces of the core 4 and the corrugated core 16, Mg
By arranging the lump, the Mg powder, or the lump of the alloy likely to contain Mg, the fear can be easily eliminated.

Further, since the content of Si in the brazing alloy used here is 6% by weight or more,
If the amount of Si is too small, insufficient melting of the brazing alloy will not occur, thereby preventing poor joining between the corrugated core 16 and the upper and lower plates 12, 14. The upper limit of the content of Si is relatively low at 9% by weight. Therefore, in an excessively heated portion of the assembled body 17 located in a high-temperature region or the like in a vacuum heating furnace,
It is avoided that the amount of Si in the heat-melted braze alloy becomes too large and erosion occurs,
This advantageously prevents the corrugated core 16 from deforming, collapsing or collapsing.

Incidentally, for example, the cladding ratio of the brazing alloy of the brazing sheet for providing the corrugated core 16 and the upper and lower plates 12 and 14 is reduced, or
The thickness of the brazing alloy sheet disposed between the corrugated core 16 and the upper and lower plates 12, 14 is further reduced by reducing the thickness of the thin plate of the brazing alloy disposed between the upper and lower plates 12, 14. If the amount of the brazing alloy to be reduced is reduced, even if an Al-Si-based brazing alloy generally used conventionally, that is, a brazing alloy containing Si in a larger amount than that used in the present embodiment, such a brazing alloy is used. The amount of Si in the heated and molten state of the alloy can be kept low. However, as is well known, it is difficult to reduce the cladding ratio of the brazing alloy of the brazing sheet to 5% or less, and since the brazing alloy containing a large amount of Si is easily broken, a thin plate of such a brazing alloy is used. Is more difficult than reducing the brazing alloy cladding rate of the brazing sheet, and therefore, in practice, the common Al-S
It is almost impossible to braze the thin corrugated core 16 and the upper and lower plates 12, 14 soundly using an i-based brazing alloy.

Conversely, the cladding ratio of the brazing alloy for the brazing sheet for providing the corrugated core 16 and the upper and lower plates 12 and 14 may be increased, or between the corrugated core 16 and the upper and lower plates 12 and 14. By increasing the thickness of the brazing alloy thin plate to be disposed, or by increasing the amount of brazing alloy existing between the mutually joined surfaces of the corrugated core 16 and the upper and lower plates 12, 14, the present embodiment It is considered that even if a brazing alloy having a lower Si content than that used in the form is used, insufficient melting of the brazing alloy will be resolved. However,
An Al-Si brazing alloy having a low content of Si has poor fluidity in a heated and molten state, and does not sufficiently flow between the contact portions between the corrugated core 16 and the upper and lower plates 12 and 14. Even if the cladding ratio of a brazing sheet clad with such an Al-Si brazing alloy having a low Si content is increased or the thickness of a thin plate made of such brazing alloy is increased, the corrugated core 16 and the corrugated core 16 are not affected. Lower plate 12, 1
It is difficult to eliminate the poor bonding with the brazing alloy 4. On the contrary, if the thickness of the brazing alloy is increased, the thickness of the brazing alloy decreases with heating and melting. In addition, new problems such as impairing the jointability and dimensional accuracy between the lower plates 12 and 14 are caused.

Thereafter, the brazed assembly 17 is
While being held under pressure between the upper and lower forming jigs 22 and 26, the jig is cooled in a vacuum heating furnace or taken out of the vacuum heating furnace, naturally or by using a special cooling device. Thereby, the brazing process is completed. The brazed assembly 17 is taken out of the heating furnace after nitrogen gas or the like is introduced into the vacuum heating furnace and the pressure is restored. It is desirable that the cooling operation of the assembled body 17 be performed by a rapid cooling operation in order to improve the strength by quenching and shorten the manufacturing cycle.

Then, after such cooling, the upper forming jig 22 and the lower forming jig 26 are opened, and the panel to which the assembly 17 is brazed is taken out.
2, 6 and 8, the intended sandwich panel 10 having a small thickness obtained by brazing the upper and lower plates 12 and 14 integrally with each other is obtained. Here, since the plurality of assembled bodies 17 are simultaneously brazed and joined, a plurality of sandwich panels 10 can be obtained at once.

As described above, in the present embodiment, the interval between the upper and lower plates 12 and 14 is reduced by making the corrugated core 16 sandwiched between the upper and lower plates 12 and 14 thin. Can be advantageously made narrow, so that the overall thickness of the panel can be very small.

In this embodiment, the waveform core 1
6 has an integral structure made of an aluminum molded body having a corrugated plate shape.
The labor, time, cost, and the like required when assembling the assembly 6 by sandwiching it between the upper and lower plates 12 and 14, and when brazing and joining the assembly 17 obtained by the assembly 6 are reduced.
6 can advantageously be completely absent.

Therefore, according to the present embodiment,
The sandwich panel 10 having an extremely small thickness as compared with a relatively thick panel generally used in the related art can be easily manufactured without reducing productivity and economic efficiency. Further weight reduction of the panel 10 can be achieved very effectively. And
The sandwich panel 10 thus obtained can be used as a member or material conventionally made of corrugated cardboard in terms of lightness or the like, for example, as a side plate or a bottom plate of a packaging material formed of a housing, or made of a lightweight thin plate material. It can be used as a general desk top plate, door face plate, shelf board, etc.,
Thereby, not only can the range of application of the sandwich panel 10 be advantageously expanded, but also the robustness of the members, materials, products, etc., to which such a sandwich panel 10 is applied can be effectively improved. is there.

