JP7131371B2 - Honeycomb structure manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a honeycomb structure.

Conventionally, various studies have been made on a method of manufacturing a honeycomb structure for the purpose of weight reduction.

JP-A-2002-066672 JP 2012-71514 A JP-A-2004-322369 Japanese Patent No. 5586708 JP-A-2002-35874 Japanese Patent No. 4137658 Japanese Patent No. 5479489

On the other hand, a sandwich structure has also been considered, but in the case of aiming at weight reduction, useless members have been generated.

Patent Literature 1 discloses a honeycomb structure formed by folding a sheet material. In Patent Document 1, slits having preset dimensions are formed at predetermined positions of a sheet material in a zigzag pattern at preset intervals, and a sheet material is folded in a direction substantially orthogonal to the slits. It is disclosed that concave lines and convex lines are formed. Then, it is disclosed that the slit is used as a reference for mountain folds and valley folds, and the concave and convex lines are used as references. However, Patent Literature 1 does not consider damage to the bent portion, and does not describe this point.

The present invention has been made in order to solve such problems. To provide a method for manufacturing a connecting part in which honeycomb parts are connected so as not to crack.

A method for manufacturing a honeycomb structure according to an aspect of the present invention is a method for manufacturing a honeycomb structure having a plurality of hexagonal cylinders in a honeycomb shape by forming slits in one metal plate and bending the metal plate. The slits are formed in parallel and alternately in the metal plate so that the hexagonal cylinders and connecting portions connecting the hexagonal cylinders are formed, and the connecting portions are formed at the opening ends of the hexagonal cylinders. Mountain folds and valley folds are repeated so as to connect one side and the other side alternately, and the bending inside R at the connecting portion is made greater than the plate thickness, and in the bending forming, in a state where there is no negative angle or buckling Characterized by bending. With such a configuration, it is possible to provide a method for manufacturing a honeycomb structure that is lightweight, has high strength, is low in cost, and is capable of high-speed production.

INDUSTRIAL APPLICABILITY According to the present invention, there is provided a method for manufacturing a honeycomb structure that is lightweight, has high strength, is low in cost, and can be produced at high speed.

FIG. 4 is a process perspective view illustrating a method for manufacturing a honeycomb structure according to the embodiment; FIG. 4 is a process perspective view illustrating a method for manufacturing a honeycomb structure according to the embodiment; FIG. 4 is a process perspective view illustrating a method for manufacturing a honeycomb structure according to the embodiment; FIG. 4 is a process perspective view illustrating a method for manufacturing a honeycomb structure according to the embodiment; FIG. 4 is a process perspective view illustrating a method for manufacturing a honeycomb structure according to the embodiment; (a) and (b) are cross-sectional views illustrating connecting portions of the honeycomb structure according to the embodiment. (a) to (c) are diagrams exemplifying restraining methods used when bending a metal plate. FIG. 3 is a diagram illustrating a honeycomb structure manufactured by crimping corrugated sheets by pressing.

BEST MODE FOR CARRYING OUT THE INVENTION The best mode for carrying out the present invention will be described below with reference to the accompanying drawings. However, the present invention is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings are simplified as appropriate.

(embodiment)
A honeycomb structure and a method for manufacturing a honeycomb structure according to an embodiment will be described. First, a method for manufacturing a honeycomb structure according to an embodiment will be described. After that, the manufactured honeycomb structure will be described. 1 to 5 are process perspective views illustrating a method for manufacturing a honeycomb structure according to an embodiment. The method for manufacturing a honeycomb structure of the present embodiment is a method for manufacturing a honeycomb structure having a plurality of hexagonal cylinders in a honeycomb shape by forming slits in one plate material and bending the plate material.

