JP2019034517A - Honeycomb structure, and mold for molding honeycomb structure - Google Patents

Abstract

To provide a honeycomb structure with light weight, easily manufactured, having vibration absorbability and impact absorbing function, and a mold for molding a honeycomb structure .SOLUTION: A honeycomb structure 1 according to the present invention is made of an aggregate of a plurality of cells 2, each having a plurality of, at least three, side walls 3 and formed into a polygonal cylindrical form in a planar view. The aggregate of the plurality of cells 2 is integrally formed of a synthetic resin material or a rubber material. The thickness of the side wall 3 where the cells 2 are not adjacent is thinner than the thickness of the side wall 3 where the cells 2 are adjacent to each other.SELECTED DRAWING: Figure 1

Description

The present invention relates to a honeycomb structure that is also used as an impact absorbing component for automobiles, aircraft, and the like, and a honeycomb structure molding die used for molding the honeycomb structure.
In addition, the honeycomb structure of the present invention is not limited to a structure composed of a plurality of cells formed in a regular hexagonal cylindrical shape in a plan view, but a polygonal tube such as a triangular shape or an octagonal shape in a plan view. An assembly of a plurality of cells formed in a shape is also included.

  Conventionally, honeycomb structures have been widely used as shock absorbing parts for automobiles, aircrafts and the like because they can reduce the weight and improve the mechanical strength. As a method for manufacturing this honeycomb structure, for example, in Patent Document 1, the honeycomb structure is made of an aluminum alloy in order to maintain mechanical strength, and the contact surfaces of the face plates serving as the side walls are brazed to be integrated. A manufacturing method is disclosed.

Japanese Patent Laid-Open No. 9-156000

  However, because it is made of aluminum metal, there is a problem in terms of weight in automobiles and aircraft that are required to be lighter, and the brazing and bonding method has a problem that it takes time to work.

  The present invention has been made in order to solve such problems, and an object of the present invention is to provide a honeycomb structure and a mold for forming a honeycomb structure that are lightweight, easy to manufacture, and have vibration absorption and shock absorption functions. It is to provide.

  In order to achieve such an object, the first aspect of the present invention is a honeycomb structure comprising a plurality of cell assemblies each having at least three or more side walls and formed in a polygonal cylindrical shape in plan view. The aggregate of the plurality of cells is integrally formed with a synthetic resin material or a rubber material, and the thickness of the side wall where the cells are not adjacent to each other is the thickness of the side wall where the cells are adjacent to each other. This is a honeycomb structure characterized by being thinner than that.

  A second aspect of the present invention is the honeycomb structure according to the first aspect of the present invention, wherein each of the cells has a regular hexagonal cylindrical shape in plan view.

  According to a third aspect of the present invention, in the second aspect of the present invention, the lower surface of the cell includes a reinforcing support portion that connects an intermediate point between the opposing side walls and the reinforcing support portion, and covers the entire lower surface of the cell. And a honeycomb structure characterized by comprising a thin film bottom.

  According to a fourth invention, in any one of the first invention to the third invention, the thickness of the side wall where the cells are not adjacent to each other is 1 / th of the thickness of the side wall where the cells are adjacent to each other. The honeycomb structure is characterized by being 2.

  According to a fifth aspect of the present invention, a plurality of side walls having at least three surfaces are formed by filling a synthetic resin material or a rubber material into a cavity, and are formed into a polygonal cylindrical shape in plan view. A mold for forming a honeycomb structure for forming a honeycomb structure composed of an aggregate of cells, which has an upper mold and a lower mold in which a cavity having a predetermined shape is formed on a molding surface, and an upper surface, a lower surface, and a side surface. And a plurality of cores that are formed in a polygonal prism shape in plan view and disposed at predetermined positions in the cavity. The groove is formed in a concave shape across the intermediate points of the core, the core is disposed in the lower mold so that a first gap is formed between the adjacent cores, respectively, The groove is located on the same line between adjacent cores And the upper mold is arranged with a second gap continuous with the first gap between the upper surfaces of the respective cores, and a honeycomb structure molding die, It is that.

  According to the present invention, it is possible to obtain a honeycomb structure and a mold for forming a honeycomb structure that are lightweight, easy to manufacture, and have vibration absorption and shock absorption functions.

1 is a perspective view of a honeycomb structure according to a first embodiment of the present invention. FIG. 2 is a plan view showing a partially enlarged view of the honeycomb structure of FIG. 1. It is a perspective view of the honeycomb structure concerning a second embodiment of the present invention. FIG. 4 is a plan view showing a partially enlarged view of the honeycomb structure of FIG. 3. 1. A core (piece) constituting a mold for forming a honeycomb structure of the present invention used for forming a honeycomb structure according to a second embodiment, wherein (a) shows a core (piece) viewed from the upper surface side. (B) is a perspective view of the core (piece) viewed from the bottom side. It is a perspective view which shows the lower mold | type which comprises the metal mold | die for honeycomb structure shaping | molding of this invention. FIG. 7 is a plan view showing a state in which the core (piece) shown in FIG. 5 is arranged in the lower mold shown in FIG. 6. FIG. 3 is a perspective view showing a middle mold constituting the mold for forming a honeycomb structure of the present invention. It is a perspective view which shows the upper mold | type which comprises the metal mold | die for honeycomb structure shaping | molding of this invention. It is a perspective view which shows the press lid which comprises the metal mold | die for honeycomb structure shaping | molding of this invention. FIG. 3 is an exploded cross-sectional view of a mold for forming a honeycomb structure of the present invention. It is sectional drawing of the metal mold | die for honeycomb structure formation of this invention, and shows the state which set the molding material in the pot. It is a partial expanded sectional view of FIG. It is a partial expanded sectional view which shows the state by which the molding material was press-fit in the cavity of a metal mold | die.

