JPH0538539A - Honeycomb panel and production thereof - Google Patents

Abstract

PURPOSE:To assure the effective area for joining and to impart sufficient strength to the joint parts by disposing inserts at the end faces of the joint parts and joining the inserts and face plates to other members. CONSTITUTION:The honeycomb panel 10 is constituted by holding a core 32 of a honeycomb structure and an edge material 14 between two sheets of the front and rear surface plates 28, 30 and integrally brazing these members. The edge material 14 is disposed in the outer peripheral edges on the four sides of the panel 10. A toric-shaped frame material 34 is welded to the circumference of an aperture 12. The inside of the frame material 34 is the aperture 12. Such honeycomb panel 10 can be made into a larger panel by welding the outer peripheral edges to each other. Not only the frame material 34, and honeycomb core 32 at the cut face of the aperture 12 but also the inserts 36 are integrally fixed to the panel. The inserts 36 and the surface plate 28 are superposed on each other on the outside surface side of the structural body, by which the necessary welding area is assured and the prescribed weld strength is obtd.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb panel and a method for manufacturing the same, and more particularly to a honeycomb panel suitable for joining with other structural members and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, there has been known a brazed aluminum honeycomb panel having a sandwich structure in which a honeycomb core is sandwiched between two face plates and integrally joined by a brazing material. Such an aluminum honeycomb panel is disclosed in, for example, Japanese Patent Laid-Open No. 64-44268, Japanese Utility Model Publication No. 1-
No. 143668.

Since such an aluminum / honeycomb panel is lightweight, has high strength, and can be welded, it can be considered to be applied to a vehicle body of a vehicle, a structure of a railway vehicle, or a building material. There is.

[0004]

By the way, when the aluminum honeycomb panel is used as such various structural materials, the panel is used for piping, wiring,
An opening is appropriately formed for the purpose of forming a window.
It is usually necessary to attach an appropriate frame member to such an opening by welding or the like for reinforcement or for supporting a window member or the like. Further, when the panel is joined to another structural member, it is necessary to install a frame member not only on the opening but on the edge of the peripheral portion.

However, in the aluminum honeycomb panel, the face plate and the honeycomb core are formed to be extremely thin in order to reduce the weight, and most of the honeycomb cores interposed between the face plates are formed. Since it is a space, it is extremely difficult to secure an effective welding area for the frame material at the cut surface of the opening as described above.
Therefore, when attaching the frame member, sufficient welding strength of the frame member cannot be obtained.

In order to improve the fixing strength of the frame material attached to the aluminum / honeycomb panel, it is possible to weld a reinforcing shape member to the panel surface, but the welding of the reinforcing shape member to the surface is It is disadvantageous for the purpose of smoothing the surface of the panel and is not desirable in terms of weight reduction. Therefore, it is difficult to adopt it as a structural material used as a surface material. In particular, it cannot be used in railway vehicle structures, automobiles, etc., from the viewpoints of preventing wind noise, appearance, etc., because surface irregularities are limited.

By the way, in order to improve the strength of the honeycomb panel, there is known a honeycomb panel in which an insert is arranged in a cell of a honeycomb core to be integrally formed. For example, Japanese Utility Model Unexamined Publication No. Sho 64-25514 and Japanese Patent Laid-Open No. 2-25
No. 325 publication.

The present invention has been made in view of the above circumstances, and a problem to be solved is to join other members such as a frame member or a structural member to a honeycomb panel. It is an object of the present invention to provide a honeycomb panel that can sufficiently secure the strength of the bonded portion.

Another object of the present invention is to provide a method for manufacturing a honeycomb panel which can rationally manufacture a honeycomb panel which can sufficiently secure the strength of a joint portion with another member. Especially.

Another object of the present invention is to provide a vehicle body structure using a honeycomb panel, which can sufficiently secure the strength around the window portion.

[0011]

In order to solve the above problems, a first invention is that an insert is arranged in a desired cell of a honeycomb core arranged between two face plates,
In a honeycomb panel formed by integrally bonding at least the honeycomb core to each of the two face plates, the honeycomb panel has a cut surface in a thickness direction at a position including cells having the insert. It is formed, and a frame member is arranged on the cut surface, and the frame member is butt-welded to at least one of the face plate and the insert.

In addition, in the honeycomb panel having such a structure, the insert is formed, for example, at substantially the same height as the height of the honeycomb core.

Furthermore, in the honeycomb panel having the above-mentioned structure, the insert is bonded to, for example, the two face plates, and the cut surface is, for example, in the plane of the honeycomb panel. The cut surface forms an opening that penetrates the honeycomb panel.

In addition, in the honeycomb panel having the above-mentioned structure, the insert preferably has a structure composed of a piece joined to each of the two face plates and a piece connecting the two pieces. Used.

Further, in order to solve the above-mentioned problems, in the second invention, an insert is arranged in a desired cell of a honeycomb core arranged between two face plates, and at least the honeycomb core is arranged. In a honeycomb panel integrally bonded to each of the two face plates, the honeycomb panel is formed with a cut surface in a thickness direction thereof at a position including cells having the insert. In such a cut surface, the end surface of the insert and the end surface of the face plate are substantially at the same position, which is a feature thereof.

In the honeycomb panel having such a structure, preferably, the insert has a channel-shaped cross section in the thickness direction of the honeycomb panel in a cut state, and two pieces facing each other in the thickness direction of the honeycomb panel. Are joined to each of the face plates.

Further, in order to solve the above-mentioned problems, in the third invention, a honeycomb core is installed between two face plates, and the honeycomb core is bonded to each of the two face plates. In the integrally formed honeycomb panel, the honeycomb panel has an opening portion that penetrates the honeycomb panel in its surface, and an insert is arranged at an end surface portion of the opening portion of the honeycomb panel. At the same time, a frame material is arranged at the edge of the opening, and the frame material is joined to at least one of the face plate and the insert by butt welding.

In order to solve the above problems,
A fourth invention is a honeycomb panel in which a honeycomb core is installed between two face plates, and the honeycomb core is integrally formed by bonding the honeycomb core to each of the two face plates. It has an opening penetrating the honeycomb panel in its plane, and an insert is arranged at the end face of the opening of the honeycomb panel, and the insert has a cross-sectional shape in the thickness direction of the honeycomb panel. It is channel-shaped, and is characterized in that the end surface of the insert and the end surface of the face plate are substantially at the same position.

Further, in order to solve the above-mentioned problems, a fifth aspect of the present invention is: (a) a step of obtaining an assembly in which a honeycomb core and an insert are arranged between two face plates;
(B) a step of obtaining a honeycomb panel in which the honeycomb core is fixed to the two face plates by joining the assembly, and (c) such a honeycomb panel along the insert in a thickness direction of the panel. And a step of exposing the insert to the cut surface, which is characterized by a method for manufacturing a honeycomb panel.

Further, in a preferred aspect of the method for manufacturing a honeycomb panel, the insert is bonded to the face plate in the step of bonding the assembly. Alternatively, it is effective to perform the cutting in the step of exposing the insert according to the indication provided on the surface of the face plate corresponding to the installation position of the insert.

Further, in one mode of the preferable method for manufacturing a honeycomb panel, for example, a frame member having a shape corresponding to the shape of the cut portion is arranged at a cut portion formed by the step of cutting the honeycomb panel, By welding the frame member to the insert and at least one of the face plates, the frame member is fixed, or the fixing of such a frame member is performed by, for example, a step of welding the frame member. In the previous step, the honeycomb panel is bent in the thickness direction thereof, and in the step of welding the frame member, the frame member bent at substantially the same curvature as the bent honeycomb panel is cut into the cutting portion. It is carried out by arranging in the above position and performing the welding.

