JP2009214140A - Hollow panel, its manufacturing method, and panel structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a hollow panel capable of easily manufacturing a hollow panel with an arbitrary length, and also to provide its manufacturing method. <P>SOLUTION: The hollow panel 101 is configured of a first panel sheet 1, a plurality of L shaped support plates 21-25 arranged in a straight line with an equal interval on the first panel sheet, and a second panel sheet 3 formed of a plurality of split panel sheets 31-35 which are split along the L shaped support plates 21-25 and are butt-joined at the split parts. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to, for example, a hollow panel constituting a casing of an air conditioner mounted on a railway vehicle, a method for manufacturing the same, and a panel structure including the hollow panel.

  Conventionally, in order to increase the rigidity of a panel, a corrugated support member formed by pressing a single plate material into a corrugated shape is sandwiched between two panel sheets, and a valley portion and a peak portion of the panel sheet and the corrugated support member are sandwiched. There is known a hollow panel having a double skin structure formed by joining the contact portion with the welded portion by welding. In this hollow panel, the corrugated support member is placed on the first panel sheet, the contact portion between the first panel sheet and the corrugated support member is welded from above, that is, from the support member side, and then joined. The panel sheet is placed on the corrugated support member, and the contact portion between the second panel sheet and the corrugated support member is welded and joined from above, that is, from the second panel sheet side.

JP 2000-247227 A

In such a hollow panel, a panel sheet and a supporting member are manufactured by pressing a single plate material, etc., so in order to obtain an arbitrary length, production facilities such as molds must be replaced each time. However, there is a problem that it is difficult to manufacture a hollow panel having an arbitrary length.
Further, in such a method for manufacturing a hollow panel, since the flat panel sheet and the corrugated support member are overlapped, the contact portion between the panel sheet and the corrugated support member is welded from above, so that the contact portion is joined. There is a problem that the state cannot be visually checked, and a nondestructive inspection device such as ultrasonic flaw detection must be used in order to confirm the bonding state.

The present invention has been made to solve the above-described problems, and a first object is to obtain a hollow panel that can easily manufacture a hollow panel having an arbitrary length.
Moreover, the 2nd objective is to obtain the manufacturing method of the hollow panel which can confirm the joining state of a panel sheet | seat and a supporting member easily visually.

  A hollow panel according to the present invention is fixed to a first panel sheet, a plurality of support plates arranged on one side of the first panel sheet, and the other sides of the plurality of support plates. The second panel sheet is a plurality of divided panel sheets divided along the other side of the support plate and butt-joined at the divided portions. It is formed.

  The method for manufacturing a hollow panel according to the present invention includes a first panel sheet, a plurality of support plates arranged on one side of the first panel sheet, and a plurality of support plates. A plurality of divided panel sheets that are divided along the other side of the support plate and are butt-joined at the divided portions. In the method for manufacturing a hollow panel, the support plate is arranged on the split panel sheet so that a part thereof overlaps, and the split panel sheet and one side of the support plate are joined and split. A first step of forming a panel structure, a second step of joining the other side of the support plate of the split panel structure and the first panel sheet, the split panel sheet of the split panel structure, and the first In one process And a third step of forming the second panel sheet by abutting the divided panel sheets of the other divided panel structure formed at the divided portion and joining the abutted portions. It is.

According to the present invention, it is possible to easily manufacture a hollow panel having an arbitrary length simply by changing the number of support plates and divided panel sheets.
Moreover, according to this invention, the manufacturing method of the hollow panel which can confirm the joining state of a panel sheet | seat and a supporting member visually, and can ensure joining quality easily is obtained.

Embodiment 1 FIG.
FIG. 1 is a perspective view showing a hollow panel according to Embodiment 1 of the present invention, and FIGS. 2 and 3 are perspective views showing a part of a manufacturing process of the hollow panel according to this embodiment.
In FIG. 1, the hollow panel 101 includes a first panel sheet 1, identical support plates 21 to 25 arranged linearly on the first panel sheet 1 at equal intervals, and a second panel sheet. 3. The support plates 21 to 25 have an L-shaped cross section, and one side is fixed to the first panel sheet 1 and the other side is fixed to the second panel sheet 3 by welding. The second panel sheet 3 is divided into a plurality of divided panel sheets 31 to 35 having the same length along the support plates 21 to 25, and butt-joined at the divided portions 31a to 34a. The support plates 21 to 25 and the divided panel sheets 31 to 35 are configured in the same number so as to correspond one-to-one, and the divided portions are arranged on the support plates 21 to 25.