The honeycomb structure according to the embodiment of the present invention is formed by, for example, pot transfer molding using the honeycomb structure forming mold according to the embodiment of the present invention.
In the present embodiment, a rubber material (silicone rubber) is employed as an example of the molding material. The molding material may be a resin material in addition to a rubber material.
Hereinafter, an embodiment of a honeycomb structure of the present invention will be described with reference to the drawings, and then an embodiment of a mold for forming a honeycomb structure of the present invention for forming the honeycomb structure will be described with reference to the drawings.

"Honeycomb structure"
The honeycomb structure of the present invention can be exemplified by, for example, two embodiments of the first embodiment and the second embodiment, and will be described in order with reference to the drawings.
In the present embodiment, a so-called honeycomb-shaped honeycomb structure composed of an assembly of a plurality of cells formed in a regular hexagonal cylindrical shape in plan view is employed as an example. Further, the numerical values and the relationships between the dimensions described as examples are merely examples, and may naturally vary depending on the form of the honeycomb structure and the molding material.

[First embodiment]
As shown in FIG. 1, the honeycomb structure 1 of the first embodiment is a plane formed by integrally forming a plurality of cells 2 formed in a regular hexagonal cylindrical shape in a plan view on the same plane. It is an aggregate.
One cell 2 includes six side walls 3 constituting a regular hexagonal cylindrical shape in plan view, and the thickness W1 of the side wall 3b (3) where the cells 2 are not adjacent to each other is such that the cells 2 are adjacent to each other. The side wall 3a (3) is formed thinner than the thickness W2 (see FIG. 2).
In the present embodiment, the thickness W1 of the side wall 3b (3) where the cells 2 are not adjacent to each other is about ½ of the thickness of the side wall 3a (3) where the cells 2 are adjacent to each other.
Moreover, the upper and lower surfaces of each cell 2 are opened. That is, each cell 2 constituting the present embodiment is formed in a cylindrical shape having upper and lower surfaces opened.

The number of cells 2 constituting the honeycomb structure 1 of the present embodiment is a total of 25 cells of 5 vertical × 5 horizontal, and these are arranged in parallel in a predetermined direction and are integrally formed.
In addition, as shown in FIG. 2, the cell size (width between the inner surfaces of the opposite side walls 3) W3 of one cell 2 is selected depending on the usage and durability. That is, the smaller the cell size W3, the higher the shear strength, and the smaller the amount of deflection. In the present embodiment, the cell size W3 is 25.98 mm.
Further, the thickness W2 of the side wall 3a (3) where the cells 2 are adjacent to each other is 1 mm, and the thickness W1 of the side wall 3b (3) where the cells 2 are not adjacent to each other is 1 of the thickness W2 of the side wall 3a (3). / 2 which is 500 μm.

The honeycomb structure 1 of the present embodiment can be used in a single form. For example, a predetermined number of honeycomb structures 1 are prepared, and the cells 2 in each honeycomb structure 1 are adjacent to each other. By connecting the side walls 3b (3) that are not in contact with each other on the same plane, the entire area of the honeycomb structure 1 (area of the plane assembly) can be set to an arbitrary size according to the intended use. .
In this case, since the joined side walls 3b (3) are adjacent to each other, the thicknesses W1 and W1 of the joined side walls 3b (3) are equal to the side walls 3a (3 ) Thickness W2.
In this embodiment, since silicone rubber is used as a molding material, even if a plurality of honeycomb structures 1 are joined together to form a large area, the weight is reduced as compared with a metal honeycomb structure having the same area. can do.
In this way, when bonding a plurality of honeycomb structures 1, for example, a silicone adhesive can be used. In addition, the adhesive according to the molding material of the honeycomb structure 1 is appropriately selected within the scope of the present invention.

  The honeycomb structure of the present invention has at least three or more side walls, and is composed of a collection of a plurality of cells formed in a polygonal cylindrical shape in plan view, all within the scope of the present invention. Therefore, the design can be changed as appropriate.

Silicone rubber is highly elastic and can be greatly deformed by bending, stretching, and contracting compared to general organic rubber. Such a property can also be used for a curved surface shape, for example, an inner member (shock absorbing member) of a helmet where shock absorption is most important.
In addition, since it is possible to impart shock absorption while reducing the weight, the honeycomb structure of the present embodiment can be effectively used in applications other than the inside of the body of an automobile, the body of an aircraft, or the inside. .