Further, in one aspect of the preferred method for manufacturing a honeycomb panel as described above, the step of obtaining the assembly includes, for example, a step of inserting an insert into a cell of the honeycomb core, and cutting the panel. Is performed by cutting at a position including the cell in which the insert is inserted.

Further, in order to solve the above-mentioned problems, a sixth aspect of the present invention is to: (a) place a honeycomb core and an insert between two face plates, on a planned cutting line forming a cut portion. In a desired plurality of cells of the honeycomb core located in the step of obtaining an assembly with the insert inserted, (b) by joining the assembly, at least the honeycomb core to the two face plates A method of manufacturing a honeycomb panel, comprising: a step of obtaining a fixed honeycomb panel; and (c) a step of cutting the honeycomb panel in a thickness direction of the honeycomb panel along the planned cutting line to remove an unnecessary portion. Is its characteristic.

[0024] In the method for manufacturing a honeycomb panel, preferably, the insert is composed of two horizontal pieces that respectively come into contact with the face plate and a vertical piece that connects the two horizontal pieces, and the insert to the cell. Is inserted so that the vertical piece is located closer to the necessary portion of the honeycomb panel than the planned cutting line.

Further, in order to solve the above-mentioned problems, a seventh invention is (a) a honeycomb panel in which a honeycomb core and an insert inserted into a cell of the honeycomb core are joined to at least one face plate. A step of cutting the honeycomb panel in a thickness direction of the honeycomb panel at a position including cells having the insert, and exposing the insert to a surface formed by the cutting, and (b) a frame material on the surface formed by the cutting. And the step of welding the frame member to the insert and at least one of the face plates.

Further, in order to solve the above-mentioned problems, the eighth invention is (a) a honeycomb panel in which at least one face plate is joined with a honeycomb core and an insert inserted into a cell of the honeycomb core. In the thickness direction of the honeycomb panel, (b) measuring the depth of the cells opened by the cutting, and (c) the second cutting based on the obtained cell depth. A method for manufacturing a honeycomb panel is characterized by including a step of obtaining a position and (d) a step of exposing the insert by cutting at the second cutting position.

In the method for manufacturing a honeycomb panel, it is also possible to determine the position of the outer edge of the honeycomb panel parallel to the second cutting position, corresponding to the second cutting position, and perform the cutting. Is.

Further, in order to solve the above-mentioned problems, a ninth aspect of the present invention is to provide (a) a channel-shaped profile having a horizontal piece and a vertical piece on a face plate, the vertical piece being a honeycomb. A step of arranging so as to be located on the necessary part side of the panel and performing temporary welding of the shape member to the face plate on the unnecessary part side of the honeycomb panel; and (b) the face plate on the necessary part side of the honeycomb panel. Placing a honeycomb core on the above, a step of placing another face plate on the profile and the honeycomb core,
(C) fixing the two face plates to the honeycomb core by bonding, (d) forming an opening in the plate thickness direction in the integrally bonded honeycomb panel, and (e) A method for manufacturing a honeycomb panel is characterized by including a step of welding an edge member to a horizontal piece of the shaped member and a face plate exposed at an opening penetrating in the thickness direction of the honeycomb core.

Further, in order to solve the above-mentioned problems, a tenth aspect of the present invention provides a honeycomb panel in which a honeycomb core is disposed between two face plates, and these are joined together to be integrally formed. An opening is formed so as to penetrate in the thickness direction, and an insert is jointly arranged between two face plates at the edge of the opening, which is a member for attaching a third member, A frame member having an outward flange that can be fitted to the portion and that can be engaged with the opening edge at the outer peripheral portion, with respect to the face plate and the insert inside the honeycomb panel,
A honeycomb panel for a vehicle structure, which is joined by welding and constitutes at least a part of the outer wall surface of the vehicle body, is also a feature thereof.

Further, in order to solve the above-mentioned problems, the eleventh aspect of the present invention is (a) a step of preparing a brazed honeycomb panel in which a honeycomb core is sandwiched between two face plates and integrally joined. And (b) a step of cutting the honeycomb panel to form an opening penetrating in a panel thickness direction at a predetermined position of the honeycomb panel, and (c) a plurality of locations on the circumference of the cut surface of the opening. In the cells of the honeycomb core that are opened at, the steps of assembling by inserting the inserts respectively, and (d) by inserting a frame material corresponding to the shape into the opening provided in the honeycomb panel, A method of manufacturing a honeycomb panel is characterized in that it is integrally attached to the cut surface of the opening by welding the face plate and the insert.

Further, in order to solve the above-mentioned problems, the twelfth aspect of the invention is (a) a step of preparing a brazed honeycomb panel in which a honeycomb core is sandwiched between two face plates and integrally bonded. And (b) a step of cutting the honeycomb panel to form a prepared hole for an opening at a predetermined position through the honeycomb panel, and (c) a cut surface of the prepared hole for the opening. In the cells of the honeycomb core that are open at a plurality of locations on the circumference thereof, a step of inserting and inserting an insert, respectively, and (d) the honeycomb panel,
By cutting the periphery along the prepared hole for the opening, an opening that is slightly larger than the prepared hole for the opening is formed, and the end face of the insert is formed by cutting the end face of the insert in the cut surface of the prepared opening. And a step of aligning with the end face of the honeycomb core, and (e) by fitting a frame material corresponding to the shape into the opening provided in the honeycomb panel and welding the frame material to the face plate and the insert, A honeycomb panel manufacturing method including a step of integrally attaching to the cut surface of the opening is characterized.

In the honeycomb panel manufacturing method according to the eleventh and twelfth aspects of the invention, it is preferable that the insert be attached to the cut surface of the opening of the honeycomb panel of the at least one face plate. The frame material is attached by being assembled in the cells of the honeycomb core in a state of being intimately contacted with the inner side surface, and by welding the frame material to the intimate contact portion between the face plate and the insert.

[0033]

According to the honeycomb panel of the first aspect of the present invention, the insert is arranged on the cut surface for joining with another member and is joined with the other member. Since the frame member for joining is joined to the face plate and the insert, it is possible to sufficiently secure the joining strength as compared with the case where the frame member is joined to other members only through the thin face plate. Further, even when the cut surface is formed so as to form an opening in the surface of the honeycomb panel, the bonding strength with other members can be secured in the same manner.

Next, according to the honeycomb panel of the second aspect of the present invention, the insert is exposed at the same position as the end face of the face plate on the cut surface for joining other members. Therefore, other members can be easily joined to the insert and the face plate, and the strength of these joined portions can be sufficiently ensured. Further, according to the honeycomb panel of the present invention described in claim 7, since the inserts installed at the end faces of the openings or the cut portions have a channel-shaped cross section, the inserts have two face plates. Since it is joined to the other member, the joining strength with the other member can be more advantageously secured.

Further, in the honeycomb panel according to the third aspect of the present invention, since the insert can be inserted and arranged in the cells of the honeycomb core opening in the panel opening, By using the honeycomb panel having the structure, it becomes possible to advantageously improve the bonding strength of the opening to the frame material.

Furthermore, in the honeycomb panel according to the fourth aspect of the present invention, the insert inserted into the cell of the honeycomb core opening at the panel opening has a channel-shaped cross section. In addition, since it is exposed at the same position as the end face of the face plate in the panel opening, other members can be easily joined to the insert and face plate, and the strength of these joints is high. Can be sufficiently secured.

Next, according to the honeycomb panel manufacturing method of the fifth aspect of the present invention, the insert is placed between the face plates before the assembly is joined and joined. By exposing the insert by cutting later, it is possible to rationally manufacture a honeycomb panel having sufficient bonding strength without significantly changing the manufacturing process of the honeycomb panel.