Further, in the present embodiment, as a brazing alloy for brazing the corrugated core 16 and the upper and lower plates 12 and 14 integrally, Si is contained at a low ratio of 6 to 9% by weight, And the balance consists of Al and inevitable impurities.
Special Al-Si substantially free of magnesium Mg
Since the brazing alloy is used, the corrugated core 16 having a small thickness and the upper and lower plates 12 and 14 have a sound brazing state in which there is no defective joint, deformation, collapse, or collapse of the core. Therefore, excellent quality and high surface accuracy can be extremely effectively secured in the thin and lightweight sandwich panel 10 because it can be easily and reliably brazed.

In this embodiment, the waveform core 1
6 and the upper and lower plates 12, 14 and the brazing alloy for brazing them are all made of aluminum, so that the strength, durability, heat resistance (fire resistance), chemical resistance,
Demonstrates excellent properties in both points and workability,
Moreover, there is an advantage that a sandwich panel having a feature that it can be easily recycled can be easily obtained.

Furthermore, in the present embodiment, the corrugated core 16 and the upper and lower plates 12, 14 are both made of an Al-Mg-Si-based 6000 series aluminum alloy exhibiting excellent strength. Therefore, although the corrugated cores 16 are thinned and the overall thickness of the sandwich panel 10 is reduced, high strength can be advantageously secured, and the corrugated cores 16 and Lower plate 1
2 and 14 exhibit the same characteristics in terms of thermal physical properties such as the coefficient of thermal expansion, and are deformed due to a difference in thermal physical properties between the corrugated core 16 and the upper and lower plates 12 and 14 during brazing by heating or the like. Can be advantageously avoided, so that the excellent quality and surface accuracy of the thinner sandwich panel 10 can be more effectively ensured.

By the way, the sandwich panel according to the present invention is not construed as being limited to only the above-described exemplary structure, and various modifications can be made without departing from the spirit of the present invention. Some examples are shown in FIGS. In addition,
In FIGS. 5 to 10, members and portions having the same structure as in the previous embodiment are denoted by the same reference numerals in the drawings, and detailed description thereof is omitted.

That is, FIGS. 5 and 6 show two corrugated cores 16 a, 16 a between the upper and lower plates 12, 14.
2 shows an example of a structure in which b is stacked and arranged in the direction in which the upper and lower plates 12 and 14 face each other, that is, in the vertical direction. In this case, the upper waveform core 16a located on the upper side of the two waveform cores 16a and 16b and the lower waveform core 16b located on the lower side have the respective directions of forming the waveforms, in other words, the waveforms. In a state where the directions in which the concave and convex portions (valleys and peaks) of the shape are continuous with each other are overlapped with each other so as to be orthogonal to each other, they are sandwiched between the upper and lower plates 12 and 14 in the height direction of each corrugated shape. Is located.

In such an arrangement state, the laminated upper and lower corrugated cores 16a and 16b are integrally brazed and joined together, and
a is integrally brazed to the lower surface of the upper surface plate 12 at its upper end (the peak portion of the convex portion in the waveform shape), and the lower corrugated core 16b is further brazed to its lower end (corrugated shape). (The bottom portion of the concave portion in the shape), and is integrally brazed to the upper surface of the lower surface plate 14. In this case as well, a brazing alloy for brazing the upper and lower corrugated cores 16a and 16b to each other and a brazing alloy for brazing the upper and lower corrugated cores 16a and 16b to the upper and lower plates 12 and 14. However, all contain 6 to 9% by weight of Si.
And a special Al-Si-based brazing alloy substantially free of magnesium Mg, containing a relatively low percentage and the balance consisting of Al and unavoidable impurities.

The sandwich panel 10 having such a structure is as follows.
When forming the assembly 17, except that the upper corrugated core 16 a and the lower corrugated core 16 b are vertically stacked as described above, and disposed between the upper and lower plates 12 and 14.
Sandwich panel 10 shown in the first embodiment
It is manufactured by the same method as described above.

As described above, also in the present embodiment, the corrugated core 16 made of an aluminum alloy having a corrugated plate shape is made of the upper and lower plates 12, 1 made of the same kind of aluminum alloy.
4 and they are low in Si content,
Since the sandwich panel 10 is integrally brazed with a special Al-Si-based brazing alloy containing no g, the same effect as in the first embodiment can be effectively enjoyed. You get.

In this embodiment, two upper and lower corrugated cores 16 are provided between the upper and lower face plates 12 and 14.
a and 16b are brazed integrally with each other in such a form that they are stacked so that the directions of forming the corrugated shapes are orthogonal to each other, and are integrally brazed to the upper and lower face plates 12 and 14, respectively. Due to the attachment, the feature that the anisotropy of the bending rigidity and the bending strength of the sandwich panel 10 can be effectively eliminated can also be advantageously exhibited.