Moreover, since the silicone rubber is excellent in transparency, it can be easily colored with a pigment, and a colorful honeycomb structure can be provided. For example, by using various colors such as white, pink, red, and yellow, the size and the number of used honeycomb structures can be easily understood.
The color and geometric pattern of the honeycomb structure can be used as a wall material for homes, for example.This not only enhances decorativeness, but even if children accidentally collide with indoor walls, The shock can be absorbed and relaxed, and a safe indoor space can be provided. Furthermore, since the honeycomb structure also has sound absorption, it can be used as a sound barrier by adjusting the size of the cell 2 and the like.

[Second Embodiment]
Next, the honeycomb structure of the second embodiment of the present invention will be described.
The honeycomb structure 1 of the second embodiment has a regular hexagonal cylindrical shape in plan view, and a plurality of cells 2 having six side walls 3 (3a, 3b) having predetermined thicknesses W1 and W2 on the same plane. About the point which is arranged in parallel and integrally formed, and the operation effect is the same as that of the honeycomb structure 1 of the first embodiment, the description of this point is omitted, and in particular, the unique configuration and the second embodiment The effect will be described in detail.

As shown in FIG. 3 and FIG. 4, the honeycomb structure 2 of the second embodiment has the opposite side walls 3 and 3 (3a, 3b or 3a, 3a or 3b, 3b) on the lower surface of the cell 2, respectively. Three reinforcing support portions 4 that extend across the intermediate points 3c and 3c of the cell 2 and intersect at the center point 6 of the cell 2, and a thin film bottom portion 5 that includes the reinforcing support portion 4 and covers the entire lower surface of the cell 2. Yes.
That is, in the first embodiment, each cylindrical cell 2 constituting the honeycomb structure 1 is constituted by only six side walls 3 and is open in both the vertical direction. In the cell 2 of the structure 2, only the upper surface is opened, and the lower surface is closed by the reinforcing support portion 4 and the thin film bottom portion 5.

As shown in FIG. 4, the reinforcing support part 4 has a substantially rectangular parallelepiped shape with a predetermined thickness, and all the reinforcing support parts 4 have the same shape. Therefore, the crossing angle at the center point 6 of each reinforcing support portion 4 is 60 degrees.
Moreover, since it is comprised in this way, each reinforcement support part 4 of the adjacent cell 2 will be located on the same line.

In this embodiment, the reinforcing support member 4 is not spanned across each corner of the regular hexagon (each vertex of the regular hexagon) in plan view in each cell 2, but is opposed to the opposite side wall 3a (3). The intermediate point 3c of the cell 2 and the intermediate point 3c of the side wall 3b (3) are bridged over, so that the strength of each cell 2 in the horizontal direction (the extending direction of each reinforcing support portion 4) is reinforced. Thereby, even if the honeycomb structure 1 is deformed or buckled, it easily returns to the original state, and the change / restorability is good.
Further, the central point 6 where the reinforcing support member 4 intersects protrudes in a hemispherical shape.

  Further, the reinforcing support portion 4 is a rectangular parallelepiped having a width of 2 mm and a thickness of 1.5 mm, but is not limited thereto.

The thin film bottom 5 includes the reinforcing support 4 and is formed so as to cover the entire lower surface of the cell 2 with a thin film having a predetermined thickness. Thereby, combined with the reinforcing support portion 4 formed on the thin film bottom portion 5, it is possible to improve the strength and recoverability of each cell 2 constituting the honeycomb structure 1.
Such a thin film bottom portion 5 made of silicone rubber has good adsorptivity because it is difficult for bubbles to form between the member and the place where the honeycomb structure 1 of the present embodiment is used, and is suitable for applications having adhesion. . For example, when the honeycomb structure 1 of the present embodiment is used as a floor mat and the honeycomb structure 1 is laid on the floor surface of the flooring, the thin film bottom 5 made of silicone rubber and the floor surface are in close contact with each other (no air enters). Therefore, the frictional resistance between the floor mat and the floor surface becomes high. Therefore, it is possible to prevent a situation where the user falls and is injured due to the floor mat slipping on the floor surface.

[Die for forming honeycomb structure]
Next, an embodiment of a honeycomb structure forming mold used for forming the honeycomb structure of the second embodiment will be described with reference to FIGS.
A mold 10 for forming a honeycomb structure has a rubber formed in a cavity 20 formed by a lower mold 11, a core 12, a middle mold 13 and an upper mold 14 which are divided so as to be detachable in the vertical direction. In order to form a honeycomb structure composed of an assembly of a plurality of cells formed into a regular hexagonal cylindrical shape in a plan view, by pressing and vulcanizing a silicone rubber 16 as a material (molding material) with a plunger 15 Used.
Hereinafter, the mold 10 will be described first with respect to the core 12 which is the main part of the present invention, and then the lower mold 11 to the plunger 15 of the mold will be described in the order of lamination based on the drawings.