Next, as described in claims 16 and 17,
According to the method for manufacturing a honeycomb panel of the sixth aspect of the present invention, the planned cutting position is determined in advance at the stage of obtaining the assembly, the insert is arranged along this position, and the cutting is performed along the planned cutting line. Therefore, the placement of the insert with respect to the cut surface is favorable, and a honeycomb panel having sufficient bonding strength can be rationally manufactured.

Next, the seventh aspect described in claim 18
According to the method for manufacturing a honeycomb panel of the invention, by exposing the insert to the cut surface by cutting, and joining the frame material to the insert and the face plate by welding, the end faces of the face plate and the insert are aligned, the frame It is possible to rationally manufacture a honeycomb panel in which the joining work of the materials is easy and the joining strength is sufficient.

Next, as described in claims 19 and 20,
According to the method for manufacturing a honeycomb panel of the eighth invention, the cutting surface of the insert can be accurately determined by measuring the cell depth of the cutting portion and determining the cutting position where the insert is exposed. Therefore, it is possible to rationally manufacture a honeycomb panel having sufficient bonding strength.

Next, the ninth aspect described in claim 21.
According to the method for manufacturing a honeycomb panel of the invention, the honeycomb core and the channel-shaped material are arranged in consideration of other member joining positions, and temporary welding is performed on the unnecessary portion side of the honeycomb panel. By positioning,
Since the shape members can be accurately arranged, it is possible to rationally manufacture a honeycomb panel having sufficient bonding strength.

Next, the above-mentioned first
In the honeycomb panel for vehicle structure according to the invention of No. 0, since the insert is arranged in the opening of the honeycomb panel forming the vehicle body, the frame material having the outward flange on the insert and the face plate. By joining, it is possible to sufficiently secure the strength around the opening.

Next, according to the method for manufacturing a honeycomb panel of the eleventh aspect of the present invention described in claim 23, a honeycomb panel having a conventional structure having no insert is used, and the honeycomb is opened on the cut surface of the opening. By arranging the insert in the cell of the core, the welding strength of the frame material to the panel opening can be advantageously ensured, and the joint strength of the frame material in the opening can be advantageously ensured.

Next, according to the twelfth aspect of the manufacturing method of the honeycomb panel of the present invention, the insert is fitted into the cell opened on the cut surface of the prepared hole for the opening of the honeycomb panel. After that, by cutting around the prepared hole for the opening to form the opening, the end surface of the insert and the end surface of the face plate can be easily and satisfactorily matched with each other in the cut surface of the opening. Therefore, the butt welding of the frame material to the insert and the face plate on the cut surface can be easily performed.

Next, according to the method for manufacturing a honeycomb panel of the present invention as set forth in claim 25, since the insert is welded to the inner surface of at least one of the face plates, the positioning of the insert is advantageous. The welding strength of the frame material can be advantageously and stably obtained, and the work can be facilitated.

[0046]

The first embodiment of the present invention will be described in detail below with reference to FIGS. 1 to 9 in order to clarify the present invention more specifically.

FIGS. 1, 2 and 3 show a brazed aluminum honeycomb panel 10 obtained by the present invention and a vehicle structure using the brazed aluminum honeycomb panel 10. The honeycomb panel 10 constitutes a part of the railway vehicle structure, and has a generally rectangular flat plate shape that is curved as a whole. And, for example, as what constitutes the side wall of the structure, in the substantially central portion,
It has a circular window opening 12 for mounting a window material such as glass. A plurality of the honeycomb panels 10 are joined together to form a wall surface of a vehicle structure.

As shown in FIG. 3, the honeycomb panel 10 has a width that corresponds to the pitch of the window openings 12. A plurality of the honeycomb panels 10 are arranged in the longitudinal direction of the vehicle body, that is, four in the example of the structure shown in FIG. 3, and the side panels 16 are formed by joining the edge panels 14 (see FIGS. 1 and 2). In addition, in the honeycomb panel 10 which constitutes the side panel 16, a panel in which the window opening 12 is not formed is also used. Also, the roof panel 18
In the same manner, a plurality of honeycomb panels having no opening are joined together to be configured. Then, the side panels 16 are arranged side by side in the longitudinal direction of the vehicle body and joined to form the side frame 20. A plurality of roof panels 18 are arranged and joined to form a roof structure 22. The side wall 20 and the roof structure 22 are joined together via the eaves girder 24. The eaves girder 24 is installed on the upper side of the normal side frame 20 so as to extend in the longitudinal direction of the vehicle body. Also, the side frame 2
At the lower side of 0, a long base 26 is installed so as to extend in the vehicle body longitudinal direction. Further, the underframe 27 is installed between the long bases 26 of the gutters 20 arranged on both sides in the vehicle width direction, and the end structure 21 is installed to form a vehicle structure.

As shown in FIGS. 1 and 2, the honeycomb panel 10 is brazed integrally by sandwiching the honeycomb structure core 32 and the edge member 14 between the two front and back face plates 28 and 30. The structure is made up of: Edge material 1
4 are arranged on the outer peripheral edge portions of the four sides of the panel 10.
An annular frame member 34 is welded around the opening 12. The inside of the frame member 34 is the opening 12. Face plate 2
8, 30, honeycomb core 32, edge member 14 and frame member 34
Is made of aluminum alloy. The frame member 34 serves as a member for fixing the window member, and has a Z-shaped cross section.

The honeycomb panel 10 can be made into a large panel by welding the outer peripheral edge portions thereof to each other. The edge member 14 becomes a welded joint.

A method of manufacturing the brazed aluminum honeycomb panel 10 having such an opening will be described below with reference to the process chart shown in FIG.

First, the face plates 28, 30 and the honeycomb forming material of the honeycomb core 32, and the edge member 14 are manufactured (step S10).

Fabrication of the face plates 28, 30 and the honeycomb forming material is known. The face plates 28 and 30 have a plate thickness of 1 mm, and a brazing material having a clad ratio of 5% is clad on the honeycomb core 32 side.

The honeycomb forming material is a strip having a thickness of 0.2 mm and a width (height in the thickness direction of the honeycomb panel 10) of 28 mm, and a brazing material having a clad ratio of 5% is clad on both sides. Has been done. This honeycomb forming material is corrugated into a half-hexagonal shape. By arranging the corrugated honeycomb forming materials, a honeycomb core having hexagonal cells is obtained. Here, a honeycomb core having cells with a cell size of 3/4 ″ is configured. The cell size is the size of the diameter of the circle inscribed in the hexagonal cells.

The edge material 14 has a thickness of 2 mm, a height (same as the width of the honeycomb forming material) of 28 mm, and a depth of 1
It is 5 mm.

Further, in a step different from the step of forming the face plates 28, 30, the honeycomb forming material, and the edge member 14,
An aluminum alloy insert 36 is formed (step S100).

The insert 36 has a distance between the facing surfaces of the double-sided plates 28 and 30 in the formed honeycomb panel 10, that is, the width of the honeycomb forming material, that is, the honeycomb core 32.
The height of the honeycomb core 32 is the same as that of the honeycomb core 32, and is large enough to be accommodated in the cells of the honeycomb core 32. Although various shapes can be adopted as the shape of the insert 36, the insert 36 is in contact with the double-sided plates 28 and 30 in the largest possible area, and has a predetermined thickness as a welding member in the thickness direction of the honeycomb panel 10. In addition, it is desirable that it is lightweight.