First, as shown in FIG. 1, one plate material 10 is prepared. The plate material 10 may be a single sheet material or a strip-shaped steel plate. The honeycomb structure of the present embodiment is mainly intended to be applied to, for example, a battery case, and the material of the plate member 10 is preferably a galvanized steel plate. Further, the plate thickness of the plate member 10 is preferably 0.8 [mm]. However, the honeycomb structure of the present embodiment is not limited to application to battery cases. It may be used for other purposes. Therefore, the material and thickness of the plate material 10 may be selected from product specifications. For example, the plate material 10 may be an iron plate such as a hot-rolled steel plate or a cold-rolled steel plate, or may be a metal plate containing aluminum, stainless steel, or titanium. Also, the plate material 10 containing resin may be used regardless of whether it is metal or non-metal. A honeycomb structure of skeletal members having strength is continuously formed from a single sheet material or band-shaped material.

One plate surface of the plate material 10 is defined as a main surface 11 . The plate surface on the opposite side of the main surface 11 is called the back surface 12 . Here, XYZ orthogonal coordinate axes are introduced in order to explain the manufacturing method of the honeycomb structure. A plane parallel to the main surface 11 is defined as an XY plane. A direction orthogonal to the main surface 11 is defined as a Z-axis direction. The upward direction is also called the +Z-axis direction, and the downward direction is also called the −Z-axis direction. Further, when one direction on the XY plane is the X-axis direction, the other direction perpendicular to the one direction on the XY plane is the Y-axis direction.

Next, as shown in FIG. 2, a plurality of slits 21 and 22 are formed in one sheet of plate material 10 . A plurality of slits 21 and 22 are formed in rows on the main surface 11 . For example, the row 31 is formed by arranging a plurality of slits 21 extending in the X-axis direction on the main surface 11 of one plate member 10 at intervals in the X-axis direction. A plurality of such columns are formed. For example, row 32 is spaced from row 31 in the Y-axis direction. Like the row 31, the row 32 is formed by arranging a plurality of slits 21 at intervals in the X-axis direction. A row 33 is formed between the rows 31 and 32 . The row 33 is formed by arranging a plurality of slits 22 extending in the X-axis direction at intervals in the X-axis direction. The distance between the rows 31 and 33 in the Y-axis direction is substantially equal to the distance between the rows 33 and 32 in the Y-axis direction.

A portion between the slits 21 in the same row is called a connecting portion 41 . The length of the connecting portion 41 in the X-axis direction is from the −X-axis direction side end of the slit 21 on the +X-axis direction side of the connecting portion 41 to the +X-axis direction of the slit 21 on the −X-axis direction side of the connecting portion 41. is the length to the end of the side. A portion between the slits 22 in the same row is called a connecting portion 42 . The length of the connecting portion 42 in the X-axis direction is from the −X-axis direction side end of the slit 22 on the +X-axis direction side of the connecting portion 42 to the +X-axis direction of the slit 22 on the −X-axis direction side of the connecting portion 42. is the length to the end of the side. The length of the connecting portion 41 in the X-axis direction and the length of the connecting portion 42 in the X-axis direction are substantially equal.

The length of the slit 21 in the X-axis direction is the length from the end of the slit 21 on the +X-axis direction to the end of the slit 21 on the −X-axis direction. The length of the slit 22 in the X-axis direction is the length from the end of the slit 22 on the +X-axis direction to the end of the slit 22 on the −X-axis direction. The length of the slit 21 in the X-axis direction and the length of the slit 22 in the X-axis direction are substantially equal. The length of the slits 21 and 22 in the X-axis direction is approximately three times the length of the connecting portions 41 and 42 in the X-axis direction.

When the rows 31, 32 and 33 are formed, the positions of the slits 21 in the row 31 on the X axis and the positions of the slits 21 in the row 32 on the X axis are formed to match. Therefore, the plurality of slits 21 in the row 31 and the plurality of slits 21 in the row 32 are line symmetrical with respect to the row 33 . That is, each slit 21 in row 31 is positioned in the +Y-axis direction of each slit 21 in row 32 . Each connecting portion 41 in the row 31 is positioned in the +Y-axis direction of each connecting portion 41 in the row 32 .