[Core]
In this embodiment, the core 12 has an upper surface 12e, a lower surface 12f, and six side surfaces 12a. The main body 12h is formed in a regular hexagonal prism shape in plan view, and the lower surface of the main body 12h. In the center region of 12f, it is comprised with the leg part 12b which protrudes smaller than this lower surface 12f, and is integrally molded (refer FIG. 5).
As shown in FIG. 5 (a), the size (width between the side surfaces 12a, 12a facing each other) T3 of the core (piece) 12 constitutes the honeycomb structure 1 shown in FIGS. A cell that matches the cell size W3 of the two cells 2 is selected.
In addition, the core (piece) 12 of this embodiment is formed and processed with a chromium plating film on a metal material, and is made easy to insert by utilizing the hardness and slipperiness of the metal chromium.

The leg portion 12b is fitted into a concave portion 11a of the lower mold 11 described later, and positions and fixes the core 12 at a predetermined position. In the present embodiment, each corner is chamfered.
The shape and number of the leg portions 12b are not particularly limited and can be changed within the scope of the present invention.

  The upper surface 12e includes three groove portions 12c having a predetermined depth spanned between the intermediate points P and P of the upper sides 12g and 12g of the opposite side surfaces 12a and 12a, and the groove portion 12c The intersecting central point Q has a concave portion 12d made of a hemispherical surface. If the groove part 12c is comprised as mentioned above, each crossing angle of the groove part 12c and the groove part 12c will be 60 degree | times.

  The recess 12d is located at the center of the upper surface 12e of the core 12 and has a diameter S1 of 6 mm and a depth S2 of 1 mm (see FIGS. 5 and 13). By providing the concave portion 12d formed of such a hemispherical surface, when the unvulcanized silicone rubber 16 is press-fitted into the gap (cavity) 20 between the core 12 and the upper mold 14, a gap (cavity) is formed. It fills so that it may flow through the groove part 12c in 20 equally. Thus, since the filling of the silicone rubber 16 is made uniform, the lower surface of the cell 2 constituted by the reinforcing support portion 4 and the thin film bottom portion 5 can be formed with high dimensional accuracy.

In FIG. 5, the groove width T1 of the groove portion 12c in this embodiment is 2 mm, the depth T2 is 1.5 mm, and the reinforcing support member 4 of the cell 2 is formed into a rectangular parallelepiped. The dimensions of the width T1 and the depth T2 can arbitrarily change the width and depth of the groove 12c and the reinforcing support member 4 according to the size of the cell 2. The size T3 of the core 12 in this embodiment is 25.98 mm.
The length (height) H1 of the core 12 is about 10 mm, the length (height) H2 of the substantially trapezoidal leg 12b protruding from the lower surface 12f is 5 mm, and the length H3 of the short side is The long side length H4 is 5 mm and is 16 mm, but is not limited to the dimensions of the present embodiment (see FIGS. 5 and 13).

  In addition, when the thickness W1 and W2 of the side wall 3 of the cell 2 of the honeycomb structure 1 to be formed is changed, the sizes are different without changing the size and structure of the lower die 11, the middle die 13 and the upper die 14. It is only necessary to replace the core (piece) 12. That is, the thickness W1 and W2 of the side wall 3 of the cell 2 can be easily changed by changing the size of the core 12 (changing the core) according to the manufacturing requirements of the honeycomb structure 1. Can be reasonable and economical.

  As described above, even when the thicknesses W1 and W2 of the side walls 3 of the cell 2 are changed, the size of the leg portion 12b is the same, and therefore it is not necessary to change the lower mold 11 (the shape of the recess 11a). Therefore, it is not necessary to prepare a plurality of lower molds 11 having different sizes, and it is rational and economical because the mold 10 is not reconstructed.

  When a plurality of cores (pieces) 12 are inserted into the lower mold 11 one by one in the process of assembling the mold 10, a plurality of cores (pieces) 12 are inserted. The hollow space region 13d of the middle mold 13 that takes the shape of the outer periphery of the medium 13 is disposed so as to be filled.

[Lower mold]
The lower mold 11 is detachable in the vertical direction, and is disposed on the lowermost layer of the mold 10 (see FIG. 11).
As shown in FIG. 6, the lower mold 11 is formed, for example, in the shape of a rectangular plate having a predetermined thickness, and includes a set area 11 b of a core 12 in the center area. The first guide pin 11c and the second guide pin 11d for alignment are projected from the four corners of the upper surface avoiding the set region 11b so that the alignment positions of the molds 10 are not displaced.

The first guide pin 11c functions as an alignment for positioning the lower mold 11, the middle mold 13 and the upper mold 14 at predetermined positions.
The first guide pin 11c is a steel cylinder having a diameter of about 15 mm, and the third fitting hole 13c formed in the upper die 14 of the upper layer via the second fitting hole 13a formed in the middle die 13. It touches to the middle part. Thereby, the lower mold | type 11, the middle mold | type 13, and the upper mold | type 14 can be positioned in a predetermined position.