As shown in FIG. 5, the insert 36 of this embodiment is formed by cutting a channel-shaped material in units of a predetermined length. The height of the vertical piece 36a: L ₁ is 28 mm, which is the same as the height of the honeycomb core 32, and the horizontal pieces 36b, 3
Length of 6c: L ₂ is 13 mm, cutting length: L ₃ is 13 mm,
The plate thickness is 2 mm. The horizontal pieces 36b and 36c are parallel to each other. In FIG. 5, the upper surface of the horizontal piece 36b and the horizontal piece 36c
The lower surface of is a contact surface with the face plates 28 and 30. The insert 36 is formed by cutting an extruded shape member made of aluminum alloy into an appropriate length, but may be another cutting work material or a plastic work material. As an insert, I
Type or substantially Z type may be used.

Next, as shown in FIG. 6, by arranging a plurality of honeycomb forming materials on one face plate 30 side by side so as to form a honeycomb structure,
The honeycomb core 32 is made. Further, four edge members 14 are arranged on the face plate 30 at the outer peripheral edge of the honeycomb core 32. Further, among the cells 38 in the honeycomb core 32, the inserts 36 are inserted into all of the cells 38 substantially located on the planned cutting line 40 for forming the opening 12.
Next, the face plate 28 is placed on this (step S2
0). This is called an assembly.

In inserting the insert 36, since the frame member 34 is continuously welded along the cutting line (planned cutting line 40), as many inserts 36 as possible are planned to be cut line 4.
It is desirable to place them in all cells located on 0.
Since the actual cutting line varies due to manufacturing error, it is considered that the cutting line has a width in the radial direction.
Insert 6 so that it is in a state of almost two rows.

The vertical piece 36a of the insert 36 is
It is arranged so as to be located outside the circular planned cutting line 40, that is, on the side of a necessary portion used as a product of this panel. Alternatively, the vertical piece 36a is arranged so as to intersect the planned cutting line 40. Even in the case of this intersection, some vertical pieces 36a
Is located outside the planned cutting line 40.

Further, in order to clarify the insertion position of the insert 36, a mark (not shown) is provided on the upper surface of the face plate 30 along the planned cutting line 40. This mark is painted by a color that is easy to visually recognize, and is placed inside the planned cutting line 40, that is, on an unnecessary portion of this panel that is not used as a product. Since there is no coating as the mark on the portion of the honeycomb panel 10 that is to be a product, it is possible to reduce the adverse effect of the coating on brazing.

Next, this assembly is heated above the melting temperature of the brazing material to obtain a brazed aluminum honeycomb panel in which all the members are integrally joined (step S30). That is, the honeycomb forming materials are brazed together to form a honeycomb core 32 having a honeycomb structure. The honeycomb core 32 includes the face plates 28 and 30, and the edge member 14.
To be brazed together. In addition, the edge member 14 is a face plate 28, 3
It is tied to 0. Also, the horizontal piece 36 of the insert 36
b and 36c are also brazed to the face plates 28 and 30.

Next, the honeycomb panel thus obtained is subjected to a bending process so as to have a curved shape corresponding to the shape of the product panel, that is, the honeycomb panel 10 constituting the structure (step S40). ..

Next, the honeycomb panel 10 is cut along the planned cutting line 40 to form the opening 12 that penetrates the honeycomb panel in the thickness direction (step S50).

As a result of this cutting, the cut surface is shown in FIG.
As shown in the cross-sectional schematic diagram of
The cells 38 of the honeycomb core 32 are opened. Then, the insert 36 brazed to the inner surface is provided in almost all of the opened cells 38, and the cut surface of the insert 36 is exposed on the cut surface.

Incidentally, for cutting such a honeycomb panel,
Various known methods such as a band saw cutting method, a wire cutting method, a plasma cutting method, and a laser cutting method can be adopted.

Next, as shown in FIG. 8, the opening 1
The frame material 34 made of an aluminum alloy separately formed for the honeycomb panel 42 which is the intermediate product in which 2 is formed.
Is assembled in the opening 12 and integrally attached by welding (steps S60 and S70).

The frame member 34 is formed, for example, by bending a shape member obtained by extrusion molding with an appropriate curvature, further cutting and welding it into an annular shape, and then forming the honeycomb panel. It is formed by bending with a curvature corresponding to 42 (steps S210, S).
220, S230).

The frame member 34 is formed by using a shape member having a substantially Z-shaped cross section. That is, the inward flange portion 46 and the outward flange portion 48 are integrally provided on both axial sides of the tubular portion 44 having a length substantially equal to the thickness of the honeycomb panel 42. The frame member 34 is fitted into the opening 12 from the back surface side (face plate 30 side) of the honeycomb panel 42. Then, with the outward flange portion 48 of the frame member 34 in contact with the face plate 30 on the panel rear surface side, the surface of the inward flange portion 46 is located on the same plane as the surface of the face plate 28 on the panel front surface side. In this assembled state, the outer peripheral surface of the inward flange portion 46 and the inner peripheral surface of the opening of the face plate 28 and the insert 36 are butt-welded. The outer peripheral edge portion of the outward flange portion 48 is fillet welded to the face plate 30.

The frame member 34, the face plate 28, the insert 3
In the butt-welding portion of 6 with the horizontal piece 36b, a die groove or a V-shaped groove is provided in advance and welding is performed. The processing of this groove is performed in steps S50 and S230.

By the way, in the above description, the insert 36 has the same height as the honeycomb core 32. However, the height dimension of the insert is the honeycomb core 3
It may be lower than the height dimension of 2. When the height dimension of the insert is lower than the height dimension of the honeycomb core 32, the insert is brazed only to one face plate. However, since the frame member 34 is welded only to the face plate and the insert or the face plate as described above, the insert does not necessarily have to be joined to both face plates.

The state in which the insert is brazed to both the face plates is strongest when the frame members are joined. However, in view of the welding condition of the frame material described above, the decrease in strength when the insert is brazed to only one of the face plates is very slight, and there is no problem.

The diameter of the outer edge portion of the outward flange portion 48 is set so that at least one effective cell that is not cut exists between the cut surface of the opening 12 and the outer edge portion of the outward flange portion 48. .. This is advantageous when pressure acts from the face plate 30 side (outward flange portion 48 side) toward the face plate 28 side (inward flange portion 46 side), and the outward flange portion 48.
The overlap margin between the honeycomb panel 42 and the honeycomb panel 42 is increased to reduce the possibility of breaking the honeycomb panel.

Then, after such welding, as shown in FIG. 9, the weld bead portion on the panel surface side is finished to be smooth. As a result, the intended aluminum honeycomb panel 10 having the opening 12 formed by welding and fixing the frame member 34 as shown in FIGS. 1 and 2 is obtained.

Honeycomb panel 1 obtained as described above
In 0, not only the thin face plate 28 and the honeycomb core 32 are welded to the frame material 34 and the honeycomb panel on the cut surface of the opening 12, but also the horizontal piece 36b or the vertical piece 36a of the thick insert 36. Also becomes an object to be welded. The insert 36 is integrally fixed to the panel. Therefore, particularly on the outer surface side of the structure, the necessary welding area can be secured and a predetermined welding strength can be obtained by overlapping the insert 36 and the face plate 28.

Since the inserts 36 are present in almost all cells on the cut surface, the strength is sufficient, and
Welding conditions can be made almost uniform along the welding line, and automatic welding becomes easy.

Further, in this embodiment, the insert 36 has a channel shape and has substantially the same height as the height of the honeycomb core 32, and the horizontal pieces 36b and 36c are fixed to the face plates 28 and 30. .. In addition, after the opening 12 is cut, the vertical piece 36a is positioned outside the cutting line (that is, on the necessary portion side of the honeycomb panel). Therefore, the external force acting on the butt weld is
Since it is also transmitted to the face plate 28, it is possible to obtain the honeycomb panel 10 having proof stress.