  Here, the first panel sheet 1, the L-shaped support plates 21 to 25, and the divided panel sheets 31 to 35 are formed of a metal material that can be welded, such as stainless steel or a JIS-A6000 series aluminum alloy. Is done. Further, the cross section of the support plates 21 to 25 may have any shape other than the L shape, for example, a shape having a surface on which the divided panel sheets 31 to 35 can be placed, such as an I shape, a T shape, and an H shape. In addition, when making the cross section of the support plates 21-25 into an L shape, the angle of the bending part 21a can be made into an acute angle or an obtuse angle, but when considering the assembly property of a hollow panel, it is desirable to be as close to a right angle as possible.

Next, the manufacturing method of this hollow panel 101 is demonstrated.
First, as shown in FIG. 2, the support plate 21 having a L-shaped cross section formed using a press die is arranged so that a part of one side thereof overlaps the surface of the divided panel sheet 31. A protruding surface 21 b is formed between the bent portion 21 a and the divided portion 31 a of the divided panel sheet 31. And the division | segmentation panel sheet | seat 31 and the L-shaped support plate 21 are fillet welded and joined by the one side 21c of the L-shaped support plate 21, and the 1st division | segmentation panel structure 41 is formed (1st process).

  Next, the first divided panel structure 41 formed in this way is arranged so that the end surface 21 d of the L-shaped support plate 21 is in contact with the surface of the first panel sheet 1 as shown in FIG. 3. At this time, the installation angle of the first divided panel structure 41 is adjusted using a jig or the like so that the divided panel sheet 31 of the first panel structure 41 is parallel to the first panel sheet 1. Thereafter, one side 21e of the L-shaped support plate 21 is fillet welded to join the first panel sheet 1 and the first divided panel structure 41 (second step).

  Then, in the second divided panel structure 42 manufactured in the same process as the first process, as shown in FIG. 3, the end surface 22 d of the L-shaped support plate 22 is in contact with the surface of the first panel sheet 1. Further, while the divided panel sheet 42 is placed on the protruding portion 21 b of the first divided panel structure 41, the divided panel sheet 31 and the divided portion 31 a of the divided panel sheet 32 are arranged so that the short surfaces thereof face each other. In this state, similarly to the second step, the joint 22e is fillet welded to join the first panel sheet 1 and the second divided panel structure 42 together.

After that, as shown in FIG. 3, the butted portions 31b of the divided panel sheet 31 and the divided panel sheet 32 are welded, and the divided panel sheets 31 and 32 are joined to form the second panel sheet 3 (third Process).
Thereafter, the first to third steps are sequentially repeated until the hollow panel portion reaches a desired length to form the hollow panel 101 as shown in FIG.

  By performing the welding in each of the above steps not by spot welding but by continuous welding, the airtightness of the welded portion can be ensured. For welding, general arc welding such as TIG and MIG can be used, but in order to minimize the thermal distortion of the joint, a method that requires as little heat input as possible, such as arc brazing or laser welding. Etc. are preferable. Further, it is preferable to use a jig that makes positioning of the member accurate and easy in welding.

  According to the present embodiment, the first panel sheet 1, the same support plates 21 to 25 arranged at equal intervals on the first panel sheet 1, and divided along the support plates 21 to 25 Since the hollow panel 101 is composed of the second panel sheet 3 formed by the divided panel sheets 31 to 35 having the same length butted and joined at the divided portions 31a to 34a, the division panel sheet and the support plate are standardized. Therefore, it is possible to easily manufacture a hollow panel having an arbitrary length simply by changing these numbers. Further, since the support plate can be easily formed using one kind of press mold, productivity can be improved.

Moreover, since the joining state of the 1st and 2nd panel sheets 1 and 3 and the support plates 21-25 can be confirmed visually, it can aim at ensuring joining quality easily, without using a nondestructive inspection apparatus. it can.
Moreover, since all the joining locations can be visually observed, positioning at the time of joining becomes easy, and productivity can be further improved.