  The second guide pin 11d is short in the vicinity of the first guide pin 11c, in this embodiment, outside the first guide pin 11c, shorter than the first guide pin 11c, and projects in a conical shape with a tapered tip. The middle mold 13 is double-positioned together with the first guide pins 11c to improve alignment accuracy, and the thickness (W1) of the side walls 3 (3a, 3b) of the cells 2 of the honeycomb structure 1 to be molded , W2) can be improved in dimensional accuracy. In this embodiment, the maximum diameter is made of steel of about 18 mm.

  The shape of the first guide pin 11c and the second guide pin 11d can be changed according to the size of the mold 10 and is not limited to the present embodiment, and the first guide pin 11c or the second guide pin 11d The entire mold 10 may be assembled by extending to the uppermost pot lid 15.

  Further, in the vicinity of the second guide pin 11d, a first fitting hole 11e into which a rod-shaped third guide pin (not shown) protruding from the upper die 14 is fitted is formed at four corners. Yes. As a result, the first guide pin 11c and the second guide pin 11d are aligned, and the alignment when the lower mold 11 to the upper mold 14 are combined is ensured.

  The first guide pin 11c and the second guide pin 11d are not limited to a pin shape but may be a block shape, and the shape of each fitting hole is arbitrary, such as a slit shape, an oval shape, or an oval shape.

The set region 11b represents the outer peripheral contour of the honeycomb structure 1 when all the cores (pieces) 12 are inserted and arranged, and a plurality of concave portions 11a (25 pieces) are arranged in rows at predetermined positions in the set region 11b. ) Is formed.
The concave portion 11a has a hole shape enough to fit the leg portion 12b of the core (piece) 12. When the leg portion 12b is fitted into the concave portion 11a, the core 12 is positioned at a predetermined position.
Specifically, when the entire leg portion 11b of the core (piece) 12 is fitted in the recessed portion 11a, the leg portion is formed so that no gap is generated between the leg portion 11b and the recessed portion 11a. A fitting space corresponding to the shape of 11b is formed.
In the present embodiment, the recess 11a is a recess having a long side of 16 mm, a short side of 5 mm, and a depth of about 6 mm in accordance with the length of the leg portion 11b.
As shown in FIG. 6, the concave portions 11a are arranged in five rows in the vertical and horizontal directions, and are arranged so as to be shifted from one row to another so as to be the same as the center of the cell 2 of the honeycomb structure 1 and the center of the concave portion 11a. Several 25 cells 2 of the body 1 are formed.

  FIG. 7 is a view showing a state in which the leg 11b of the core 12 is inserted and fitted into the recess 11a and set. When 25 cores (pieces) 12 are assembled, the gap (first gap) L2 between the adjacent cores (pieces) 12 is equal to the thickness W2 of the side wall 3a of the cell 2 of the honeycomb structure 1. 1 mm. In other words, the recess 11a is set at a drilling position so that a gap distance that allows the side wall 3a of the cell 2 having the thickness W2 to be formed can be formed between the adjacent cores 12.

  The lower mold 11 of the present embodiment is made of a metal plate having a long side length of 280 mm, a short side length of 200 mm, and a thickness of about 25 mm, and the entire surface including the inner surface of the recess 11a is accurate. Hard chrome plated. Further, since the core 12 is also formed with a chrome-plated film, the core 12 does not move (displace) in the lower mold 11 due to the hardness and slipperiness of the metal chrome. It is firmly fixed. As a result, the press-fitted silicone rubber does not form an unnecessary burr between the core 12 and the lower mold 11.

  Further, the lower mold 11 has handle attachment portions (not shown) on both sides in the short direction of the lower mold 11 so that an operator can assemble and carry the same.

[Medium]
The middle mold 13 is detachable in the vertical direction, and is disposed in a layer above the lower mold 11 to constitute a part of the cavity 20 (see FIG. 11). As shown in FIG. 8, the thickness of the middle mold 13 is 10 mm with the same thickness as the core 12, and is a metal plate formed in a rectangular plate shape having the same dimensions as the lower mold 11. The whole is hard chrome plated.
Further, since the alignment positions of the dies are not shifted, the first fitting hole 13a, the second fitting hole 13b, and the third fitting hole 13c for the guide pin protruding from the lower die 11 are also provided on the upper surface of the middle die 13. A total of 12 holes are drilled in 3 corners.

The first fitting holes 13a are respectively drilled at the four corners for allowing the rod-shaped first guide pins 11c protruding from the lower mold 11 to pass therethrough. Thereby, the middle mold 13 and the lower mold 11 can be fitted and assembled at a predetermined position.
Four second fitting holes 13b are formed in the vicinity of the fitting hole 13a for the second guide pin 11d projecting from the lower mold 11.
Four third fitting holes 13c are drilled in the vicinity of the second fitting hole 13b for a third guide pin (not shown) protruding from the upper mold 14. Thereby, when the lower mold 11 to the upper mold 14 are combined with the first guide pin 11c and the second guide pin 11d, the alignment of the entire mold including the middle mold 13 is ensured.