Next, FIGS. 7 and 8 show the upper and lower plates 1.
An example of a structure is shown in which an intermediate plate 34 is further sandwiched between two upper and lower corrugated cores 16a and 16b stacked between the upper and lower corrugated cores 2 and 14. Here, the upper and lower corrugated cores 16a and 16b are laminated such that the directions of forming the corrugated shapes are orthogonal to each other, as in the above-described embodiment. The upper and lower corrugated cores 16
a, 16b, the upper and lower face plates 1
It has a thin rectangular shape of the same size as 2, 14,
It is formed from a 1-Mg-Si-based 6000 series aluminum alloy. As the intermediate plate 34, a plate made of a brazing sheet having a brazing material clad on one or both sides is used as necessary.

In such an arrangement, the upper corrugated core 16a and the lower corrugated core 16b are brazed integrally via an intermediate plate 34, and the upper corrugated core 16a is At the upper end, the top plate 12
The lower corrugated core 16b is integrally brazed to the upper surface of the lower surface plate 14 at the lower end thereof.

In this case, too, a brazing alloy for brazing the upper and lower corrugated cores 16a, 16b to each other via the intermediate plate 34, and the upper and lower corrugated cores 16a, 16a
The brazing alloys that braze 6b to the upper and lower plates 12, 14 all contain a relatively low proportion of 6-9% by weight Si and the balance consists essentially of Al and unavoidable impurities. Special Al that does not contain magnesium Mg
-It is constituted by a Si-based brazing alloy.

Thus, the sandwich panel 10 having such a structure, when the assembly 17 is formed, forms the upper and lower corrugated cores 16 a and 16 between the upper plate 12 and the lower plate 14.
b and the intermediate plate 34 are laminated from the bottom in the order of the lower corrugated core 16b, the intermediate plate 34, and the upper corrugated core 16a, and the upper and lower corrugated cores 16a, 16b are formed so that the directions of forming the corrugated shapes are orthogonal to each other. The sandwich panel 10 is manufactured by the same method as that of the sandwich panel 10 shown in the first embodiment except that the sandwich panel 10 is arranged so as to perform the above operation.

Even in such an embodiment, the upper and lower corrugated cores 16 made of an aluminum alloy exhibiting a corrugated plate shape.
a, 16b are sandwiched between upper and lower plates 12, 14 made of the same type of aluminum alloy, and they are made of Si.
Is low, and the sandwich panel 10 is integrally brazed with a special Al-Si brazing alloy that does not contain Mg. Can be effectively exerted.

In this embodiment, the upper and lower corrugated cores 16a, 16a are provided between the upper and lower plates 12, 14.
Since b is laminated so that the directions of forming the corrugated shapes are orthogonal to each other, the anisotropy of the bending stiffness and bending strength of the sandwich panel 10 can be effectively eliminated, and the upper and lower portions thereof can be eliminated. Side corrugated cores 16a, 16b
The intermediate plate 34 interposed therebetween functions as a reinforcing member, whereby the sandwich panel 10 can advantageously exhibit more excellent bending strength and compressive strength.

Further, in the present embodiment, the upper and lower corrugated cores 16 a and 16 b stacked so that the directions of forming the corrugated shapes are orthogonal to each other are interposed via the intermediate plate 34.
Since they are brazed together, both the upper corrugated core 16a and the lower corrugated core 16b to be laminated are brought into line contact with the intermediate plate 34, whereby Upper and lower corrugated cores 16 stacked so that the directions of forming the corrugated shapes are orthogonal to each other
The joining strength of the upper and lower corrugated cores 16a and 16b can be effectively increased as compared with the case where the a and 16b are directly brazed.

Further, in the present embodiment, the intermediate plate 34 exhibiting the above-described excellent characteristics has excellent strength, similarly to the upper and lower plates 12, 14 and the upper and lower corrugated cores 16a, 16b. Al-Mg-Si based 600 having
Because of the use of the upper and lower corrugated cores 16a, 16b and the upper and lower corrugated cores 16a, 16b made of such an aluminum alloy, the advantages as described above are obtained from the intermediate plate. Damage by the arrangement of 34 can advantageously be avoided.

FIG. 9 shows a so-called curved panel which has a predetermined curved surface shape which is convex upward and is laminated as a whole between the upper and lower plates 12 and 14. An example of a structure in which an intermediate plate 34 is disposed between two lower corrugated cores 16a and 16b is shown. There, the upper and lower corrugated cores 16
a, 16b, so that the directions of formation of the waveform shape coincide.
The upper surface plate 12 having a convex curved surface shape and the lower surface plate 1 having a concave curved surface shape in the height direction of each corrugated shape in a state of being overlapped with each other via the intermediate plate 34.
4 and is located.

Under such an arrangement, the upper corrugated core 16a and the lower corrugated core 16b are integrally brazed via an intermediate plate 34, and the upper corrugated core 16a is At the upper end, the top plate 12
The lower corrugated core 16b is integrally brazed to the upper surface of the lower surface plate 14 at the lower end thereof.

In this case, too, the brazing alloy for brazing the upper and lower corrugated cores 16a, 16b to each other via the intermediate plate 34, and the upper and lower corrugated cores 16a, 16a
The brazing alloys that braze 6b to the upper and lower plates 12, 14 all contain a relatively low proportion of 6-9% by weight Si and the balance consists essentially of Al and unavoidable impurities. Special Al that does not contain magnesium Mg
-It is constituted by a Si-based brazing alloy.

