JPH05200924A - Structural material - Google Patents

Abstract

PURPOSE:To easily attach various parts and to also realize a three-dimensional structure in a structural material having a honeycomb sandwich structure. CONSTITUTION:Outsert molded parts 2 such as bosses or ribs are formed on the aluminum upper surface panel 1 being the surface structural material of a honeycomb panel by outsert molding and various parts can be easily attached to the structural material by screwing said parts on the molded parts 2. As the outsert molded parts 2, ones having a three-dimensional structure such as various ribs, cams or stops can be realized.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to basic structural materials such as chassis and bases for various devices, and more particularly to basic structural materials for precision instruments such as optical instruments and measuring instruments.

[0002]

2. Description of the Related Art Honeycomb panels are made of aluminum plates, steel plates,
A sandwich structure in which flat plates such as CFRP plates (carbon fiber reinforced plastic plates) sandwich a honeycomb-shaped structural material made of aluminum or aramid paper, and join them by a method such as welding, brazing, or adhesion to integrate them. It is a structural material. Due to its structure, the honeycomb panel has a high rigidity while being lightweight, and is mainly used as a structural material for aircraft, vehicles and the like. Further, since the honeycomb panel has high rigidity and can maintain high flatness, an optical surface plate using the honeycomb panel is also known.

FIG. 5 shows the structure of a conventional general aluminum honeycomb panel. As shown in FIG. 5, in this honeycomb panel, a honeycomb core 23, which is a hexagonal honeycomb-shaped structural material formed of aluminum or the like, is provided with two aluminum flat plates 2.
The honeycomb core 23 and the aluminum flat plates 21 and 22 are joined to each other by a method such as welding, brazing, or adhesion after sandwiching them with Nos. 1 and 22 and applying pressure to improve the flatness.

[0004]

As described above, the honeycomb panel has an excellent characteristic that it is lightweight and has high rigidity, but in order to make the most of its advantage, a flat plate (which constitutes both sides of the honeycomb panel) In most cases, the surface constituent material is a thin plate excellent in light weight such as an aluminum plate or a CFRP plate. Therefore, there are the following drawbacks.

First, since the surface constituting material is a thin flat plate, it is extremely difficult to provide a screw hole or the like for mounting when various parts are mounted thereon. This drawback is not a big obstacle when it is only necessary to form a surface such as an outer plate or floor plate of an aircraft or a vehicle. However, when a honeycomb panel is used as a basic structural material such as a chassis and a base, and various functional parts are mounted thereon to form a complicated device configuration, it is difficult to mount such parts with screws or the like, It becomes a serious problem.
In order to solve such a problem, a method of forming a flat plate on the surface of the panel with a thick plate of steel, for example, and performing processing such as tapping may be considered, but in this case, the greatest feature of the honeycomb panel that is lightweight is Will be lost.

Further, as mentioned above, the surface constituting material of the honeycomb panel is generally a flat plate, and the bosses, ribs, and any pits (movable parts of the movable parts) which are necessary when constructing the above-mentioned complicated apparatus are formed. It cannot realize a three-dimensional structure such as the one that stops the movement or the positioning), the supporting member of the rotating portion, etc., and the degree of freedom in shape is low. In various conventional precision instruments such as measuring instruments and optical instruments, such a three-dimensional structure is realized by using, for example, aluminum die casting as the basic structural material, which reduces the number of parts. Costs have been reduced and the relative accuracy of the position of each mounting part has been improved. If the honeycomb panel can play such a role that aluminum die casting has played, it will be possible to reduce the weight and improve the accuracy of the device by utilizing the advantage of the honeycomb panel that it is lightweight and has high rigidity and high flatness. Can contribute. However, as described above, since the honeycomb panel has a low degree of freedom in shape and it is extremely difficult to realize a three-dimensional structure, the conventional application of the honeycomb panel in the field of precision machinery is to use a flat surface such as an optical surface plate. It was limited to applications where it could be formed correctly.

The present invention has been made in order to overcome the above drawbacks, and an object of the present invention is to make it possible to easily attach various parts and to realize a three-dimensional structure. An object of the present invention is to provide a structural material that has flexibility and that can reduce the weight of the device and improve its accuracy.

[0008]

A structural material according to the present invention made to solve the above problems is a structural material having a honeycomb sandwich structure in which a honeycomb core member is sandwiched between two flat plates to be integrated. A resin component is formed and attached to at least one of the two flat plates by outsert molding.