  The middle mold 13 is a hollow mold having a contour of the entire outer periphery of the side wall of the main body 12h of each core 12 disposed on the outer periphery when a predetermined number of cores 12 are disposed on the lower mold 11. A space area (set area) 13d is provided. This space region 13d is the entire outer periphery of the side surface of the main body 12h of each core (piece) 12 arranged on the inner periphery and outer periphery of the space region 13d when the core (piece) 12 is accommodated in the space region 13d. The gap L1 having a predetermined interval is formed over the entire circumference (see FIGS. 13 and 14). The gap L1 is formed at a predetermined interval over the entire height direction of the side wall 12a. The gap L1 is a gap for forming the thickness W1 (5 mm) of the side wall 3b of the cell 2.

The depth of the space region 13d (depth in the vertical direction) is the main body 12h of the core 12 that is disposed so as to protrude from the upper surface of the lower mold 11 in a state where the legs 12b are fitted in the recesses 11a of the lower mold 11. It is formed deeper than the height (vertical height) (see FIGS. 13 and 14). With this configuration, when the middle mold 13 is disposed at a predetermined position, a predetermined gap (second gap) is formed between the upper edge 13e of the space area 13d of the middle mold 13 and the upper surface 12e of the main body 12h of the core 12. ) S3 is formed.
In other words, this gap (second gap) S3 is arranged so that the lower surface of the upper die 14 comes into contact with the upper surface of the middle die 13 when the upper die 14 is placed after the middle die 13 is placed. It becomes a gap with a constant depth over the entire width of the space region 13d formed between them. Further, this gap (second gap) S3 determines the thickness of the thin film bottom 5 of the honeycomb structure 1, and the design can be appropriately changed according to the required thickness of the thin film bottom 5 and is within the scope of the present invention. Is within.

  Each of the wall surfaces of the first fitting hole 13a, the second fitting hole 13b, and the third fitting hole 13c of the middle mold 13 is also chrome plated.

The middle mold 13 has handle attachment portions (not shown) on both sides of the middle mold 13 in the short side direction so that an operator can assemble and carry it.
In the present embodiment, the middle mold 13 is used together with the core 12 to mold the side wall 3 of the cell 2 formed in a polygonal cylindrical shape in plan view. However, the lower mold 11 and the core 12 are used. When the cavity 20 is formed with the upper mold 14 and the side wall 3 of the cell 2 can be formed, it can be omitted.

[Upper type]
The upper die 14 is detachable in the vertical direction, and is disposed in a layer above the middle die 13 (see FIG. 11). As shown in FIG. 9, a metal plate formed in a rectangular plate shape having the same dimensions as the middle mold 13 is entirely plated with hard chrome. Since the upper mold 14 has a structure of a pot 14, a runner 14d, and a gate 14e, which will be described later, the upper mold 14 is made thicker than the plate thickness of the lower mold 11 and the middle mold 13 that do not have such a structure. Yes.

The upper die 14 is also provided with fitting holes 14a through the first guide pins 11c protruding from the lower die 11 at the four corners for alignment.
9 shows only the upper surface (on the plunger 15 side) of one surface of the upper die 14, and therefore, guide pins not shown in the drawing are formed on the lower surface (middle die 13 side) of the upper die 14. ing. This guide pin has a substantially conical shape and is rounded at the tip, and has a diameter of about 15 mm and is made of a steel rod for positioning with the lower die 11. Thereby, the upper mold | type 14 contact | abuts with the middle mold | type 13, and can be assembled with exact dimensional accuracy.

  The upper mold 14 is formed with a concave and rectangular pot 14c into which unvulcanized silicone rubber 16 is charged. The pot 14c is a rectangular depression whose bottom area has a length and width of 130 mm × 180 mm and a depth of 15 mm. In addition, it is not limited to the volume dimension of this pot 14c, It can change with the magnitude | size of the projection area of the honeycomb structure 1. FIG.

As shown in FIGS. 12 to 14, the pot 14 c is formed with a runner 14 d of a through hole and a gate 14 e for filling the cavity 20 with a rubber material. The center of the runner 14d is formed at the same position as the center of the core (piece) 12 arranged in the lower mold 11, and has the same number (25) of the arranged cores (pieces) 12. Yes.
Further, as shown in FIG. 13, the runner 14d is inclined by approximately 10 degrees from the upper surface (honeycomb pot 15 side) opening surface of the pot 14c toward the lower surface (medium mold 12 side) to a midway position of the pot 14c. It is a taper groove | channel (sectional view trapezoid shape). On the tip side, a cylindrical gate 14e having the same center as that of the runner 14d and having a smaller step is provided.
As an example, the length of the runner 14d in this embodiment is 15 mm, and the length of the gate 14e is 5 mm.

  By making the runner 14d into a taper groove (draft angle) in this way, the silicone rubber 16 can be smoothly press-fitted into the cavity 20, and the pot burr in the runner 14d that has become unnecessary after vulcanization can be easily taken out. be able to. In addition, the gate 14e has substantially the same diameter as the concave portion 12d at the center of the core 12 so that the speed at which the rubber material flows in does not vary slightly. This can prevent jetting when the speed is too fast, or flow marks (stripes) when the speed is too slow.