Thus, the sandwich panel 10 having such a structure, for example, first has the upper and lower corrugated cores 16 a and 16 b and the intermediate plate 34 between the upper plate 12 and the lower plate 14.
Are laminated from the bottom in the order of the lower corrugated core 16b, the intermediate plate 34, and the upper corrugated core 16a, and the upper and lower corrugated cores 16a, 16b are arranged so that the directions of forming the corrugated shapes coincide with each other. Thus, the assembled body 17 is formed. In addition,
As the upper and lower plates 12 and 14 and the intermediate plate 34 that provide the assembly 17, flat plates are used.
The upper and lower corrugated cores 16a, 16b are also generally
Those that are not bent are used. That is, here, the assembly 17 is formed so as to have a flat plate shape as a whole.

Next, the flat plate-shaped assembly 17 thus obtained is brazed and joined in accordance with, for example, a method for manufacturing a curved panel described in Japanese Patent Application Laid-Open No. HEI 8-174111. Thus, the intended sandwich panel 10 having a curved surface shape that is convex toward. In adopting such a brazing method, the respective curved surface shapes of the convex pressing surface of the upper forming jig (upper pressing jig) and the concave pressing surface of the lower forming jig (lower pressing jig) are set. By using a molding device having a composite curved surface shape in which the radius of curvature gradually changes, the intended sandwich panel 10 can be easily obtained as a composite curved panel having a composite curved surface shape.

According to such an embodiment, the upper and lower corrugated cores 16 made of an aluminum alloy exhibiting a corrugated plate shape.
a, 16b are sandwiched between upper and lower plates 12, 14 made of the same type of aluminum alloy, and they are made of Si.
Is low, and is integrally brazed with a special Al-Si-based brazing alloy containing no Mg, so that the sandwich panel 10 having a curved surface shape as a whole is formed. The same effects as those of the first embodiment relating to the sandwich panel formed as a flat panel can be effectively enjoyed even in the sandwich panel 10 formed as a so-called curved panel as a whole having a curved surface shape. is there.

In this embodiment, the upper corrugated core 16
Since “a” and the lower corrugated core 16b are laminated so that the directions in which the corrugated shapes are formed coincide with each other, there is an advantage that the step of bending the flat plate-shaped assembly 17 can be performed smoothly.

Further, in the present embodiment, the intermediate plate 34 is provided between the upper corrugated core 16a and the lower corrugated core 16b.
When the assembled body 17 is formed, the upper and lower corrugated cores 16a, 16a, 1
Unlike the case of directly laminating the upper corrugated core 6b and the upper corrugated core 16a, there is no need to perform troublesome positioning such that the apex portion of the concave portion of the upper corrugated core 16a and the apex portion of the convex portion of the lower corrugated core 16b abut each other. As a result, the forming operation of the assembly 17 can be performed more easily and quickly.

In FIG. 10, the corrugated core 16 and a plurality of (here, seven) frame members 36 surrounding the corrugated core 16 are sandwiched between the upper plate 12 and the lower plate 14. An example of the arrangement is shown.

In this case, the plurality of frame members 36 are each formed of an extruded member having a square cross section made of an Al-Mg-Si-based 6000 series aluminum alloy having excellent strength. The frame members 36 have a substantially “day” shape as a whole, and the upper and lower plate 1
The frame body 40 having two rectangular windows 38, 38 is formed by being assembled so as to have substantially the same size as 2, 2. In the two rectangular windows 38, 38 of the frame 40, the corrugated cores 16, 16 having the same thickness as the frame 36 are accommodated and positioned one by one. ing. Thereby, a plurality of frame members 36 are provided around the two corrugated cores 16, 16.
It is arranged so as to surround each corrugated core 16,16. Then, the plurality of frame members 36 and the two corrugated cores 16, 16 are sandwiched between the upper surface plate 12 and the lower surface plate 14 in the height direction of the corrugated shape of each corrugated core 16, 16 and arranged. In this arrangement, the two corrugated cores 16 and 16 and the plurality of frame members 36 are
The upper and lower plates 12 and 14 are integrally brazed.

Then, also in this case, the two waveform cores 16,
The brazing alloy which brazes 16 and the plurality of frame members 36 to the upper and lower plates 12 and 14 contains Si at a relatively low ratio of 6 to 9% by weight, and the balance is made of Al and unavoidable impurities. , A special Al-Si-based brazing alloy substantially free of magnesium Mg. In the present embodiment, the frame member 36 surrounding the corrugated core 16 is made of an extruded aluminum alloy having a hollow hollow cross section.
Is, for example, constituted by a flat plate having an appropriate thickness,
No problem.

Thus, in the sandwich panel 10 having such a structure, the corrugated cores 16, 16 are accommodated one by one in the two rectangular windows 38, 38 of the frame 40 composed of the plurality of frame members 36. The first embodiment except that the plurality of frame members 36 and the two corrugated cores 16 are arranged and sandwiched between the upper surface plate 12 and the lower surface plate 14 in the squeezed state to form the assembled body 17. It will be manufactured by the same method as the sandwich panel 10 shown in the embodiment. When the assembled body 17 is formed, the frame member 40 is formed in a fixed shape by welding a plurality of frame members 36 in advance, and in this state, the plurality of frame members 36 are attached to the upper and lower plates. It may be arranged between 12 and 14, and the plurality of frame members 3
The frame body 40 is formed by merely assembling without joining any of the frame members 6, and in this state, the plurality of frame members 3 are formed.
6 may be arranged between the upper and lower plates 12 and 14.