Furthermore, in the cut surface of the opening 12,
Since the insert 36 is exposed at the same position as the face plate 28, it can be easily welded to the frame member 34, and their welding strength can be sufficiently secured.

Further, since the insert 36 has a channel shape, the contact area with the face plates 28 and 30 can be widened.
Further, the insert 36 is lighter than a solid rod-shaped member.

Further, since the insert 36 is incorporated in the cells 38 of the honeycomb core 32, no unevenness is caused on the surface of the honeycomb panel 10. Therefore, the smoothing of the vehicle structure surface can be easily achieved.

Further, in the above-mentioned method, since the insert 36 is inserted into the cell 38 of the honeycomb core 32 at the time of manufacturing the assembly, the process and the operation are almost the same as those of the conventional brazed aluminum honeycomb panel. The intended aluminum honeycomb panel 10 can be manufactured. Therefore, it is possible to manufacture a honeycomb panel in which the strength of an opening such as a window is improved without changing the equipment or changing the process.

Further, in the method of this embodiment, the planned cutting position is determined in advance at the stage of obtaining the assembly, the insert 36 is arranged along this position, and the cutting is carried out along the planned cutting line 40. , Insert 36 for the cut surface
Are well arranged, and the initial bonding strength can be stably obtained.

If the face plate 28 or 30 is provided with a mark, the planned cutting value can be easily grasped and the setup can be done easily, so that the workability can be improved. Further, since the mark is provided in the unnecessary portion of the honeycomb panel 10, it is possible to eliminate the adverse effect of the mark paint or the like on the brazing material.

By the way, in the above embodiment, the frame member 34 is attached to the inner peripheral surface of the opening 12 to form the honeycomb panel 10. However, even a honeycomb panel in which the frame member 34 is not provided is It can be used as a structural member. That is, even with the honeycomb panel 42 in the state shown in FIG. 7 in which the insert 36 is exposed on the inner peripheral surface of the opening 12,
The other member joined to the opening 12 may be formed in a shape and size that can be fitted into the opening 12. In addition,
As the other structural member (hereinafter, simply referred to as a third member), a window frame, an entrance / exit frame, an inspection lid receiver, and a support member for a current collector attached to the outer peripheral portion of the structure can be considered. When the honeycomb panel 42 is used by being bonded to the third member, the shape of the bonding portion of the third member to be bonded can be fitted in correspondence with the inner peripheral shape and the size of the opening 12. If formed, they can be joined by welding in a fitted state. Further, even if a member corresponding to the frame member 34 is previously joined to another structure or a structural member and the honeycomb panel 42 is attached to this, the same situation occurs, and the honeycomb panel 42 can be used. As described above, the honeycomb panel 42 can be used without necessarily joining the frame members 34.

The structure is composed of the side structure 20 and the roof structure 2.
Although 2 is a honeycomb panel structure, if the honeycomb structure and the underframe of the body structure are also formed by using the honeycomb panel, similar effects can be achieved for these portions. That is, the gable structure has a through-passage opening, and it is easy to install a frame member attached to this portion or another member such as a hood bridge. In addition, it is possible to sufficiently secure the joint strength of these members. Further, even in the underframe, it is easy to install the inspection lid receiver provided on the floor plate made of the honeycomb panel or the frame member for the wiring through hole.

By the way, in the above embodiment, the insert 3 is formed before the honeycomb panel is integrally formed by brazing.
6 was arranged between two face plates, but a second embodiment in which an insert is provided later on a honeycomb panel in which a face plate and a honeycomb core are joined by brazing will be described with reference to FIGS. Based on this, description will be made below.

In the description of the second embodiment, the same reference numerals as those in the first embodiment will be used for the members having the same structures and the same steps as those in the first embodiment. Further, detailed description of members and steps having the same reference numerals as those in the first embodiment will be omitted.

That is, when manufacturing such a honeycomb panel 10, first, according to a known method, the opening 1 is formed.
Make a brazed aluminum honeycomb panel without 2.

Similar to step S10 of the first embodiment, the face plates 28, 30, the honeycomb forming material and the frame material 14 are obtained.

Next, the honeycomb forming material and the edging material 14 are placed between the double-sided plates 28, 30 to obtain an assembly. Then, by heating this assembly, a known brazed aluminum honeycomb panel can be obtained (step S320). Steps S20 and S30 of the first embodiment
Equivalent to. However, the work of inserting the insert into the honeycomb core is not included.

Then, the honeycomb panel thus obtained is first subjected to bending to obtain
A curved shape is formed in accordance with the shape of the product panel, that is, the honeycomb panel 10 forming the structure (step S40).

Further, as shown in FIGS. 11 and 12, a prepared hole 50 for an opening is formed in a portion corresponding to the opening 12 formed in the honeycomb panel 10 (step S340). The opening pilot hole 50 is made smaller than the opening 12 by a predetermined dimension. In the honeycomb panel 42, which is an intermediate product in which the pilot holes 50 for openings are formed in this manner, as is clear from the drawing, the plurality of cells 3 of the honeycomb core 32 are provided over the entire circumference of the cut surface.
8 is to be opened.

Next, as shown in FIG. 12 and FIG. 13, among the cells 38 of the honeycomb core 32 opened in the cut surface of the prepared hole 50 of the honeycomb panel 42,
The insert 36 is fitted and assembled to the appropriate number (step S350). The insert 36 is manufactured in the same manner as in step S100 of the first embodiment. Further, it is desirable that the insert 36 is assembled in the cell 38 that opens with a particularly large depth depth among the cells 38 that open in the cut surface of the prepared hole 50. Further, the number of the inserts 36 installed is not particularly limited, but in order to secure the fixing strength of the frame member 34 described later, as many as possible in the cut surface of the prepared hole 50, at least 4 or more. It is desirable to assemble. At the time of assembling the insert 36, it is not necessary to match the end surface thereof with the cut surface of the prepared hole 50, but the insert 36 is assembled in a state where the insert 36 is present across the inside and outside of the cut surface of the opening 12. .. The inserts 36 are temporarily fixed to the face plates 28 and 30 with an appropriate adhesive or the like.

Next, as shown in FIGS. 12 and 14, the regular openings 12 are formed in the honeycomb panel 42 as in step S50 of the first embodiment. That is, by such cutting work, the end surface of the insert 36 is made to coincide with the end surfaces of the face plates 28 and 30 and the honeycomb core 32 in the cut surface of the opening 12.

The following work is performed in steps S210, S220, S230, S60, S70 and S8 of the first embodiment.
The same as 0.

Honeycomb panel 1 obtained as described above
0, the effective bonding area between the frame member 34 and the honeycomb panel on the cut surface of the opening 12 is equal to the insert 3
Increase by 6. Therefore, it is possible to sufficiently secure the welding strength of the frame material 34 to the honeycomb panel.

By incorporating the insert 36 into the opening 12, not only the welding strength of the frame member 34 to the honeycomb panel 42 but also the strength of the opening 12 of the panel can be improved. Moreover, regarding the smoothing of the surface of the honeycomb panel 10, the same effect as that of the first embodiment can be achieved.

Further, as described above, according to the method of this embodiment, after the insert 36 is assembled in the prepared hole 50, the opening 12 which is slightly larger than the prepared hole 50 is formed.
In the opening 12, the end face of the insert 36 and the face plate 2
The end faces of 8, 30 and the honeycomb core 32 can be easily matched. Thereby, fitting and welding (particularly, butt welding) of the frame member 34 to the opening 12 can be easily performed.