  The upper die 14 has handle attachment portions (not shown) on both sides in the short direction of the upper die 14 so that an operator can assemble and carry the handle.

[Plunger]
The plunger 15 is detachable in the vertical direction and is arranged in a layer above the upper mold 14 (see FIG. 11). The plunger 15 is a metal plate having a predetermined thickness formed in the shape of a rectangular plate having the same size as the upper mold 14 and is entirely plated with hard chrome. As shown in FIG. 10, the plunger 15 also has four rod-shaped guide pins 15 a protruding one by one at the four corners for alignment. Thereby, when the plunger 15 is pressed from a compression molding machine (press machine), it can prevent that a position with respect to the upper mold | type 14 shifts | deviates.
Further, the guide pin 15a passes through the second fitting hole 13a formed in the middle die 13 to the middle part of the fitting hole 14a formed in the upper die 14 of the upper layer, and thereby, from the lower die 11 The middle mold 13 and the upper mold 14 can be fitted and assembled at predetermined positions.

  The plurality of guide pins 15a are steel rods having a diameter of about 15 mm, and the tip circumferences of the guide pins 15a are rounded. However, these shapes can be changed according to the size of the mold. The present embodiment is not limited to this.

  Further, on the lower surface of the plunger 15 (on the upper die 14 side), a convex portion 15b having a volume substantially the same as the pot 14c of the upper die 14 is formed as a step. The convex portion 15b is provided to press the unvulcanized silicone rubber 16 put into the pot 14c after the cavity 20 is assembled (see the press indicated by the arrow in FIG. 12) and press-fit it into the runner 14d. ing. Therefore, the height of the convex portion 15b is set to 14 mm, which is substantially the same as the depth 15mm of the pot 14c. Pot burrs that are unnecessary for the formation of the honeycomb structure 1 are formed in the gap of 1 mm of the difference. By pulling out the burrs, the operator easily takes out the pot burrs in the runner 14d after forming. be able to.

  The plunger 15 has handle attachment portions (not shown) on both sides in the short direction of the plunger 15 so that an operator can assemble and carry the handle.

  In the present embodiment, the mold for forming the honeycomb structure of the second embodiment will be described. However, the mold has a plurality of side walls of at least three surfaces and a plurality of polygonal cylindrical shapes in a plan view. A honeycomb structure forming mold for forming a honeycomb structure formed of an aggregate of cells is within the scope of the present invention, and can be appropriately changed in design. Specifically, the core 12 and the middle mold 13 may be configured to match the planar view shape of the cell to be molded.

[Manufacturing method of honeycomb structure]
In the present embodiment, the honeycomb structure 1 of the present invention is manufactured by a pot transfer molding method using a press machine (not shown). FIG. 11 shows a state in which the mold 10 is separated, and FIG. 12 shows a state in which these are assembled in a stack from the lower side to the upper side in the vertical direction.
11 to 12, the guide pins 11c, 11d, 15a and the corresponding fitting holes 11e, 13a, 13b, 13c, 14a, 14b when the mold 10 is assembled are omitted. Is not shown.

  First, as shown in FIG. 7, the leg 12 b of the core 12 is fitted into all the recesses 11 a of the lower mold 11, and the core 12 is disposed on the lower mold 11.

Next, a cavity 20 for forming the honeycomb structure 1 is formed by sequentially combining the molds 10 excluding the plunger 15 into the stack. As shown in FIG. 13 (an enlarged view of the space portion of the cavity 20 in FIG. 12), the gap distance W2 between the cores 12 in the cavity 20 is the thickness of the side wall 3a of the cell 2 of the honeycomb structure 1. The gap distance W1 at which the cores 12 are not opposed to each other is 500 μm, which is half of the gap distance W2.
Further, a gap S <b> 3 (second gap) is provided between the upper surface of the core 12 and the lower surface of the upper mold 14. By providing such a gap (second gap) S3, the thin film portion 5 can be formed. Further, the core 12 and the upper mold 14 do not buffer each other during assembly. In this case, the distance of the gap (second gap) S3 is 100 μm, but is not limited to this and can be determined by the size of the cavity 20.

Next, as shown in FIG. 12, after the cavity 20 is formed, the unvulcanized silicone rubber 16 is put into the pot 14 c of the upper mold 14. Here, the amount of the silicone rubber 16 that is added is slightly larger than the equivalent amount so that there is no shortage of the amount for forming the honeycomb structure 1 (cell 2). In this case, a portion larger than the amount for forming the honeycomb structure 1 (cell 2) becomes a pot burr.
Even if some pot burrs are generated, the manufacturing cost of the honeycomb structure 1 can be reduced because the silicone rubber itself is inexpensive. The silicone rubber will be described below.