[0009]

To manufacture such a structural material, first, a prepared hole for outsert molding is formed on a flat plate which is a surface constituent material, and then a resin is outsert molded by an injection molding method. That is, a flat plate serving as a surface constituent material is sandwiched between molds, and bosses, ribs, etc. are formed and attached to the portion provided with the prepared hole by a single injection molding. Next, this flat plate and another flat plate are bonded to the upper surface and the lower surface of the honeycomb core as surface constituent materials. As described above, in the structural material of the present invention, resin parts such as bosses for mounting various parts can be formed on the structural material by injection molding. Therefore, even if a thin flat plate is used as the surface constituting material, The parts can be easily attached. Moreover, since a large number of resin parts can be formed at once by a single injection molding, it is possible to easily cope with a large number of various parts to be attached to the structure. Further, since the resin having a high degree of freedom in shape is outsert-molded in the structural material of the present invention, the degree of freedom in shape as a structural material is substantially higher than that of the conventional honeycomb panel which can be formed only on a flat surface. Can be increased to

[0010]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing a configuration of a structural material that is an embodiment of the present invention. This structural material is also a kind of honeycomb panel, and its basic configuration is the same as that of the conventional honeycomb panel shown in FIG. The honeycomb panel which is the structural material of the present embodiment is different from the conventional one in that resin is outsert-molded on the aluminum flat plate which is the surface constituent material of the honeycomb panel to form resin parts such as bosses and ribs. Is. That is, as shown in FIG. 1, after forming a prepared hole for outsert molding by press working or the like in advance on the aluminum upper surface plate 1 which is the surface constituent material of the honeycomb panel upper surface, the aluminum upper surface plate 1 is placed between the molds. Sandwich the resin parts 2 such as bosses and ribs so as to pierce the pilot hole by resin injection molding (the aluminum top plate 1 is "outserted" to the molded resin parts) and the aluminum top plate. 1
Form and attach to. Polyacetal or the like is often used as the resin because of its mechanical properties and moldability, but the resin is not limited to this. The outsert molding itself is a well-known molding method from the past (reference: Polyplastics Co., Ltd., technical data “outsert molding method”, etc.).

FIG. 3 shows an example of a boss formed by outsert molding. In this example, when the boss 2 is formed by injection molding, the self-tapping pilot hole 5 is simultaneously formed in the boss 2. This allows the components to be screwed to the aluminum top plate 1 without cutting taps, and as shown in FIG. 3, the components can be attached to the aluminum top plate 1 at an appropriate height H. It will be possible. The conventional honeycomb panel has a low degree of freedom in shape,
Although the mounting surface of the component is limited to the aluminum upper plate, the degree of freedom in design is greatly improved in this embodiment in that the height H from the aluminum upper plate 1 can be changed.

In the example of FIG. 3, the boss is formed by outsert molding. However, the formed boss is not limited to the boss, and various ribs, cams, ataris, etc. can be formed. It can be applied. That is, since the resin having a high degree of freedom in shape is outsert-molded, the degree of freedom in the shape as a structural material is substantially higher than that of a conventional honeycomb panel that can be formed only on a flat surface, and the resin parts may be different. A three-dimensional structure can also be realized.

After the resin is outsert-molded on the aluminum upper plate 1, the honeycomb core 3 is sandwiched between the aluminum upper plate 1 and the aluminum lower plate 4 as shown in FIG. 1 to improve the flatness. Join while applying pressure. As shown in FIG. 4, the pressure applied at this time is a part formed by outsert molding (hereinafter referred to as "outsert molding part").
Is performed by using the press die 7 having the relief 8 formed therein. Thereby, the flatness of the aluminum upper plate 1 and the lower plate 4 can be improved without applying pressure to the outsert molded part 2. Also, some methods have been known for joining, but in consideration of heat resistance of outsert molded parts, which are resin parts, avoid welding and brazing, and use hot melt adhesives or epoxy resin adhesives. Bonding is performed by using. For example, when polyacetal is used as the resin of the outsert molded part, by using a room temperature curing type epoxy resin adhesive or the like, bonding can be performed without increasing the temperature.

In general, in an outsert-molded part, as shown in FIG. 3 or 4, it is necessary to form a retaining portion 10 on the opposite surface of the base substrate (rear surface of the aluminum upper surface plate 1) in the outsert molding. Therefore, when the honeycomb cores 3 are joined, the polygonal shape of the honeycomb cores (6 in the drawing
The protrusion of this outsert molded part must enter the space of the square shape. For this purpose, it is necessary to consider the position of the outsert-molded part at the time of designing, and it is necessary to match the positional relationship between the honeycomb core 3 and the aluminum upper surface plate 1. This alignment can be done by using an appropriate positioning jig at the time of joining, but as shown in FIG. 6, for example, the polygonal shape (hexagon) of the honeycomb core 3 is aligned with the back surface of the aluminum upper surface plate 1. By forming the polygonal ribs 11 by outsert molding and fitting the ribs 11 into the polygonal space of the honeycomb core 3, positioning can be performed efficiently.