Also, when forming the rows 31 , 32 and 33 , the slits 22 are arranged between the connecting portions 41 in the row 31 and the connecting portions 41 in the row 32 . Furthermore, the connecting portions 42 are arranged between the slits 21 in the row 31 and the slits 21 in the row 32 .

In this manner, each slit is formed parallel to the Y-axis direction, and the slits 21 and slits 22 are alternately formed in the X-axis direction. As a result, as will be described later, a hexagonal tube and connecting portions 41 and 42 that connect the hexagonal tubes are formed in the plate member 10 .

Next, as shown in FIG. 3, a mountain fold line 51 (indicated by a dashed line) and a valley fold line 52 (indicated by a dotted line) are set. For example, a mountain fold line 51 extending in the X-axis direction is set on the connecting portion 41 . Also, a valley fold line 52 extending in the X-axis direction is set on the connecting portion 42 . Further, a valley fold line 52 extending in the Y-axis direction through the end of the slit 21 in the X-axis direction is set. Also, a mountain fold line 51 extending in the Y-axis direction through the end of the slit 22 in the X-axis direction is set. Reference numerals are appropriately omitted so as not to complicate the drawing. The same applies to the following drawings.

Next, as shown in FIG. 4, the mountain fold line 51 is folded into a mountain fold. The valley fold line 52 is folded into a valley fold. Then, the slit 21 opens upward. A connecting portion 41 between the slits 21 is mountain-folded. On the other hand, the slit 22 opens downward. A connecting portion 42 between the slits 22 is valley-folded. Then, the main surface 11 is bent so that the portions on both sides of the slit 22 become the inner peripheral surface of the hexagonal cylinder, and the portions on both sides of the slit 21 of the main surface 11 become the outer peripheral surface of the hexagonal cylinder. Mountain folds and valley folds are repeated so that the connecting portions 41 and 42 alternately connect the upper and lower sides of the open end of the hexagonal tube. Therefore, the connection portion 42 for the valley fold is adjacent to the connection portion 41 for the mountain fold. A mountain-fold connecting portion 41 is adjacent to the valley-fold connecting portion 42 . Mountain folds and valley folds alternately connect the hexagonal cylinders.

Moreover, the connecting portions 41 and 42 alternately connect the upper side and the lower side of the hexagonal tube. Since the connecting portions 41 and 42 connect the hexagonal cylinders, joints and welds can be eliminated. Therefore, the strength of the honeycomb structure is the material strength of the plate member 10 without depending on the joints and welds. Therefore, the strength of the honeycomb structure can be improved.

The mountain fold and valley fold are bent in a state where there is no negative angle or buckling. For example, molding is performed in a state where there is no negative angle with respect to the pressing direction. Further, when the connecting portions 41 and 42 are formed by bending, the bending inner radius R of the connecting portions 41 and 42 should be greater than or equal to the plate thickness. In this manner, a honeycomb structure 1 can be manufactured as shown in FIG.

The manufacturing method of the honeycomb structure 1 of the present embodiment is a method of manufacturing a continuous honeycomb structure 1 from a single plate material 10 such as a sheet material or a belt-like material. Moreover, in order to manufacture a continuous honeycomb having a plurality of hexagonal cylinders connected from one plate material 10, the connecting portions 41 and 42 have a bent shape. The honeycomb structure 1 is formed by forming slits 21 and 22 in a plate material 10 such as a belt-like metal plate and repeating a plurality of bending processes. A hexagonal cylinder continuous in one direction can be easily formed. By alternately providing the connecting portions 41 and 42 on the upper side and the lower side, it is possible to connect these hexagonal cylinders. They are manufactured by bending and can be formed without negative angles to the pressing direction. Therefore, the continuous honeycomb structure 1 can be manufactured even if the belt-like plate material 10 is fed progressively or a construction method with excellent productivity such as roll forming is adopted.