By adjusting the hardness of the silicone rubber 16, the flexibility when the honeycomb structure 1 is used as a cushioning material or a cushioning material can be changed. For example, when the addition amount of the silica-based powder filler is large, the rubber hardness is high (hard), and conversely, when the addition amount is small, the rubber hardness is low (soft). In addition, when making rubber hardness low (soft), the method of adding silicone type oil may be used.
The silicone rubber 16 does not have a toxic substance in its component structure, is chemically stable and physiologically inert, and its properties do not change. Therefore, various types of silicone rubber 16 using the safe honeycomb structure 1 are used. Product is possible.

Further, since the silicone rubber 16 is excellent in transparency, it is possible to provide a product using the colorful honeycomb structure 1 which is easily colored with a pigment and is colorful. For example, since the color tone can be adjusted by using coloring colors such as white, pink, red, and yellow in combination with pigments specifically for silicone rubber, the size and number of honeycomb structures can be seen at a glance.
Thereby, it can be used not only for a cushioning material inside a body such as an automobile or an aircraft that is required to be lightweight, but also for various decorations using various colors together with the geometric pattern of the cell wall 3.

  Next, as shown in FIG. 12, it is lowered in a compression molding (pressing) machine (not shown) and pressed in the plunger 15 (indicated by “press” and an arrow symbol in the drawing) to heat in the pot 14c. The softened unvulcanized silicone rubber 16 is pressed into the cavity 20 from the runner 14d through the gate 14e. Further, the silicone rubber 16 from the gate 14 e flows evenly in the cavity 20 formed by the core 12 and the upper die 14 after being injected into the concave portion 12 d formed of the hemispherical surface of the core 12. The area filled with the silicone rubber 16 is hatched (see FIG. 14).

  When the silicone rubber 16 reaches the entire area in the cavity 20, the unvulcanized silicone rubber 16 in the cavity 20 is heated and vulcanized. Thereby, the cell 2 formed by the columnar side wall 3, the thin film bottom 5 and the reinforcing support member 4 is formed in a state where the number (25) of the arranged cores (pieces) 12 is set (coupled), One honeycomb structure 1 is completed.

  The die 10 for forming a honeycomb structure and the manufacturing method of the present embodiment are an embodiment for forming the honeycomb structure 1 of the second embodiment, but the first embodiment shown in FIGS. It can also be used when the honeycomb structure 1 is formed. When the honeycomb structure 1 of the first embodiment is formed, the groove portion 12c provided on the upper surface of the core 12 is unnecessary, and therefore a core having a flat upper surface can be employed. In addition, you may shape | mold the honeycomb structure 1 of 1st embodiment using the metal mold | die 10 and manufacturing method of this embodiment as it is, and in this case, the reinforcement support member 4 shape | molded on the lower surface of each cell 2, and a thin film Since the bottom portion 5 is unnecessary, the portion may be separated and removed as a burr after demolding.

  In addition, transfer molding does not require special equipment, and the cost of silicone rubber is low. Therefore, even if some unnecessary burrs are generated in the molded product, the manufacturing cost of the honeycomb structure is reduced overall. Can be suppressed.

DESCRIPTION OF SYMBOLS 1 Honeycomb structure 2 Cell 3 Side wall 4 Reinforcement support member 5 Thin film bottom part 6 Cell center point 10 Mold 11 Lower mold 12 Core (piece)
13 Middle mold 14 Upper mold 15 Plunger 16 Silicone rubber 20 Cavity

Claims (5)

A honeycomb structure comprising a plurality of side walls of at least three surfaces and comprising an aggregate of a plurality of cells formed in a polygonal cylindrical shape in plan view,
The assembly of the plurality of cells is integrally formed with a synthetic resin material or a rubber material,
The honeycomb structure according to claim 1, wherein a thickness of the side wall where the cells are not adjacent to each other is thinner than a thickness of the side wall where the cells are adjacent to each other.   The honeycomb structure according to claim 1, wherein each cell has a regular hexagonal cylindrical shape in plan view. The lower surface of the cell is
A reinforcing support for connecting the intermediate points of the opposing side walls;
The honeycomb structure according to claim 2, comprising a thin film bottom portion including the reinforcing support portion and covering the entire lower surface of the cell.   The honeycomb structure according to any one of claims 1 to 3, wherein a thickness of the side wall where the cells are not adjacent to each other is ½ of a thickness of the side wall where the cells are adjacent to each other. A honeycomb made of an aggregate of a plurality of cells formed into a polygonal cylindrical shape in a plan view, having a plurality of side walls of at least three or more by filling a synthetic resin material or rubber material into a cavity and molding A mold for forming a honeycomb structure for forming a structure,
An upper mold and a lower mold formed by forming a cavity of a predetermined shape on the molding surface;
A plurality of cores having an upper surface, a lower surface, and side surfaces, formed in a polygonal prism shape in plan view, and arranged at predetermined positions in the cavity;
The upper surface of the plurality of cores is configured to include a groove formed in a concave shape across the midpoints of the opposing sides,
The cores are arranged in the lower mold such that a first gap is formed between adjacent cores, and the groove is positioned on the same line between the adjacent cores. Arranged,
The honeycomb mold forming die, wherein the upper die is disposed with a second gap continuous with the first gap between the upper surfaces of the respective cores.

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