JP3122521B2 - Honeycomb panel and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb panel made of a metal plate such as stainless steel or titanium. Usually, these honeycomb panels include a honeycomb core sandwiched between a pair of face sheets. The honeycomb core is generally corrugated or hexagonal, and is fixed to the face sheet by bonding or other means. Such a structure is very light and excellent in strength. This type of panel is generally used for aircraft, ships, vehicles and the like.

[0002]

2. Description of the Related Art FIG. 8 is an explanatory view of a conventional honeycomb panel, and FIG. Conventional honeycomb core 3
Is a corrugated sheet in which corrugated grooves are formed by pressing or stretching, etc. The honeycomb core 3 is sandwiched between two face sheets 2a and 2b, and the face sheets 2a and 3 or 2b and 3
Are joined by an adhesive or a wax material.

FIGS. 8 (B) and 8 (C) are diagrams for explaining the problems of the conventional honeycomb panel. First, the honeycomb core 3 is joined to the face sheet 2b. Then face sheet 2a
To the honeycomb core 3. But the error of the error or by welding 4 positioning on the molding of corrugated grooves, FIG. 8 (B), for example different internal angle theta is the inner angle theta ₁ regular theta ₂
When the corrugation 13 is formed, since the corrugation 13 is different in height from the regular corrugations 12 and 14, a gap is formed between the corrugation 13 and the face sheet 2a, and the weld 5 is formed. Difficult to do.

In FIG. 8C, when the face sheet 2a is pressed downward, the corrugation 13 and the face sheet 2a are welded to each other.
Can be joined by the regular wave forms 12 and 14
Is distorted, and it becomes difficult to join the regular corrugations 12, 14 and the face sheet 2a. Also the D _2, and the no honeycomb panel regular thickness D ₁ is obtained thickness of the honeycomb panel. For this reason, welding defects are likely to occur in the conventional honeycomb panel, and the dimensions of the honeycomb panel are likely to have insufficient accuracy.

Furthermore, although described in detail later, the wave plate of the honeycomb core to L direction bending is difficult, conventionally, honeycomb panels 2-dimensional or 3-dimensional curved surface shape can not be manufactured with rather Problems was there.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a honeycomb panel which can be easily manufactured, has no welding defects, and has excellent dimensional accuracy, and a method of manufacturing the same. The present invention also discloses a honeycomb panel having a two-dimensional or three-dimensional curved surface and a method for manufacturing the same.

[0007]

FIG. 1 shows the present invention.
It is an explanatory view of a honeycomb panel to which is applied . The honeycomb panel 1 of the present invention includes two face sheets 2a and 2b,
And a honeycomb core 3 sandwiched between two face sheets. The honeycomb core 3 has a large number of tubes 3-1,.
3-m, a large number of tubes 3-1 to 3-m are closely arranged in parallel with each other, and the respective tubes are joined to each other along a contact line by, for example, welding 6. And

[0008] FIG. 2 is an explanatory view of an example of a method for manufacturing a honeycomb panel according to claim 2 of the present invention. In FIG. 2A, the (n + 1) th tube 3n + 1 is arranged in close contact with one of the face sheet 2b and the nth tube 3n of the honeycomb panel, and the laser beam L ₁ extends along the contact line between the tube 3n + 1 and the face sheet 2b.
To join the pipe 3n + 1 and the face sheet 2b (welding 7). The laser beam L ₂ is irradiated with welding the pipe 3n and tube 3n + 1 along the contact line of the tube 3n and tube 3n + 1 (welding 6). These welds 6 and 7 are connected to pipes 3-1 to 3-
m. The welding 6 may be performed alternately with the welding 7, or the welding 6 may be performed after the welding 7 of all pipes is completed.

In FIG. 2B, the other face sheet 2a is joined to a joined body in which one face sheet 2b and a large number of tubes 3-1 to 3-m are joined. This joint is made of pipes
It can be performed by forming a weld 8 by a laser beam or other welding means W from the face sheet 2a side along the contact line between the 3-m and the face sheet 2a.

FIG. 3 is an explanatory diagram of the reflection characteristics of a laser beam on a metal surface. In FIG. 3A, a laser beam having a long wavelength shows a high reflectance to a metal surface. In FIG. 3 (B), when a long-wavelength laser beam is applied to the narrow groove of the metal,
The laser beam repeatedly reflects toward the back, and gradually increases the energy density. In the method of FIG. 2, the laser beam L ₁ and the face sheet 2b and the tube 3-1 to 3-m,
Further, each of the tubes 3-1 to 3-m are welded by the laser beam L _2.