Embodiment 2. FIG.
FIG. 4 is a perspective view showing a hollow panel according to the second embodiment of the present invention, and FIG. 5 is a perspective view showing a part of a manufacturing process of the hollow panel according to the present embodiment.
In FIG. 4, the hollow panel 102 includes a first panel sheet 1, a plurality of support plates 21 to 25, and a second panel sheet 3. Support plates 61 and 62 having a U-shaped cross section are provided at both ends in the longitudinal direction of the first panel sheet 1 so as to face the openings, and one side of the support plates 61 and 62 is the first panel. The sheet 1 and the other side are joined to the second panel sheet 3 by welding. Similarly to the first embodiment, the second panel sheet 3 includes a plurality of divided panel sheets 31 to 35 having the same length and a single divided panel sheet 301 for size adjustment. The divided panel sheet 301 is disposed at one end of the second panel sheet 3. Since other configurations are the same as those of the first embodiment, the same reference numerals are given and description thereof is omitted.

Next, a method for manufacturing the hollow panel 102 will be described.
First, as shown in FIG. 5, support plates 61 and 62 having a U-shaped cross section are arranged on both end surfaces in the longitudinal direction of the first panel sheet 1 so that the openings face each other, and then the U-shaped support plate 61. The first panel sheet 1 and the U-shaped support plates 61 and 62 are joined by fillet welding at one side 61a and the one side 62a of the U-shaped support plate 62, respectively.
Next, as shown in FIG. 4, the divided panel sheet 31 is formed on the U-shaped support plate 61 in the first divided panel structure 41 formed in the same process as the first process shown in the first embodiment. It arrange | positions so that it may mount, and also arrange | positions so that the end surface 21d of the L-shaped support plate 21 may contact the surface of the 1st panel sheet | seat 1. FIG. Then, the joints 21d and 31c are fillet welded to join the members.
Thereafter, the first to third steps shown in the first embodiment are sequentially repeated until the hollow panel portion reaches a predetermined length.
Finally, the division panel sheet 301 for dimension adjustment is placed so as to straddle the U-shaped support plate 62 and the protruding surface 25b of the division panel structure 45, and the joining portion 35b and the joining portion 301a are welded and joined. To do.

According to the present embodiment, since the support plates 61 and 62 are provided at the longitudinal ends of the first panel sheet 1 and the second panel sheet 3 of the hollow panel 102, respectively, the rigidity of the hollow panel end is increased. be able to.
Moreover, since the division panel sheet 301 for dimension adjustment is arranged at one end of the second panel sheet 3, the division panel sheet 301 can be used as a dimension adjustment allowance and can easily cope with a change in the length of the hollow panel. can do.
Further, the U-shaped support plate 61 is fixed to the longitudinal end portion of the first panel sheet 1 at the beginning of the manufacturing process, so that the first divided panel structure 41 is installed on the first panel sheet 1. In this case, it is not necessary to use a jig for adjusting the installation angle as in the first embodiment, and the assemblability of the hollow panel is improved.

  In the above embodiment, the U-shaped support plates 61 and 62 are installed at both longitudinal ends of the first panel sheet 1 and the second panel sheet 3, but both ends on the side orthogonal to the longitudinal direction. Support plates 61 and 62 can also be installed in the section. Further, as shown in FIG. 6, one end may be constituted by an L-shaped support plate 25 instead of the U-shaped support member 62.

Embodiment 3 FIG.
FIG. 7 is a perspective view showing a hollow panel according to the third embodiment of the present invention, and FIG. 8 is a perspective view showing a part of a manufacturing process of the hollow panel according to the present embodiment.
In FIG. 7, the hollow panel 104 includes a first panel sheet 1, a plurality of support plates 21 to 25, and a second panel sheet 3. Here, the first panel sheet 1 is bent at both ends in the longitudinal direction, and the ends of the bent portions 1a and 1b are joined to the second panel sheet 3 by welding. Since other components are the same as those in the second embodiment, the same reference numerals are given and description thereof is omitted.

  As shown in FIG. 8, such a hollow panel 104 is formed by bending both ends in the longitudinal direction of the first panel sheet 1 to form the bent portions 1a and 1b, and then the bent portions 1a and 1b. In the meantime, as shown in FIG. 7, the divided panel structures 41 to 45 are sequentially installed and welded in the same process as in the second embodiment, and finally the divided panel sheet 301 for dimension adjustment is attached to the L-shaped support plate 25. The first panel sheet 1 is manufactured by being placed over the bent portion 1b and welded and joined.