By the way, in the second embodiment, the cells 3 opened on the cut surface of the prepared hole 50 formed in the honeycomb panel 42.
After inserting the insert 36 into the inside 8, the periphery of the prepared hole 50 is cut to form the opening 12 which is slightly larger than the prepared hole 50. But,
In processing the honeycomb panel 42, it is not always necessary to form the prepared hole. That is, the openings 12 are formed directly in the honeycomb panel 42, and the inserts 36 are inserted in the cells of the honeycomb core 32 that are opened in the cut surface of the openings 12.
Insert. Then, the end face of the insert 36 is cut so as to match the end faces of the face plates 28, 30 and the honeycomb core 32. It is also possible to weld the frame member 34 to the opening of the honeycomb panel 42.

By the way, if the above-mentioned method is adopted, it is possible to make the end face of the insert not coincide with the end faces of the face plate and the honeycomb core in the cut surface of the opening of the panel. It is also possible to project the end surface of such an insert more inwardly than the end surfaces of the face plate and the honeycomb core so that the frame member is supported by the projection.

Next, a third embodiment in which an opening having a linear portion like a rectangle is formed in a honeycomb panel will be described with reference to FIG.
5 will be described. The method of installing the insert on the honeycomb panel in the third embodiment is the same as that in the first embodiment.

In FIG. 15, when the honeycomb panel is cut linearly in the lateral direction (direction orthogonal to the continuous direction of the honeycomb forming material) at the time of forming the opening, a predetermined cutting position (cutting line 52a). When the cutting position is displaced in the vertical direction (shown by the cutting line 52b) with respect to the vertical direction, the insert 36 does not exist on the cutting line 52b, or even if the horizontal piece of the insert 36 exists on the cutting line, the face plate The contact area with can be very small. The latter horizontal piece is not effective as a welding member. Since this state is continuous along the straight cutting line 52b, the required welding strength cannot be obtained.

On the other hand, in FIG. 15, when the honeycomb panel is cut along the cutting line 54 in the vertical direction (the continuous direction of the honeycomb forming material) in forming the opening, even if the cutting line 54 is displaced in the horizontal direction, There will be at least every other cell on the cutting line 54 a horizontal piece of insert 36 that is effective as a welding member. However, it is desirable to have a horizontal piece in each cell on the cut line 54 as much as possible.

Therefore, it is desirable to determine each cutting line so that the horizontal piece of the insert 36 effective as a welding member can be exposed on these cutting lines in the horizontal and vertical directions. As a specific method therefor, in the case of cutting in the lateral direction, it is possible to cut at the position of the cutting line 52a (the position where the horizontal piece 36b fixed to the face plate 28 with a required area is exposed on the cutting surface). Will be described.

First, in the honeycomb panel 42, inside the planned cutting line 52a (on the side of the opening 12),
A square hole 56 that opens near the planned cutting line 52a is cut and formed. The cutting line 58 in the lateral direction of the square hole 56
The cut line 58 is positioned so that there is at least one cell 38 without the insert 36 between and the expected cut line 52a.

Next, the cell 38 opened by the above cutting.
A measuring instrument is inserted into the inside of the cell to measure the depth Ls of the opened cell. For example, such a measuring instrument is a caliper for measuring depth, and the tip of the instrument to be inserted into the cell has a triangular shape. Then, based on this depth, a cutting line 52 through which the horizontal piece of insert 36 may be exposed.
Obtain the position of a and cut at that position.

According to such a method, the cutting line 5
The distance from 2a to the outer edge of the honeycomb panel parallel to this changes. Therefore, corresponding to the position of the cutting line 52a,
The outer edge rim 14 and the face plates 28, 30 are cut so as to determine the required panel width and the position of the opening 12. This cutting method can also be used to determine the position of the cutting line 54 in the vertical direction.

Further, according to this cutting method, since the insert 36 and the frame member 34 can be accurately aligned with each other, the horizontal piece of the insert 36 is placed at the projection position of the outer edge portion of the outward flange portion of the frame member 34. It is also possible to make the outer edge portion of the outward flange portion small so as to be positioned so that it can be welded to the horizontal piece through the face plate 30.

In the first and third embodiments, the honeycomb panel is provided with a cylindrical opening such as a circle or a quadrangle.
However, in the present invention, the end portion of the honeycomb panel is cut out in a semicircular shape or a square shape, and another member is joined to the end surface, or the end surface is joined to another member, whereby It can also be used for attaching to a member.

Next, a fourth embodiment of the present invention will be described with reference to FIGS. 16 and 17.

In the fourth embodiment shown in FIG. 16 and FIG. 17, a square cut line 7 is formed between two face plates 61 and 62.
6 which is continuous along 6 and has a predetermined length
5 is arranged. FIG. 16 shows the face plate 6
FIG. 3 is a plan view showing a state in which the insert 65 is arranged along the planned cutting line 76 on FIG. Also, FIG.
7 shows a cross section of the main part after the completion of the present embodiment, that is, the installation portion of the insert 65.

The honeycomb panel of the fourth embodiment is used as an outer wall panel for construction, for example, and has a rectangular opening 75 for a window. In FIG. 16 and FIG. 17, continuous inserts 65 (65U, 65D, 65L, 65R) are arranged along a quadrangular cut line 76. The insert 65 is composed of four pieces 65U, 65D, 65L, 65R on the left, right, top and bottom in FIG. The ends of the inserts 65U, 65D, 65L, 65R are welded to each other to form a quadrangular integral frame shape as a whole. Insert 65U, 65D, 65L, 65R
Is formed of a channel-shaped material, and its vertical piece 65a is arranged outside the planned cutting line 76.

The frame material 70 arranged in the opening 75 has a channel-shaped cross section. Then, two parallel horizontal pieces of the frame member 70 are welded to the two horizontal pieces 65b and 65c of the insert 60 and the two face plates 61 and 62. Then, the frame member 70 is formed by each insert 65.
They are arranged in a quadrangle along U, 65D, 65L, and 65R. In addition, the frame member 70 includes the inserts 65U, 65
It welds so that the opening of the recessed part of D, 65L, 65R may be covered.

Next, the manufacturing procedure of the panel having the structure of this embodiment will be described. First, as shown in FIG. 16, a square insert 65 is placed on the face plate 61 arranged on the lower side, and the insert 65 is temporarily welded to the face plate 61 inside the planned cutting line 76. Next, the honeycomb core forming material and the edging material are arranged outside the insert 65 (the same honeycomb core forming material and edging material as those used in the first embodiment are used). In addition, in FIG. 17, reference numeral 62 denotes a face plate disposed on the insert 65 and the honeycomb core 32. The face plate 62 is placed on the insert 65 and the honeycomb core 32 to form an assembly, and brazing, cutting of the opening and welding of the frame member 70 are performed in the same manner as in the first embodiment. Thus, the desired honeycomb panel is formed.

According to the above manufacturing method, the insert 65 can be easily arranged. Further, since there is no honeycomb core inside the insert 65, the material can be saved. Further, since the frame member 70 is welded to the insert 65, the frame member 70 has a large wall thickness and facilitates automatic welding by MIG.

As the face plates 61 and 62, it is also possible to use those having an opening provided in advance.

The embodiments of the present invention have been described in detail above, but these are literal examples and the present invention should not be construed as being limited to such specific examples.

Specifically, the shape and the number of the inserts fitted into the cells of the honeycomb core are not limited, and depending on the strength required for the panel, the size of the cells of the honeycomb core, and the like. It is determined as appropriate.

Further, such an insert may be any one that can be brought into contact with the face plate in the mounted state of the honeycomb core in the cell, and it is also possible to use a plurality of different sizes and shapes. Is.