Next, the manufactured honeycomb structure 1 will be described. As shown in FIG. 5 , the honeycomb structure 1 of this embodiment includes a plurality of hexagonal cylinders 61 and 62 . Each hexagonal cylinder 61 and 62 has a cavity surrounded by six side walls. The cavity opening is hexagonal. The opening of the hexagonal tube 61 and the opening of the hexagonal tube 62 are, for example, regular hexagons of the same size.

Here, for convenience of explanation of the honeycomb structure 1, an XYZ orthogonal coordinate axis system is introduced. Let the opening direction of the cavity be the Z-axis direction. Therefore, the opening is hexagonal when viewed from the Z-axis direction.

The honeycomb structure 1 has arrays 71 to 73 in which a plurality of hexagonal cylinders 61 and 62 are connected. Arrays 71 and 72 are arrays in which a plurality of hexagonal cylinders 61 are connected via connecting portions 41 in the X-axis direction. An array 73 is an array in which a plurality of hexagonal cylinders 62 are connected via connecting portions 42 in the X-axis direction. The array 72 is spaced apart from the array 71 in the Y-axis direction. Array 73 is arranged between array 71 and array 72 .

The hexagonal cylinders 61 in the array 71 and the hexagonal cylinders 61 in the array 72 are arranged side by side in the Y-axis direction. The −Y-axis direction side wall of the hexagonal cylinder 61 in the array 71 faces the +Y-axis direction side wall of the hexagonal cylinder 61 in the array 72 . The opposing side walls of the hexagonal cylinders 61 that are adjacent in the Y-axis direction form the connecting portion 42 in the array 73 . That is, the side wall of the hexagonal tube 61 perpendicular to the Y-axis direction forms the connecting portion 42 . On the other hand, a side wall of the hexagonal tube 62 perpendicular to the Y-axis direction forms a connecting portion 41 . The side walls of the hexagonal cylinder 61 other than the side walls orthogonal to the Y-axis direction are shared with the side walls of the hexagonal cylinder 62 other than the side walls orthogonal to the Y-axis direction.

6(a) and 6(b) are cross-sectional views illustrating connecting portions of the honeycomb structure according to the embodiment. As shown in FIGS. 6A and 6B, the connecting portion 41 has a curved portion 41a curved toward the upper portion, that is, the +Z-axis direction side. Therefore, when the connecting portion 41 is cut along a plane orthogonal to the X-axis direction, it has an upside-down U shape. The inner radius of the curved portion 41a is greater than or equal to the plate thickness, and satisfies the following formula (1).

Inner R ≧ plate thickness (1)

The connecting portion 42 has a lower portion, that is, a curved portion 42a that is bent toward the -Z-axis direction. Therefore, when the connecting portion 42 is cut along a plane orthogonal to the X-axis direction, it has a U shape. The inner radius of the curved portion 42a is also greater than or equal to the plate thickness and satisfies the above formula (1). In the present embodiment, when the honeycomb structure 1 is manufactured, the bend radius R of the connecting portions 41 and 42 is set to be equal to or larger than the plate thickness, as shown in formula (1). For example, bending with a small radius may cause cracking. However, as in the present embodiment, by setting the inner R to be equal to or greater than the plate thickness, the strength can be improved to prevent cracking.

FIGS. 7A to 7C are diagrams exemplifying restraining methods used when bending a metal plate. If the metal plate 10 is subjected to bending, springback may occur. If the required dimensional accuracy of the product is strict, this spring pack becomes an issue. Therefore, by constraining the bent portion, it is possible to satisfy these required dimensional accuracies. As a restraint method, a joining method such as adhesion or welding (spot, arm, etc.) as shown in FIG. 7(c), and a method of bending the ends in a shape such as hemming to constrain them. Such a technique may be used when bending the plate member 10 .

The honeycomb structure 1 of this embodiment has the following characteristics. That is, the honeycomb structure 1 in which a plurality of hexagonal cylinders are connected is manufactured from one plate member 10 . Specifically, a plurality of slits 21 and 22 are formed in one plate material 10 . Then, it is manufactured by folding along mountain fold lines 51 and valley fold lines 52 passing through the connecting portions 41 and 42 and the ends of the slits 21 and 22 . As described above, in the present embodiment, since the honeycomb structure 1 is manufactured from one plate member 10, a structure without joints can be obtained. Therefore, it is possible to manufacture a large-area honeycomb structure at low cost, which is lightweight and strong, enables high-speed production such as progressive feeding and roll forming, and the like.