  According to the present embodiment, since the bent portions 1a and 1b are provided at both ends of the first panel sheet 1 of the hollow panel 104, the U-shaped support plates 61 and 62 described in the second embodiment are not necessary, The number of parts can be reduced.

  In the above embodiment, the bent portions 1a and 1b are provided at both ends in the longitudinal direction of the first panel sheet 1. However, the bent portions may be provided at both ends in the direction orthogonal to the longitudinal direction. A bent portion may be provided only at one end of the first panel sheet 1 and a U-shaped or L-shaped support plate may be disposed at the other end.

Embodiment 4 FIG.
FIG. 9 is a perspective view showing a hollow panel according to Embodiment 4 of the present invention.
In FIG. 9, the hollow panel 105 includes a first panel sheet 1 having bent portions 1a and 1b at opposite ends, a plurality of L-shaped support plates 21, 221, 231, 24, 25, and a plurality of divisions. It is comprised from the panel sheet | seat 31,32,331,341,35, and the 2nd panel sheet | seat 3 formed by butt-joining the division | segmentation panel sheet 301 for dimension adjustment in a division part. Here, the L-shaped support plates 221 and 231 have the same thickness, and the plate thickness is larger than the other L-shaped support plates 21, 24 and 25. Further, the divided panel sheets 331 and 341 have the same plate thickness, and are formed to be larger than the other divided panel sheets 31, 32 and 35. Other configurations are the same as those in the third embodiment.

  According to the present embodiment, since the plate thicknesses of the divided panel sheets 331 and 341 and the support plates 221 and 231 are made thicker than others, the rigidity of the hollow panel can be locally increased.

  Further, as shown in FIG. 10, in the hollow panel having a structure in which the first panel sheet 100 and the second panel sheet 300 are coupled by a support member to provide a hollow portion, the width a of the second panel sheet 300 When it is necessary to secure the rigidity of the hollow panel by increasing the plate thickness by c times in the range of the above, by using the method shown in the present embodiment, the divided panel having a plate thickness c times thick only in the range of the width a By applying the sheet, it is possible to suppress the increase in the weight of the hollow panel to a / b as compared with the case where the entire second panel sheet 300 having the width b (b> a) is increased by c times. Therefore, an increase in the weight of the hollow panel can be minimized while ensuring the necessary rigidity.

  In the above embodiment, two divided panel sheets and two support plates each having a large thickness are used. However, only one of these may be used, or the number may be changed as necessary. Also good. Moreover, in the said embodiment, although the division | segmentation panel sheet | seat with a large plate | board thickness and a support plate were each formed with the equal thickness, you may combine arbitrarily what differs in plate | board thickness.

Embodiment 5 FIG.
FIG. 11 is a perspective view showing a panel structure according to Embodiment 5 of the present invention.
In FIG. 11, the panel structure 106 includes a bottom plate 7, three side plates 81 to 83, a closing plate 9 that covers the top of the panel structure, a service plate 10 that covers the front surface of the panel structure, a bottom plate 7, and a side plate. For example, it is used as a housing of an air conditioner mounted under the floor of a railway vehicle.

  The bottom plate 7 and the side plates 81 to 83 are configured by the hollow panel described in any one of the first to fourth embodiments, and the outer surface of the panel structure is formed by the first panel sheet having no divided portion. Is assembled to form. Since the bottom plate 7 and the side plate 8 are joined by welding via the connecting body 11 and the entire end portion of the bottom plate 7 is covered with the connecting body 11, the hollow portion of the bottom plate 7 is not exposed to the outside. ing. Further, since the end portions of the side plates 81 to 83 are covered by the bottom plate 7 and the closing plate 9, the hollow portions of any of the side plates 81 to 83 are not exposed to the outside. In addition, you may insert a heat insulating material, a sound insulation material, etc. in the hollow part of a hollow panel.