For example, the insert may have an I-shaped cross section. However, if an I-shaped cross section is used, the vertical piece is easily cut, so care must be taken.
Further, the insert may be a prism, and further, if the insert is formed into a hexagonal shape that substantially matches the cross-sectional shape of the cell, and if it is brazed to the honeycomb core, the contact surface with the honeycomb core increases, so the strength is improved Can be planned.

Since the weld bead generated on the panel surface by welding the frame material to the panel is small, it is not always necessary to erase this weld bead.

By the way, in each of the above embodiments, the face plate, the honeycomb core, the insert and the like are joined by brazing. However, the present invention should not be construed as being limited to brazing as the joining, and the members may be joined by a technique such as resistance welding or diffusion joining. The joining is metallic joining with the face plate, the honeycomb core and the insert.

When smoothness is required on both surfaces of the peripheral edge of the panel or the edge of the opening, the height of the frame material is set to be approximately the same as the thickness of the panel, and both sides in the height direction are set. At the end, butt welding is performed on the insert and both side plates of the panel. Then, if the surface of the welded portion is finished, the smoothness of the surface of the panel can be ensured relatively easily.

The honeycomb panel of the present invention can be used as various structural members such as automobile bodies or building materials. Particularly, it is most suitable for application to a portion having an opening. Also,
The manufacturing method of the panel of the present invention is widely used for manufacturing honeycomb panels having various structural materials such as automobile bodies and building materials, and having openings for piping, wiring, window formation, etc. It can be applied.

Although not listed one by one, the present invention
Based on the knowledge of those skilled in the art, it can be implemented in various modified, modified, and improved modes, and
It goes without saying that all such embodiments are included in the scope of the present invention without departing from the spirit of the present invention.

In each of the above-mentioned embodiments, an example in which a honeycomb core having hexagonal cells is used as the core arranged between the face plates has been described, but the present invention is not limited to this. That is, the same effect can be achieved by using a core in which the cell shape of the core is quadrangular or substantially triangular. Further, the core having a quadrangular cell shape is easy to manufacture itself, and the core having a substantially triangular cell shape has a feature that a spherical surface can be easily formed as a panel. As an example of the cell shape of these cores, see: Light Metal (1990) Vol. 40, N.
O. 5, page 394. Therefore, the "honeycomb" in the present invention includes not only hexagonal cells but also the above-mentioned quadrangle, triangle, and the like. Moreover, the honeycomb panel is composed of at least two face plates and a core connecting the two face plates. The core is
It is usually composed of a plurality of plate materials, and cells are formed between the plurality of plate materials. The plurality of plate members are joined to the face plate substantially orthogonally.

[0128]

As described above, according to the present invention, when joining a honeycomb panel and another member such as a frame member or a structural member, an insert is arranged on the end face of the joining portion, and the insert and the face plate are joined together. By joining to other members,
It is possible to secure an effective area for joining and to give sufficient strength to the joining portion.

Further, according to the present invention, it is sufficient to assemble the insert into the cell at the stage of obtaining the assembly or at the stage after the assembly is manufactured. It is possible to rationally manufacture the honeycomb panel that can secure the strength of the joint portion with the member.

Therefore, for example, when the honeycomb panel according to the present invention is applied to a vehicle body structure, sufficient strength around the window opening can be secured.

[Brief description of drawings]

FIG. 1 is a perspective view showing a honeycomb panel of a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of the honeycomb panel shown in FIG.

FIG. 3 is a perspective view showing an outline of a vehicle structure using the honeycomb panel shown in FIG.

FIG. 4 is a process diagram for explaining a method for manufacturing the honeycomb panel shown in FIG.

FIG. 5 is a perspective view for explaining a manufacturing method and a shape of an insert used in the honeycomb panel shown in FIG.

FIG. 6 is a plan view of a main part of a honeycomb panel in the process of being manufactured by the manufacturing method of FIG.

FIG. 7 is a cross-sectional view of an essential part of a honeycomb panel in the process of being manufactured by the manufacturing method of FIG.

FIG. 8 is a cross-sectional view of a main part of a honeycomb panel in the process of being manufactured by the manufacturing method of FIG.

9 is a cross-sectional view of a main part of the honeycomb panel shown in FIG.

FIG. 10 is a process drawing for explaining the manufacturing method of the honeycomb panel according to the second embodiment of the present invention.

FIG. 11 is a cross-sectional view of essential parts of the honeycomb panel in the process of being manufactured by the manufacturing method shown in FIG.

FIG. 12 is a plan view of a main part of the honeycomb panel in the process of being manufactured by the manufacturing method shown in FIG. 10, with one face plate removed from the drawing.

FIG. 13 is a cross-sectional view of essential parts of the honeycomb panel in the process of being manufactured by the manufacturing method shown in FIG.

FIG. 14 is a cross-sectional view of an essential part of a honeycomb panel in the process of being manufactured by the manufacturing method shown in FIG.

FIG. 15 is a plan view of a main part of a honeycomb panel according to a third embodiment of the present invention.

FIG. 16 is a plan view of a main part of the honeycomb panel of the fourth embodiment of the present invention during manufacturing.

FIG. 17 is a cross-sectional view showing an enlarged main part of the honeycomb panel shown in FIG.

[Explanation of reference numerals] 10,42 Honeycomb panel 12 Opening 14 Edge material 28,30 Face plate 32 Honeycomb core 34 Frame material 36 Insert 38 Cell 40 Scheduled cutting line 50 Opening hole 52a, 52b Cutting line 56 Square hole 58 Cutting Line 61, 62 Face plate 65 Insert 70 Frame material 75 Opening 76 Planned cutting line

Front Page Continuation (72) Inventor Sumio Okuno 502 Jinritsucho, Tsuchiura-shi, Ibaraki Hiritsu Seisakusho Co., Ltd.Mechanical Research Laboratory (72) Inventor Yuichiro Okudo Sumitomo Light Metal Co., Ltd. 3-12-12, Minen-ku, Nagoya (72) Inventor, Hiroshi Irie, 3-12-12, Millennial, Minato-ku, Nagoya-shi, Aichi Sumitomo Light Metal Industries, Ltd.

Claims (25)