Also in such an embodiment, the corrugated core 16 is sandwiched between the upper and lower plates 12, 14 made of the same kind of aluminum alloy, and has a low Si content and contains Mg. Since the sandwich panel 10 is formed by brazing integrally with a special Al-Si-based brazing alloy, the same effect as that of the first embodiment can be effectively enjoyed. .

Further, in this embodiment, a plurality of frame members 36 made of extruded aluminum alloy are arranged between the upper and lower plates 12 and 14 so as to surround the corrugated cores 16 and 16. Therefore, the anisotropy of the bending rigidity and the bending strength in the sandwich panel 10 can be advantageously eliminated or alleviated. Of the sandwich panel 10 can be used as a joining surface for welding or the like.
It becomes possible to weld them together. As a result, a large-sized large panel or the like can be easily manufactured.

Further, in the present embodiment, since each of the frame members 36 has a hollow shape having a square hollow cross section, these frame members 3
There is also an advantage that the inside of the hollow portion of No. 6 can be used as, for example, a refrigerant distribution route or an electrical wiring route.

By the following specific steps according to the method of the present invention, a sandwich panel 10 having the structure shown in FIG. 10 or FIG. An evaluation on points was made.

That is, first, 695 having a thickness of 0.2 mm
Using a large number of 1 alloy plates, they are press-formed, and irregularities with a height of 2.6 mm are continuously formed in one direction at a pitch of 3.0 mm. A number of rectangular corrugated sheets of 500 mm were obtained. Then, a number of corrugated sheets thus obtained were used as corrugated cores. Separately, a rectangular 6 having a length of 500 mm, a width of 500 mm, and a thickness of 0.8 mm.
951 alloy plates were used, and as shown in Tables 1 and 2 below, Si was added at 4%, 6%, 9%, and 1% to one side of each of the multiple alloy plates.
12 types of Al-Si brazing alloys containing 1% by weight and containing no Mg or containing 0.6% by weight or 1.2% by weight of Mg A plurality of 12 types of brazing sheets, each of which was clad at a cladding ratio of 5%, and having different types of brazing alloys, were obtained. These brazing sheets were used as upper and lower plates, respectively. Furthermore, a 500 mm length and 2.6
elongate rectangular 6 having a width of 7 mm and a thickness of 7 mm
A number of 063 alloy plates were prepared and used as frame materials.

Next, a corrugated core and a frame member are placed between the upper plate and the lower plate made of any one of the twelve types of brazing sheets obtained as described above, as shown in FIG. An assembled body was obtained by sandwiching and disposing in the state.
Similarly, the corrugated core and the frame material are interposed between the upper surface plate and the lower surface plate made of each of the other 11 types of brazing sheets to form the assembled bodies. Twelve types of assembled bodies were obtained, in which the brazing alloys for brazing the frame material and the upper and lower plates were different from each other. Here, ten of these twelve kinds of assembled bodies were formed respectively. The thickness of each of the assembled bodies was 4.2 mm .

After that, out of the twelve kinds of assembled bodies thus formed, ten of any one of the assembled bodies are vertically stacked and stacked, and set in a predetermined molding apparatus. After putting them in a vacuum heating furnace,
In a state where the inside of the vacuum heating furnace was evacuated, the inside of the vacuum heating furnace was heated while pressurizing the ten assembled bodies at a pressure of 1 kPa. Then, of the ten assembled bodies, the assembled bodies located at the uppermost stage (first stage from the top), the lowermost stage (tenth stage from the top), and the center stage (sixth stage from the top) The heating is terminated when the temperatures measured by the thermocouples attached to the center and the corner of each of the above all exceed 580 ° C., which is almost the same as the melting point of the brazing alloy. After nitrogen gas was introduced into the furnace and the inside of the heating furnace was restored, ten assembled bodies were taken out of the heating furnace and cooled. By this, the brazing of each of the assembled bodies is completed, and the corrugated core and the frame material are integrally brazed to the upper and lower plates with the same type of brazing alloy. Ten sandwich panels were obtained. Separately, the same operation was performed with respect to the remaining 11 types of assembled bodies.
As shown in Table 2 and Table 2, the corrugated core and the frame material are respectively different types of brazing alloys (Si and M
12 types of sandwich panels (Panel No. 1) brazed with brazing alloys having different g contents.
To 12) were obtained.

[0098]

[0099]

Thereafter, 12 kinds of sandwich panels (panel No. 1) were obtained, one for each 10 sheets.
12), the pairs located at the uppermost stage (first stage from the top), the lowermost stage (10th stage from the top), and the center stage (sixth stage from the top) in the vacuum heating furnace Each of the three sandwich panels obtained from the attachment is cut into two parts at appropriate positions, and the panel thickness of each of the cut parts is set to the maximum and minimum. Measurement at the site where
While the range of panel thickness variation in each sandwich panel was examined, the brazing condition of the brazed joint between the corrugated core and the face plate at the cut site of each sandwich panel was visually examined. The results are shown in Tables 3 to 5 below. In addition, in the evaluation of the brazing state in Tables 3 to 5, for those in which the occurrence of bonding failure was confirmed, insufficient melting of the brazing alloy was recognized, and for those in which core collapse was confirmed, Significant erosion was observed.