Moreover, the connecting portions 41 and 42 that connect the hexagonal cylinders alternately connect the upper and lower sides, that is, the one side and the other side of the open ends of the hexagonal cylinders. Therefore, it is possible to improve the strength while reducing the weight.

Furthermore, since the inner R in bending is set to be equal to or greater than the plate thickness, the occurrence of cracks can be suppressed, and the honeycomb structure can be lightweight and high in strength.

Moreover, in bending forming such as mountain folds and valley folds, bending is performed in a state where there is no negative angle and no buckling. Therefore, it is possible to manufacture a large-area honeycomb structure at low cost, which is lightweight and strong, enables high-speed production such as progressive feeding and roll forming, and the like.

On the other hand, for example, Patent Documents 1 to 7 disclose various structures of honeycomb structures for the purpose of weight reduction. However, these honeycomb structures do not have a perfect hexagonal shape, and two sides of a hexagon are not connected to adjacent hexagons. In Patent Document 5, as shown in FIG. 8, a corrugated sheet 100 is pressed to form a plurality of protrusions 101, and the peaks of the protrusions 101 are crimped to each other to manufacture a honeycomb structure 102. FIG. Such a honeycomb structure 102 has a joint portion 103, and the joint strength of the joint portion 103 determines the strength of the entire honeycomb structure. Therefore, the strength of the joint 103 may be insufficient and the strength of the whole may be lowered. Patent Literature 6 discloses improving the bonding strength by chemical treatment or the like. However, the joint strength of the joint still determines the overall strength. Patent Documents 2 and 3 disclose sandwich honeycombs. In the sandwich honeycombs of Patent Documents 2 and 3, members disadvantageous from the viewpoint of weight reduction are provided above and below the honeycomb structure. As described above, the honeycomb structures of Patent Documents 1 to 7 cannot improve strength while reducing weight.

On the other hand, in the present embodiment, as described above, the honeycombs are manufactured from one sheet of plate 10, and the honeycombs are connected alternately on the upper side and the lower side, and the inner radius of the bending is the thickness of the plate. As described above, in bending, bending is performed in a state where there is no negative angle. Therefore, since there is no joining portion, it is possible to improve the strength while reducing the weight. Moreover, high-speed production such as progressive feeding and roll forming is enabled, and a large-area honeycomb structure can be manufactured at low cost.

Although the embodiment according to the present invention has been described above, it is possible to make modifications without departing from the technical idea of the present invention without being limited to the above configuration. For example, a method of manufacturing a semiconductor device that combines Embodiment 1 and Embodiment 2 is also within the scope of the technical idea of the present invention.

10 Plate material 11 Main surface 12 Back surface 21, 22 Slits 31, 32, 33 Rows 41, 42 Connecting parts 41a, 42a Curved part 51 Mountain fold line 52 Valley fold line 61, 62 Hexagonal tube 71, 72, 73 Arrangement 100 Corrugated sheet 101 Convex portion 102 Honeycomb structure 103 Joining portion

Claims (1)

A method for manufacturing a honeycomb structure having a plurality of hexagonal cylinders in a honeycomb shape by forming slits in a single metal plate and bending the metal plate, the method comprising:
The slits are formed in parallel and alternately in the metal plate so that the hexagonal cylinders and connecting portions that connect the hexagonal cylinders are formed,
Repeat mountain folds and valley folds so that the connecting portion alternately connects one side and the other side of the open end of the hexagonal cylinder,
A method for manufacturing a honeycomb structure, characterized in that the bending radius R of the U-shaped connecting portion is set to be equal to or larger than the thickness of the plate, and the bending is performed in a state where there is no negative angle and no buckling.

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