At this time, the face sheet 2b and the pipes 3-1 to 3-3 are used.
-M and the contact between the tubes 3-1 to 3-m are shown in FIG.
A narrow metal groove similar to that shown in (B) is formed. The laser beam L ₁ or L ₂ irradiated to the repeatedly reflected towards the back naturally to increase gradually energy density, to weld the contact portion. For this reason, in the present invention, accurate focusing of the laser beam is not necessary, and therefore, the welding 7 and the welding 6 can be reliably formed at a high speed.

Further, in the method shown in FIG. 2, by controlling the irradiation energy of L ₁ and L ₂ , the welding energy of the weld 7 can be accurately controlled. For this reason, it is possible to manufacture a honeycomb panel with a beautiful front surface having no welding marks on the back surface of the face sheet 2b.

In FIG. 2, tubes 3 (3-1,..., 3-m)
For example, the outer diameter can be aligned with high accuracy by empty drawing using a die. For this reason, no special positioning jig is required for positioning the weld 7, and a gap is generated between the face sheet 2 a and the pipe 3 when welding the other face sheet 2 a in FIG. There is no. Therefore, welding of the face sheet 2a and each pipe 3 is reliable, and no welding defects occur in this welding.

FIG. 4 shows the face sheets 2a and 2b and the pipe 3-
FIG. 3 is an explanatory view of a honeycomb panel in which reinforcing pipes 9 are further arranged in gaps of 1,..., 3-m. In the honeycomb panel of FIG. 2B, since the mutual interval between the welds 7 and the mutual interval between the welds 8 are large, for example, when the face sheets 2a and 2b are thin, the surface of the honeycomb panel is easily sticky. By using the reinforcing pipe 9 of FIG. 4, this sticking can be prevented. Reinforcement pipe 9 and face sheet or pipe 3-
Each of the contact portions with 1 to 3-m forms a narrow groove. For this reason, the reinforcing pipe 9 and the face sheet or the reinforcing pipe 9 are used.
The tubes 3-1 to 3-m can be easily welded using a laser beam for the same reason as described with reference to FIGS. The present invention also includes the honeycomb panel of FIG.

FIG. 5 is an explanatory view of a honeycomb panel to which claims 2 to 3 of the present invention are applied . At this time, the honeycomb panel has two curved face sheets 20a and 20b having a two-dimensional or three-dimensional curved surface, and a honeycomb core sandwiched between 20a and 20b, and the honeycomb cores are closely and parallel to each other. The contact portions are formed by a large number of straight pipes or bent pipes 30-1,..., 30-m joined to each other.

FIG. 5A shows a large number of straight pipes 30-1,.
FIG. 5B is an example of a honeycomb panel having a two-dimensional curved surface formed by 0-m and two face sheets 20a and 20b having a two-dimensional curved surface. ,
, 30-m, and a honeycomb panel having a three-dimensional curved surface formed by two face sheets 20a, 20b having a three-dimensional curved surface.

For example, when the honeycomb panel shown in FIG. 5B is formed, a large number of curved tubes 30-1, bent in the same shape.
..., 30-m are used. These curved pipes can be formed by bending a straight pipe. For example, a flexible pipe formed by spirally winding a narrow metal band can be easily bent in two or three dimensions. Therefore, it is suitable as the bending pipes 30-1..., 30-m of the present invention.

In the third aspect of the present invention, the (n + 1) th flexible pipe 30n + 1 is used by using this flexible pipe.
Is arranged in close contact with one curved sheet 20b of the honeycomb panel and the n-th flexible tube 30n, and irradiates a laser beam along the contact curve between 30n + 1 and the curved face sheet 20b from between 30n + 1 and the curved face sheet 20b. 70 between the curved face sheet 20b and 30n + 1 and the flexible tubes 30n and 30n +
Flexible tubes 30n and 30n that are irradiated from the first side by irradiating a laser beam along a contact curve between 30n and 30n + 1
+1 and a large number of flexible pipes 30-
1,..., 30-m are successively formed to form a joined body of the curved face sheet 20b and the honeycomb core made of a large number of flexible tubes, and a large number of flexible tubes forming the honeycomb core of the joined body. 30-1 ..., 30-
m sequentially weld the curved face sheet 20a from the other side 8
Thus, a honeycomb panel having a two-dimensional or three-dimensional curved surface shape is manufactured.