[0101]

[0102]

[0103]

As is clear from the results in Tables 3 to 5, the heating temperature (brazing temperature) of each of the assembled bodies providing the respective sandwich panels due to the difference in the lamination position in the vacuum heating furnace. ), The corrugated core and the face plate are integrally brazed with an Al-Si brazing alloy containing 6% by weight or 9% by weight of Si and containing no Mg. The sandwich panel according to the present invention (panel No. 4 and panel No. 7) has not only a very small value of 0.1 mm or 0.2 mm in the thickness of the panel, but also a very small value before brazing. The amount of reduction in thickness with respect to the assembled body is extremely small, and the brazing state between the corrugated core and the face plate is good.

On the other hand, the Al—
A sandwich panel in which a corrugated core and a face plate are integrally brazed with a brazing alloy different from a Si-based brazing alloy, that is, a Si content of 6% by weight or 9% by weight.
However, a sandwich panel (panel Nos. 5, 6, 8, and 9) brazed with a brazing alloy containing 0.6% by weight or 1.2% by weight of Mg, and a sheet containing no Mg , Si content is 4% by weight or 11
Sandwich panel (panel Nos. 1 and 10) brazed with a brazing alloy having a Si content of 4% by weight.
% Or 11% by weight, and the content of Mg is 0.6% by weight or 1.2% by weight.
3,11,12), except for a very small portion,
Most of them have large variations in panel thickness and the amount of reduction in thickness relative to the assembled body before brazing, and at the joint between the corrugated core and the face plate,
Deformation or collapse of the corrugated core due to insufficient bonding of the brazing alloy or erosion has occurred.
The brazing state between the corrugated core and the face plate is defective.

From this, according to the present invention, the thin-walled assembly can be brazed and joined with a sound brazing state by the vacuum brazing method, whereby the thin-walled sandwich panel can be formed. It can be clearly recognized that it can be easily manufactured with the desired thickness and high surface accuracy.

Next, a number of 3003 alloy plates having a thickness of 0.2 mm were used, and they were press-formed to a height of 2.6 m.
m are continuously formed in one direction at a pitch of 3.0 mm, and have a length and a width of 150 m each.
A number of rectangular corrugated sheets having a thickness of mm were obtained. Then, a number of corrugated sheets thus obtained were used as corrugated cores.
Separately, a large number of rectangular 3003 alloy plates each having a length of 150 mm, a width of 150 mm, and a thickness of 0.8 mm were used, and 4 wt. %, 6% by weight, 9% by weight,
And any one of the four types of Al-Si-based brazing alloys containing Mg in any proportion of
Each of the seeds was clad at a cladding ratio of 5% to obtain a plurality of four types of brazing sheets each having a different brazing alloy type. Thereafter, in all of the brazing sheets thus obtained, a fluorine-based flux comprising a eutectic component of K ₃ AlF ₆ and KAlF ₄ was applied to the entire surface of the brazing alloy clad surface. Then, a plurality of brazing sheets coated with the flux,
The upper and lower plates were used, respectively.

Subsequently, the corrugated core is placed between the upper plate and the lower plate made of any one of the four types of brazing sheets obtained as described above in a state as shown in FIG. Then, an assembled body was obtained. Similarly, the corrugated core and the frame material are interposed between the upper surface plate and the lower surface plate made of each of the other three types of brazing sheets to form the respective assembled bodies. Thus, four types of assembled bodies having different brazing alloys for brazing to the upper and lower plates were obtained. Here, four of these four types of assembled bodies were formed. The thickness of the assembly is
All were 4.2 mm.

Thereafter, among the four types of assembled bodies thus formed, four of the assembled bodies of any one type are set in different molding devices, respectively, and housed in different heating furnaces. After that, while the inside of each heating furnace was filled with nitrogen gas, the inside of the heating furnace accommodating each of the assembled bodies was heated while each of the assembled bodies was pressurized at a pressure of 1 kPa. Then, the temperatures measured by the thermocouples attached to the respective assembled bodies are slightly higher than the melting point of the brazing alloy, respectively.
When the temperature reaches 80 ° C. and 600 ° C.
When the temperature reached 610 ° C. and 615 ° C., respectively, the heating was terminated. Immediately thereafter, each of the assembled bodies was taken out of the heating furnace in which each was housed and cooled. Thereby, the brazing of each of the assembled bodies is completed, and the corrugated core and the upper and lower plates are integrally brazed with the same type of brazing alloy at different brazing temperatures. The desired four sandwich panels were obtained. Separately, the same operation is performed for the remaining three types of assembled bodies, whereby the corrugated core is moved relative to the upper and lower plates as shown in Tables 6 and 7 below.
Four sandwich panels (panel Nos. 13 to 16) each obtained by brazing with different kinds of brazing alloys (brazing alloys having different Si contents) were obtained.

Thereafter, four kinds of sandwich panels (panel No. 13 to panel No. 13 to 4) each having four kinds obtained in this way.
All of 16) are cut into two at appropriate positions,
Then, the range of variation in panel thickness of each of the cut portions and the brazing state of the brazed joint between the corrugated core and the face plate were examined. It is to be noted that the above-described 12 types of sandwich panels (panel N
o. This was performed in the same manner as in the case where the range of thickness variation and the brazing state were examined. The results are shown in Tables 6 and 7 below. Also in this case, in the evaluation of the brazing state in Tables 6 and 7, as for those in which the occurrence of bonding failure was confirmed, insufficient melting of the brazing alloy was recognized, and further, collapse of the core was confirmed. For, significant erosion was observed.