FIG. 2 shows a structural example of a precision instrument using the structural material of this embodiment. As described above, the honeycomb panel includes the aluminum upper surface plate 1, the aluminum lower surface plate 4, the honeycomb core 3, the boss 2 formed by outsert molding, and the like. FIG. 2 schematically shows an optical device in which this honeycomb panel is used as a reference base of the device and an optical element is mounted on the base.

The optical element 12 is composed of, for example, a holder 12a and a mirror 12b previously attached to the holder 12a, and a self-tapping screw 13 is screwed into a self-tapping pilot hole 5 of a boss 2 formed on an aluminum upper plate 1. As a result, the optical element 12 can be fixed. The fixing method is not limited to the self-tapping, and other fastening methods such as insert tap and snap fit can be used. Further, by forming the positioning attrition by outsert molding, it is possible to accurately determine the position of the optical element 12, reduce the adjustment man-hours, and improve the productivity of the apparatus. Further, it is also possible to form a cam-like component or the like directly by outsert molding instead of attaching it through a boss or the like, and form a mechanism section for performing some movement, such as a mirror switching mechanism, on this base. is there.

As described above, the structural material of this embodiment is suitable as a base material for various precision equipment such as optical equipment. That is, the structural material of the present embodiment takes advantage of the advantages of the honeycomb panel that is excellent in lightweight and high in rigidity and can maintain high flatness, while overcoming the disadvantages that it is difficult to attach parts and the shape flexibility is low. ing. Therefore, if this structural material is used as a base material for precision equipment, weight reduction can be achieved without impairing the precision and stability of the precision equipment.

The present embodiment and the above-mentioned conventional example (FIG. 5)
In the above, an aluminum honeycomb was taken as an example, but if the upper and lower flat plates that are the surface constituent materials of the honeycomb panel and the honeycomb core are to be joined by adhesion, then a honeycomb core made of another material, for example, a honeycomb core made of aramid paper May be used. Further, although the aluminum plate is used as the flat plate which is the surface constituting material, another sheet metal material such as a thin steel plate may be used if the lightness is somewhat sacrificed.

Further, in this embodiment, outsert molding is performed on the surface of the upper surface plate of the surface constituting material of the honeycomb panel. However, a boss is formed on the surface of the lower surface plate, and it is used as a base material to which various parts are attached. It is also possible to use the boss of the lower surface plate to fix the structural material of this embodiment to the outer plate of the entire precision instrument.

[0020]

As described above, according to the present invention,
It is possible to provide a structural material that overcomes the drawbacks of the honeycomb panel that it is difficult to attach parts and has a low degree of freedom in shape, while making use of the excellent features of the honeycomb panel that is lightweight, yet has high rigidity and can maintain high flatness. .. Then, by using this structural material as a basic structural material such as a chassis or a base of various devices, the weight and accuracy of the device can be reduced. In particular, this structural material
Since the rigidity is high and the flatness can be maintained high, it is suitable as a base material for precision equipment, and the weight can be reduced without impairing the precision and stability of the precision equipment.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a structural material that is an embodiment of the present invention.

FIG. 2 is a diagram showing a structural example of a precision instrument using the structural material of the above-mentioned embodiment.

FIG. 3 is a sectional view showing an example of an outsert-molded boss.

FIG. 4 is a cross-sectional view showing a pressurizing method for improving the flatness of the structural material of the embodiment.

FIG. 5 is a diagram showing a configuration of a conventional aluminum honeycomb panel.

FIG. 6 is a diagram showing an example of a positioning method for joining the honeycomb core and the flat plate in the production of the structural material of the above-mentioned embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Aluminum top plate (flat plate) 2 ... Outsert molding parts (resin parts) such as bosses 3 ... Aluminum honeycomb core (honeycomb core member) 4 ... Aluminum bottom plate (flat plates) 11 ... Ribs (resin parts)

Claims (1)

[Claims] 1. A structural material having a honeycomb sandwich structure in which a honeycomb core member is sandwiched between two flat plates, and a resin component is formed on at least one of the two flat plates by outsert molding. Structural material characterized by being installed.