  The closing plate 9 has a hole 13 for taking air into the panel structure from the outside of the panel structure such as the inside of the vehicle, and a hole 14 for feeding the temperature-controlled air from the inside of the panel structure to the outside of the panel structure such as the inside of the vehicle again. Is provided. The service board 10 is detachable for maintenance of equipment installed inside the panel structure, and the service board 10 has a grill-like air hole so that air can be passed for heat exchange. 15 is provided. The attachment portion 12 is a component for connecting to the floor portion of a railway vehicle, for example, and is joined to the side plates 81 and 83 by welding.

  According to the present embodiment, the total four surfaces of the bottom surface 7 and the side surfaces 81 to 83 of the panel structure 106 are configured using the hollow panel shown in any of the first to fourth embodiments. Can be easily obtained. In addition, since the outer surface of the panel structure is formed by the first panel sheet having no divided portions, an excellent appearance can be obtained. Furthermore, since the hollow portion of the hollow panel is covered with an adjacent member and is not exposed to the outside, it is possible to prevent foreign matter from entering the hollow portion.

In the above embodiment, a total of four plates including the bottom plate 7 and the three side plates 81 to 83 are configured using the hollow panel described in any of the first to fourth embodiments. It should just be used for at least one surface of the panel structure, and can be applied to any surface such as only the bottom plate or only a part of the side plate.
Moreover, in the said embodiment, although shown about what was installed under the floor of a railway vehicle as a housing | casing of an air conditioning apparatus, you may install in the ceiling part of a railway vehicle. Moreover, it is also applicable to apparatuses other than the air conditioner.

It is a perspective view which shows the hollow panel in Embodiment 1 of this invention. It is a perspective view which shows the division | segmentation panel structure which comprises a part of the hollow panel. It is a perspective view which shows a part of manufacturing process in the hollow panel. It is a perspective view which shows the hollow panel in Embodiment 2 of this invention. It is a perspective view which shows a part of manufacturing process in the hollow panel. It is a perspective view which shows the modification of the same hollow panel. It is a perspective view which shows the hollow panel in Embodiment 3 of this invention. It is a perspective view which shows a part of manufacturing process in the hollow panel. It is a perspective view which shows the hollow panel in Embodiment 4 of this invention. It is a perspective view which shows typically the hollow panel of a double skin structure. It is a perspective view of the panel structure in Embodiment 5 of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 1st panel sheet | seat, 3 2nd panel sheet | seat, 21-25 support plate, 31-35 division | segmentation panel sheet | seat, 41-45 division | segmentation panel structure, 101-105 hollow panel, 106 panel structure.

Claims (8)

A first panel sheet; a plurality of support plates arranged on one side of the first panel sheet; and a second panel sheet fixed to the other side of the plurality of support plates. In the provided hollow panel,
The said 2nd panel sheet | seat was formed along the other side of the said support plate, and was formed with the some division | segmentation panel sheet | seat which was butt-joined in the division | segmentation part, The hollow panel characterized by the above-mentioned.   The hollow panel according to claim 1, wherein the support plates are arranged at equal intervals.   The hollow panel according to claim 1 or 2, wherein the support plates are provided at both ends of the first panel sheet and the second panel sheet, respectively.   3. The hollow panel according to claim 1, wherein the first panel sheet has a bent portion that is bent from both ends thereof, and a tip portion of which is fixed to the second panel sheet.   The hollow panel according to any one of claims 1 to 4, wherein at least one of the divided panel sheets has a larger plate thickness than the other divided panel sheets.   The hollow panel according to any one of claims 1 to 5, wherein at least one of the support plates is thicker than the other support plates. A first panel sheet; a plurality of support plates arranged on one side of the first panel sheet; and a second panel sheet fixed to the other side of the plurality of support plates. And the second panel sheet is formed of a plurality of divided panel sheets that are divided along the other side of the support plate and are butt-joined at the divided portions. In
A first step of disposing the support plate on the divided panel sheet so that a part thereof overlaps, and joining the divided panel sheet and one side of the support plate to form a divided panel structure;
A second step of joining the other side of the support plate of the divided panel structure and the first panel sheet;
The divided panel sheet of the divided panel structure and the divided panel sheet of another divided panel structure formed in the first step are butted together at the divided portion, and the butted portion is joined to form a second panel sheet And a third step of manufacturing a hollow panel.   A panel structure comprising at least one surface formed by using the hollow panel according to any one of claims 1 to 6, wherein an outer surface is formed by a first panel sheet of the hollow panel. .

Images