[Claims] 1. An insert is arranged in a desired cell of a honeycomb core arranged between two face plates, and at least the honeycomb core is joined to each of the two face plates to be integrally formed. In the above honeycomb panel, a cut surface is formed in the thickness direction of the honeycomb panel at a position including cells having the insert, and a frame material is arranged on the cut surface. Is butt-welded to at least one of the face plate and the insert. 2. The honeycomb panel according to claim 1, wherein the insert is formed at substantially the same height as the height of the honeycomb core. 3. The honeycomb panel according to claim 1, wherein the insert is bonded to each of the two face plates. 4. The honeycomb panel according to claim 3, wherein the cut surface is formed in a plane of the honeycomb panel, and the cut surface constitutes an opening penetrating the honeycomb panel. Honeycomb panel. 5. The honeycomb panel according to claim 1, wherein the insert is composed of a piece joined to each of the two face plates and a piece connecting the two pieces. 6. An insert is arranged in a desired cell of a honeycomb core arranged between two face plates, and at least the honeycomb core is bonded to each of the two face plates to be integrally formed. In the honeycomb panel consisting of, in the honeycomb panel, at a position including cells having the insert, a cut surface is formed in a thickness direction thereof, and in the cut surface, an end surface of the insert and an end surface of the face plate are formed. The honeycomb panel is characterized by being substantially in the same position. 7. The honeycomb panel according to claim 6, wherein the insert has a channel-shaped cross section in the thickness direction of the honeycomb panel in a cut state, and the two inserts facing each other in the thickness direction of the honeycomb panel. A honeycomb panel, wherein one piece is bonded to each of the face plates. 8. A honeycomb panel in which a honeycomb core is installed between two face plates, and the honeycomb core is integrally formed by bonding the honeycomb core to each of the two face plates. It has an opening portion that penetrates the honeycomb panel in the plane, and an insert is arranged at the end surface portion of the opening portion of the honeycomb panel,
A honeycomb panel is characterized in that a frame member is arranged at an edge of the opening, and the frame member is joined to at least one of the face plate and the insert by butt welding. 9. A honeycomb panel in which a honeycomb core is installed between two face plates, and the honeycomb core is integrally formed by bonding the honeycomb core to each of the two face plates. It has an opening portion that penetrates the honeycomb panel in the plane, and an insert is arranged at the end surface portion of the opening portion of the honeycomb panel,
The honeycomb panel is characterized in that the honeycomb panel has a channel-shaped cross section in the thickness direction, and the end surface of the insert and the end surface of the face plate are substantially at the same position. 10. A step of obtaining an assembly in which a honeycomb core and an insert are arranged between two face plates, and the honeycomb core is fixed to the two face plates by joining the assembly. Manufacture of a honeycomb panel comprising: a step of obtaining a honeycomb panel; and a step of cutting the honeycomb panel along the insert in a thickness direction of the panel to expose the insert on the cut surface. Method. 11. The method for manufacturing a honeycomb panel according to claim 10, wherein, in the step of bonding the assembly, the insert is bonded to the face plate. 12. The method for manufacturing a honeycomb panel according to claim 10, wherein the cutting in the step of exposing the insert is performed according to a display provided on the surface of the face plate corresponding to the installation position of the insert. A characteristic method for manufacturing honeycomb panels. 13. The method for manufacturing a honeycomb panel according to claim 11, wherein a frame member having a shape corresponding to the shape of the cut portion is arranged in the cut portion generated by the step of cutting the honeycomb panel,
A method for manufacturing a honeycomb panel, comprising welding the frame material to the insert and at least one of the face plates. 14. The method for manufacturing a honeycomb panel according to claim 13, further comprising a step of bending the honeycomb panel in a thickness direction thereof before a step of welding the frame material,
In the step of welding the frame material, the method of manufacturing a honeycomb panel, wherein the frame material bent with substantially the same curvature as that of the bent honeycomb panel is arranged in the cutting portion and the welding is performed. .. 15. The method for manufacturing a honeycomb panel according to claim 11, wherein the step of obtaining the assembly includes the step of inserting an insert into a cell of the honeycomb core, and the cutting of the panel involves A method for manufacturing a honeycomb panel, characterized in that cutting is performed at a position including a cell in which an insert is inserted. 16. When the honeycomb core and the insert are arranged between two face plates, the insert is inserted into a desired plurality of cells of the honeycomb core which are located on a planned cutting line forming a cutting portion. And a step of joining the assemblies to obtain a honeycomb panel in which at least the honeycomb core is fixed to the two face plates, and the honeycomb panel is cut along the planned cutting line. A step of cutting the honeycomb panel in the thickness direction and removing an unnecessary portion, the method for manufacturing a honeycomb panel. 17. The method for manufacturing a honeycomb panel according to claim 16, wherein the insert is composed of two horizontal pieces that respectively come into contact with the face plate and a vertical piece that connects the two horizontal pieces. A method for manufacturing a honeycomb panel, characterized in that the insertion of the insert is performed such that the vertical piece is located closer to a necessary portion side of the honeycomb panel than the planned cutting line. 18. A honeycomb panel formed by joining a honeycomb core and an insert inserted into a cell of the honeycomb core to at least one face plate, at a position including a cell having the insert, in a thickness direction of the honeycomb panel. A step of exposing the insert to a surface generated by such cutting, and a step of arranging a frame material on the surface generated by the cutting, and welding the frame material to the insert and at least one of the face plates. A method for manufacturing a honeycomb panel, comprising: 19. A step of cutting a honeycomb panel in which a honeycomb core and an insert inserted into a cell of the honeycomb core are joined to at least one face plate in a thickness direction of the honeycomb panel, and an opening is formed by the cutting. Measuring the depth of the cell, determining the second cutting position based on the obtained cell depth, and exposing the insert by cutting at the second cutting position. A method for manufacturing a honeycomb panel, comprising: 20. The method for manufacturing a honeycomb panel according to claim 19, wherein a position of an outer edge of the honeycomb panel parallel to the second cutting position is determined in correspondence with the second cutting position, A method for manufacturing a honeycomb panel, which comprises cutting. 21. A channel-shaped profile having a horizontal piece and a vertical piece is arranged on a face plate so that the vertical piece is located on a necessary part side of a honeycomb panel, and an unnecessary part of the honeycomb panel is formed. On the side, a step of temporarily welding the shape member to the face plate, and arranging a honeycomb core on the face plate on the necessary part side of the honeycomb panel, and arranging another face plate on the shape member and the honeycomb core. A step of fixing the two face plates and the honeycomb core by bonding, a step of forming an opening in the plate thickness direction in the integrally bonded honeycomb panel, and a thickness of the honeycomb core. Welding a rim member to a horizontal piece and a face plate of the shaped member exposed at an opening penetrating in the direction. 22. A honeycomb panel formed by arranging a honeycomb core between two face plates and joining them together is integrally formed with an opening penetrating in the thickness direction thereof. An insert is joined and arranged between the two face plates at the edge of the opening, is a member to which the third member is attached, and can be fitted into the opening, and at the outer peripheral portion of the edge of the opening. A honeycomb structure for a vehicle body, characterized in that a frame material having an engageable outward flange is joined to an inner face plate and an insert of a honeycomb panel by welding to form at least a part of an outer wall surface of a vehicle body. panel. 23. A step of preparing a brazed honeycomb panel in which a honeycomb core is sandwiched between two face plates and integrally joined, and the honeycomb panel is cut, and the honeycomb panel is cut at a predetermined position in the panel thickness direction. A step of forming an opening penetrating therethrough, and a step of assembling by inserting an insert into each of the cells of the honeycomb core which are opened at a plurality of positions on the circumference of the cut surface of the opening, A frame member corresponding to the shape is fitted into the opening provided in, and the frame member is welded to the face plate and the insert so as to be integrally attached to the cut surface of the opening. A method for manufacturing a honeycomb panel, comprising: 24. A step of preparing a brazed honeycomb panel in which a honeycomb core is sandwiched between two face plates and integrally joined, and the honeycomb panel is cut, and the honeycomb panel is cut at a predetermined position in the panel thickness direction. And a step of forming a pilot hole for an opening penetrating the hole, and assembling by inserting an insert into each of the cells of the honeycomb core opened at a plurality of locations on the circumference of the cut surface of the pilot hole for the opening. Step, the honeycomb panel, by cutting the periphery along the prepared hole for the opening, to form an opening that is slightly larger than the prepared hole for the opening, and at the cut surface of the opening. A step of aligning the end surface of the insert with the end surfaces of the face plate and the honeycomb core; and fitting a frame material corresponding to the shape into the opening provided in the honeycomb panel, By allowed to weld with respect to the faceplate and insert, the cutting surface of such opening and attaching integrally, a method for manufacturing a honeycomb panel, which comprises. 25. The method for manufacturing a honeycomb panel according to claim 23, wherein the insert is brought into close contact with a cut surface of an opening in the honeycomb panel with an inner surface of the at least one face plate. In this state, the honeycomb core is assembled in the cells of the honeycomb core, and the frame material is welded to the close contact portions of the face plate and the insert.