FIG. 5C shows an example of a flexible tube subjected to a two-dimensional or three-dimensional bending process used at this time. The flexible pipe is easily bent in two dimensions or three dimensions, but the flexible pipe bent in FIG.
When 0, 70, and 80 are applied, the flexible pipe is given rigidity in a bent shape by linear welding 60, 70, and 80 along the length direction of the flexible pipe, and gives rigidity to the honeycomb panel. It will be. When the flexible pipe 30 is subjected to reinforcement welding 10 in advance or along the length of the flexible pipe in a state where the honeycomb panel is bent during assembly, the rigid pipe 30 can be given even greater rigidity. .

The honeycomb panel of the present invention may have, on one or more side surfaces thereof, a side plate for joining with another honeycomb panel. The side plate may have an L-shaped or U-shaped cross section, a laterally convex shape, or a laterally concave shape.

A large-area honeycomb structure is manufactured by joining honeycomb panels to each other. FIG.
It is an example of the method for bonding honeycomb panels described in No. 8072. In the joining of the honeycomb panels 1 and 1 'in FIG.
The face sheets 2a and 2a 'are welded, and the face sheets 2b and 2b' are welded. However, since the face sheets 2a and 2a 'are thin, mutual butt welding is not easy.

In FIG. 9 (B), 2a and 2a 'sandwich the insert material 11 having a height greater than the thickness of the honeycomb panel.
And 2b and 2b 'are welded. In the method of FIG. 9 (B), welding is easy because the insert material 11 is used. However, since the height of the insert material 11 is larger than the thickness of the honeycomb panel, the joints rise and the appearance of the honeycomb structure is improved. Is impaired. Further, all of the methods shown in FIG. 9 involve joining of the face sheet only, and the honeycomb cores are not joined to each other, so that there is a problem that the joining strength is weak.

FIG. 6 shows an example in which side plates 15a, 15b, 15c, and 15d each having an L-shaped cross section are arranged on four side surfaces of a honeycomb panel. The side plates 15a and 15c are joined by welding to the end faces of a large number of tubes forming the honeycomb core. The side plates 15b and 15d are joined to the outer surfaces of the tubes 3-1 and 3-m by welding.

FIG. 7 is an explanatory view of the operation of the side plate of the honeycomb panel having the side plate 15. As shown in FIG. FIG. 7A shows an example of an L-shaped side plate.
And the side plate 15 'are welded. According to FIG. 7A, the honeycomb panels 1 and 1 ′ can be joined to each other with sufficient strength via the beam 16.

FIG. 7B is an explanatory view of the joining of a honeycomb panel having side plates having a U-shaped cross section. In this honeycomb panel, the U-shaped side plates 15, 15 'are fitted to the beams 16, and the honeycomb panels 1 and 1' can be easily joined via the beams 16. When the side plate 15 and the beam 16 are welded and the side plate 15 'and the beam 16 are welded, the honeycomb panels 1 and 1' can be firmly joined via the beam 16.

FIG. 7C shows a honeycomb panel 1 ′ having a side plate 5 ′ having a laterally concave cross section and a honeycomb panel 1 ′ having a side plate 15 ′ having a laterally convex cross section.
This is an example in which the projections are fitted and joined. At this time, if the side plates 15 and 15 'are welded to each other after the fitting, the honeycomb panels 1 and 1' can be more firmly joined.

FIGS. 6 and 7 show the honeycomb panel of the present invention.
As described above, one or more side surfaces thereof may be provided with a side plate 15 having an L-shaped, U-shaped, laterally convex or laterally concave cross section for joining with another honeycomb panel. The present invention also includes a honeycomb panel in which these side plates are further arranged on all side surfaces (four side surfaces) of the honeycomb panel.

[0028]

Embodiments of the present invention will be described below in detail with reference to the drawings. The pipe forming the honeycomb core used in the embodiment is made of stainless steel as shown in FIG. 6 and has a thickness of 0.5 mm and a diameter of 22 mm. The face sheet is also made of stainless steel and has a thickness of 2 mm. The side plate is made of L-shaped stainless steel having a thickness of 6 mm, and has a convex portion corresponding to the inner diameter of the pipe by etching on the fitting surface of the pipe, and has a height of 1 mm.

As shown in FIG. 2, when welding the pipes and welding the pipe to the face sheet, a laser beam is applied to a contact portion between them. At this time, a YAG laser was used as the laser, and a lens having a focal length of 300 mm was used. The output of the laser was a continuous wave oscillation of 250 W, and the processing speed was 1 m / min. The same laser was used for joining the pipe and the side plate. A compression breaking test was performed using such a honeycomb panel. As a result, a strong honeycomb panel was obtained without breakage of the joined portion or the honeycomb panel.