[0111]

[0112]

As is clear from the results of Tables 6 and 7, the corrugated core and the face plate are integrally brazed with an Al—Si brazing alloy having a Si content of 6% by weight or 9% by weight. In the sandwich panel according to the present invention (panel No. 14 and panel No. 15) attached,
Each of the four sheets was obtained by brazing the assembled body at 580 ° C. which is substantially the same as the melting point of the brazing alloy, and 600 ° C. and 30 ° C. higher by 20 ° C. and 610 ° C., respectively.
In the three pieces obtained by brazing each of the assembled bodies at a temperature of ℃, the reduction in thickness with respect to the assembled body before brazing was clearly reduced, and the corrugated core and the face plate were also reduced. And the brazing condition is good.

On the other hand, a sandwich panel (panel) different from the present invention, in which the corrugated core and the face plate are integrally brazed with an Al—Si brazing alloy having a Si content of 4% by weight. In the case of No. 13), of the four sheets, 600 ° C. higher than the melting point of the brazing alloy by about 20 ° C.
In the two sheets obtained by brazing the assembled body at about 610 ° C. higher by about 30 ° C., the brazing state between the corrugated core and the face plate is relatively good. 615, which is 35 ° C. or more higher than the melting point of the brazing alloy
The brazing condition between the corrugated core and the face plate is poor, not only for the case where the assembled body is brazed at 580 ° C. but also for the case where the assembled body is brazed at 580 ° C. I have. In addition, Al having an Si content of 11% by weight
-Even in a sandwich panel (panel No. 16) different from the present invention in which a corrugated core and a face plate are integrally brazed with a Si-based brazing alloy,
580 ° C, which is almost the same as the melting point of the brazing alloy, and 20 ° C
Although the brazing condition of the corrugated core and the face plate was relatively good in two sheets obtained by brazing the assembled body at a high temperature of 600 ° C., the melting point of the brazing alloy was 610 ℃ and 615 ℃ higher than 30 ℃
In the two pieces obtained by brazing the assembled bodies at the above temperature, the brazing state between the corrugated core and the face plate is poor.

From this, according to the present invention, when a thin-walled assembly is brazed by a general flux brazing method, the assembly is removed from the melting point of the brazing alloy. Even when heated in a temperature range of about 30 ° C. higher than that, the corrugated core and the upper and lower plates can be brazed and joined with a sound brazing state, so that the sandwich panel having a small thickness has good quality. Thus, it can be clearly recognized that it can be easily manufactured.

Although the specific configuration of the present invention has been described in detail above, this is merely an example, and the present invention is not limited by the above description. The present invention can be implemented in an aspect in which various changes, modifications, improvements, and the like are made based on the knowledge of the above. It goes without saying that all such embodiments are included in the scope of the present invention unless they depart from the gist of the present invention.

[0117]

As is clear from the above description, according to the method for manufacturing a sandwich panel according to the present invention, the core thickness is reduced and the entire panel is reduced in thickness, thereby reducing the weight. A sandwich panel designed in a targeted manner can be produced industrially advantageously without any reduction in productivity and economy. Then, the two face plates and the corrugated core constituting the thin sandwich panel obtained in this manner are free from joint failure, deformation of the core, collapse or collapse, regardless of the method of brazing them. It can be easily and reliably brazed with no sound brazing conditions,
In a sandwich panel having a small thickness, excellent quality and high surface accuracy can be extremely effectively secured.

Further, in the sandwich panel according to the present invention, the overall thickness of the panel can be easily reduced without lowering the quality and surface accuracy, and further weight reduction can be effectively achieved. Therefore, it can be applied to a sandwich panel such as a conventional honeycomb panel such as a general desk top plate, a door face plate, a shelf plate, or a side plate or a bottom plate of a packing material formed of a predetermined housing. The present invention can be sufficiently applied to a thin and light plate material that has not been provided, and the applicable range can be effectively expanded.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing an example of a sandwich panel according to the present invention.

FIG. 2 is an explanatory longitudinal sectional view of the sandwich panel shown in FIG. 1;

FIG. 3 is a view corresponding to FIG. 2 and showing another example of the sandwich panel according to the present invention.

FIG. 4 is an explanatory view showing an example of a step of manufacturing a sandwich panel according to the method of the present invention, and shows a state in which a plurality of assembled bodies are set in a molding apparatus.

FIG. 5 is a view corresponding to FIG. 1 and showing still another example of the sandwich panel according to the present invention.

FIG. 6 is an explanatory longitudinal sectional view of the sandwich panel shown in FIG. 5;

FIG. 7 is a view corresponding to FIG. 1 and showing another example of the brazed sandwich panel according to the present invention.

FIG. 8 is an explanatory longitudinal sectional view of the sandwich panel shown in FIG. 7;

FIG. 9 is an explanatory longitudinal sectional view showing still another example of the sandwich panel according to the present invention.