[0030]

The present invention provides a honeycomb panel and a method for manufacturing the same. Since narrow gap laser welding is used for joining, precise focusing and position control required for conventional laser welding are provided. The machining time is short, there are no welding defects, and the heat affected layer is small, so it has excellent mechanical properties, and it can be used in high-temperature places that could not be used conventionally, making it a very strong honeycomb You can get a panel. Also, the manufacturing process for using pipes for the core,
The manufacturing time can be greatly simplified, and thus an inexpensive honeycomb panel can be provided. Further, the shape of a honeycomb panel having a two-dimensional curved surface or a three-dimensional curved surface can be easily formed. Further, by adding the side plate to the end face of the panel, it is possible to easily join and join the honeycomb panels to each other or to another member.

[Brief description of the drawings]

1 is an explanatory view of a honeycomb panel of the present invention, FIG. 2 is an explanatory view of a method for manufacturing a honeycomb panel of the present invention, FIG. 3 is an explanatory view of characteristics of a laser beam, and FIG. 4 is an explanatory view of another honeycomb panel of the present invention. FIGS. 5 and 5 are explanatory views of a honeycomb panel having a curved surface of the present invention, FIG. 6 is an explanatory view of a honeycomb panel of the present invention having a side plate, FIG. 7 is an explanatory view of the operation of a side plate, and FIG. FIG. 9 is an explanatory view of a conventional connection method of a honeycomb panel.

[Explanation of symbols]

1 (1 '): honeycomb panel, 2 (2a, 2b): face sheet, 3: honeycomb core, 3-1 to 3-m: tube forming honeycomb core, 4: welding, 5: welding,
6: welding, 7: welding, 8: welding, 9: reinforcing pipe,
10: welding for reinforcement, 11: insert material, 1
2: corrugated groove, 13: corrugated groove, 14: corrugated groove, 15
(15a, 15b, 15c, 15d, 15 '): side plate,
20a (20b): face sheet, 30-1 to 30-
m: tube forming a honeycomb core, 60: welding, 70: welding, 80: welding.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Atsushi Sugihashi 5-10-1 Fuchinobe, Sagamihara City, Kanagawa Prefecture Inside Nippon Steel Corporation Electronics Research Laboratory (72) Inventor Akira Ishibashi 4-1-36 Namiki, Sagamihara City, Kanagawa Prefecture JP-A-60-174637 (JP, A) JP-A-62-169626 (JP, A) JP-A-59-145135 (JP, A) JP-A-56-118847 (JP, A) JP-A-5-123774 (JP, A) JP-A-48-36173 (JP, U) JP-B-44-24288 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B21D 47/00

Claims (3)

(57) [Claims] 1. A two-dimensional metal plate having a three- dimensional curved surface.
That the curved face sheets and and a honeycomb core sandwiched by two curved surfaces face sheets, honeycomb core metal bends multi number of contact portions disposed closely parallel to each other are welded to each other characterized in that it is more formed on a three-dimensional curved surface shape honeycomb panel. 2. The (n + 1) -th tube is disposed in close contact with one face sheet of the honeycomb panel and the n-th tube,
From (n + 1) th tube and the face sheet, (n +
1) Welding of the (n + 1) th tube and the face sheet by irradiating a laser beam along the contact line between the (n + 1) th tube and the facesheet, and the nth tube and the (n + 1) th tube side The welding between the pipes performed by irradiating a laser beam along the contact line between the n-th pipe and the (n + 1) -th pipe is sequentially performed for a large number of pipes, and the welding is performed on the face sheet and the multiple pipes. A method for manufacturing a honeycomb panel, comprising: forming a joined body, and joining the other face sheet to a large number of tubes forming a honeycomb core of the joined body. 3. The (n + 1) th flexible pipe is disposed in close contact with one of the curved face sheets of the honeycomb panel and the nth flexible pipe, and the (n + 1) th flexible pipe and the curved facesheet are arranged between the (n + 1) th flexible pipe and the curved face sheet. Welding the (n + 1) th flexible tube and the curved face sheet by irradiating a laser beam along a contact curve between the (n + 1) th flexible tube and the curved face sheet;
The welding of the flexible pipes to each other by irradiating a laser beam along the contact curve between the n-th flexible pipe and the (n + 1) -th flexible pipe from the (n + 1) -th flexible pipe side is performed by a large number of Forming a bonded body composed of the curved face sheet and a large number of flexible pipes by sequentially performing the flexible pipe, and bonding the other curved face sheet to the multiple flexible pipes forming the honeycomb core of the bonded body. A method for manufacturing a honeycomb panel having a two-dimensional or three-dimensional curved surface.