FIG. 10 is a partially exploded perspective view showing another example of the sandwich panel according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Sandwich panel 12, 14 Face plate 16 Corrugated core 18 Molding device 22 Upper molding jig 26 Lower molding jig 34 Intermediate plate 36 Frame material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04C 2/32 E04C 2/32 G // B23K 101: 18 B23K 101: 18 F-term (Reference) 2E162 BA03 BB10 CB08 CB15 4F100 AB10A AB10B AB10C BA03 BA06 BA10A BA10B BA14 BA32 DD12C EC162 GB07 JL03

Claims (10)

[Claims] 1. An assembled body formed by sandwiching at least an aluminum core between two aluminum face plates by brazing, so that at least the two face plates and the core are integrally formed. When manufacturing a brazed sandwich panel, a corrugated core having a corrugated shape in which a corrugated shape is continuously formed in one direction is used as the core, and the corrugation between the two face plates is used. After the core is sandwiched in the height direction of the corrugated shape to form the assembly, silicon (Si) is contained at a ratio of 6 to 9% by weight, and the remainder is made of aluminum (Al) and unavoidable impurities. A method of manufacturing a sandwich panel, wherein the assembly is brazed and joined with an Al-Si brazing alloy substantially free of magnesium (Mg). . 2. The apparatus according to claim 1, wherein the face plate and the corrugated core are both
The method for manufacturing a sandwich panel according to claim 1, wherein the method is configured by using an aluminum compact formed using an Al-Mg-Si-based 6000 series aluminum alloy. 3. A brazing sheet in which at least one of the face plate and the corrugated core is formed of a plate material made of aluminum or an alloy thereof, on one or both surfaces of the brazing sheet, wherein the Al-Si-based brazing alloy is clad. The method for manufacturing a sandwich panel according to claim 1, wherein the method is configured by a molded aluminum body. 4. An Al-Si brazing alloy clad between one or both surfaces of a plate material made of aluminum or an alloy thereof between at least one of the two face plates and the corrugated core. 3. The sandwich panel according to claim 1, wherein the assembled body is formed by further sandwiching a brazed sheet or a sheet or plate made of the Al—Si brazing alloy. 4. Method. 5. A plurality of corrugated cores are used, and the plurality of corrugated cores are stacked in a height direction of a corrugated shape in each of the corrugated cores, and directions of forming the corrugated shapes are mutually orthogonal between adjacent ones. The assembled body is formed by arranging the plurality of corrugated cores in such a manner as to be sandwiched between the two face plates in the laminating direction. The method for producing a sandwich panel according to any one of the above. 6. Using a plurality of said corrugated cores and at least one intermediate plate made of aluminum material, said plurality of corrugated cores are stacked in a height direction of a corrugated shape in each of said plurality of corrugated cores, and said at least one corrugated core is laminated. The intermediate plate is positioned between the plurality of laminated corrugated cores, and further, the plurality of corrugated cores laminated with the intermediate plate interposed therebetween,
In the stacking direction, the assembled body is sandwiched between the two face plates to form the assembled body, and then the assembled body is brazed and joined, so that the two face plates, the plurality of corrugated cores and the at least The method for manufacturing a sandwich panel according to any one of claims 1 to 5, wherein one intermediate plate is brazed integrally with each other. 7. A plurality of corrugated cores and at least one intermediate plate made of an aluminum material, wherein the plurality of corrugated cores are stacked in a height direction of a corrugated shape in each of the corrugated cores, and in all of them. , The corrugated shapes are arranged so as to coincide with each other, and the at least one intermediate plate is positioned between the plurality of corrugated cores to be laminated, and further laminated with the intermediate plate interposed therebetween. The plurality of corrugated cores formed in
After sandwiching between two face plates to form the assembled body, using a pair of forming jigs having a pressing surface having a predetermined curved surface shape, the pair of forming jigs was formed between the pair of forming jigs. Under the state where the assembled body is sandwiched and pressed by the pair of forming jigs,
By brazing, the face plate, the plurality of corrugated cores, and the at least one intermediate plate are brazed integrally with each other and formed into a curved surface shape corresponding to the pressing surface. Claims 1 to 4 characterized by the above-mentioned.
The method for producing a sandwich panel according to any one of the above. 8. The method according to claim 1, wherein the intermediate plate is provided on one or both sides of a plate made of aluminum or an alloy thereof.
The method for producing a sandwich panel according to claim 6, wherein the i-type brazing alloy is formed of an aluminum molded body formed using a brazing sheet clad. 9. A frame material made of aluminum is used, and the frame material is arranged around the corrugated core so as to surround the corrugated core, and the frame material and the corrugated core are formed in a corrugated shape of the corrugated core. In the height direction, the assembled body is sandwiched between the two face plates to form the assembled body, and then the assembled body is brazed to join the face plate, the corrugated core, and the frame material to each other. The method for manufacturing a sandwich panel according to any one of claims 1 to 8, wherein brazing is performed integrally. 10. A sandwich panel obtained by the manufacturing method according to any one of claims 1 to 9, wherein at least an aluminum core is sandwiched between two aluminum face plates. And at least the two face plates and the core are integrally brazed, wherein the core has a corrugated shape in which a corrugated shape is formed continuously in one direction. And the corrugated core is arranged in the height direction of the corrugated shape.
Silicon (Si) 6 ~ under the state sandwiched between two face plates
9% by weight, with the balance being aluminum (A
l) and an Al-Si-based brazing alloy substantially free of magnesium (Mg) consisting of unavoidable impurities,
A sandwich panel, wherein the two face plates are integrally brazed.