JPH06316009A - Honeycomb panel and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a honeycomb core panel and a method for manufacturing it without leaving weld trace on a face sheet and without generating waviness of the face sheet due to weld strain by using energy beam when a honeycomb core having flanges and face sheets are to be connected. CONSTITUTION:A honeycomb panel is constituted of a honeycomb core 2 having flanges 30, 31, face sheets 3, 4, and energy beam EB for superposing and welding the honeycomb core and the face sheets at the flanges.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb panel made of metal foil such as stainless steel or titanium and a method for manufacturing the same. These panels consist of a honeycomb core sandwiched between a pair of face sheets. Usually, the core is formed from a plurality of corrugated strips, which are bonded together to form a honeycomb structure. The facesheet is secured to the edges of the honeycomb core by gluing or other means. Such a structure is very light and has excellent strength. This type of panel is commonly used in aircraft and ships.

[0002]

2. Description of the Related Art A face sheet is bonded to a honeycomb core by electric resistance welding or an adhesive. Regarding the electric resistance welding method, for example, JP-A-62-9434 is used.
No. 3 publication.

According to this, an electrode bar 90 having a pair of electrode strips 92 and 94 extending as shown in FIG. 11 (A) is prepared, and a core strip 96 is provided with flange portions 30 and 32 of the electrode strip. Place on the electrode strip so that it is exposed to the outside. Next, this electrode strip and the core strip mounted thereon are placed between a pair of face sheets 98 and 100 to form a nest with the core strip 102 as shown in FIG. 11 (B). Then, an electric current is passed through the electrode wheel 104 to weld the core strip 96 to the face sheets 98 and 100.

Thereafter, the top of the core strip 96 is shown in FIG.
A nodal point welder 106 shown in FIG. 1 (C) welds to the valley portion of the core strip 102 already joined. In summary, first, the core sheet and the face sheet are joined, and then the cores are joined together. This is repeated to manufacture a honeycomb panel. Also,
There is also a method of joining the face sheet to the honeycomb core with an adhesive using a honeycomb core having no flange.

[0005]

DISCLOSURE OF THE INVENTION As mentioned above,
The conventional welding of the honeycomb core and the face sheet by the electric resistance welding method involves welding the cores one by one to the face sheet, which is very troublesome.
Furthermore, since the face sheet and the honeycomb core flange are sandwiched between the electrode wheel and the electrode bar to perform electric resistance welding,
Deformation easily occurs in the welded portion, undulations occur on the surfaces of both face sheets, and large weld marks are left on both sides of the face sheet.

Further, when the face sheet and the honeycomb core are joined by an adhesive instead of welding, the face sheet does not have welding marks and undulations, but it has a drawback that it is inferior in heat resistance to the joining method by welding. The present invention makes it possible to improve the productivity of a honeycomb panel produced by welding using an energy beam, in which no waviness occurs in the face sheet, and at least one face sheet has no welding marks left, which is excellent in heat resistance. A honeycomb panel to be manufactured and a manufacturing method thereof.

[0007]

According to the present invention, a honeycomb panel is formed by joining a honeycomb core to which a flange for welding with a face sheet is added and a face sheet by energy beam welding, to obtain heat resistance, productivity and strength. And a honeycomb panel in which welding marks are not left on at least one of the face sheets. The gist of the invention is a honeycomb panel including a pair of face sheets and a honeycomb core having a flange. A sheet is joined to the honeycomb core from the core side by lap welding with the energy beam, and the other face sheet is joined to the honeycomb core from the face sheet side by lap welding with the energy beam. Honeycomb panel characterized by being manufactured and manufactured And a method of manufacturing the same.

Further, in a honeycomb panel composed of a face sheet and a honeycomb core having a flange, one face sheet is joined to the honeycomb core from the core side by lap welding with the flange portion by an energy beam, and the other face is joined. An energy beam is injected into a V-shaped narrow groove portion which is formed by joining the sheet and the honeycomb core between the flange portion and the face sheet, and the V-shaped groove portion is moved for a while while being subjected to multiple reflection. A honeycomb panel and a method for manufacturing the same, which are manufactured by condensing light at the back of the narrow groove and welding the face sheet and the flange.

[0009]

The operation of the present invention will be described in detail below with reference to the accompanying drawings. The operation described below is intended to explain the present invention in principle, and of course has no meaning to limit the invention.

The honeycomb core used in the present invention has flanges on both sides thereof, which are joints with the face sheet (FIG. 2). The honeycomb core can be roughly classified into two types depending on the positions of the flanges on both sides thereof. The first type is a honeycomb cell having a flange on only one of both surfaces (FIG. 10B), and the second type is a honeycomb cell having a flange on both surfaces (FIG. 10C). A big difference between these two types of honeycomb cores occurs when the energy beam is injected from the core side for joining with the face sheet. The first type has a feature that the angle of incidence of the energy beam and the degree of freedom of position are large because the flange does not block the energy beam. In the second type, the flange part obstructs and it is necessary to inject the energy beam at an angle.

Hereinafter, a case of manufacturing a honeycomb panel using the first type honeycomb core will be described. The honeycomb core is pre-bonded to a size required for manufacturing a honeycomb panel. As the method, any one of conventional energy beam welding, electric resistance welding, and adhesive bonding may be selected. To form a honeycomb panel, a flange portion of the honeycomb core is superposed on a face sheet to form a contact portion, and an energy beam is applied to the contact portion,
The flange and the face sheet are overlapped and welded, and the face sheet and the honeycomb core are joined (Fig. 1).

First, one face sheet is lap-welded with the flange portion by an energy beam,
The honeycomb core is joined from the core side (FIG. 6). At this time, the flange portion is present on only one of both surfaces of the same honeycomb cell as described above, and its cross section is formed in a hook shape (FIG. 4A), or is formed so as not to exist on any surface other than the welded surface. (FIG. 4B), the energy beam is not blocked by the flange when the energy beam is injected to bond the face sheet and the honeycomb core. Therefore, at the time of joining, the positional relationship between the energy beam, the flange and the face sheet is such that the flange and the face sheet are in contact with each other, and the energy beam is shielded from the flange side of the contact surface to the flange other than the welded surface from the perpendicular direction of the contact surface. It is in a position where the energy beam can be input without being hit. At this time, by selecting the conditions for inputting the energy beam or by parallelizing the heat removal in the vicinity of the welded portion and controlling the maximum depth of the molten layer inside the face sheet to be equal to or less than the thickness of the face sheet, It is possible to eliminate the generation of welding marks, distortion in the welded portion and its periphery, and waviness of the face sheet.

The other face sheet is bonded to the honeycomb panel in which one face sheet is bonded to the honeycomb core as described above. A flange portion on the opposite surface of the honeycomb core, one surface of which is welded from the inside of the core, is overlapped with a face sheet to form a contact portion, and an energy beam is applied to the contact portion from the face sheet side to weld the face sheet and the flange (FIG. 7). ). Similar to the joining of the face sheet and the honeycomb core from the inside of the core, the conditions for inputting the energy beam were selected, or heat removal in the vicinity of the welded portion was made parallel, and the distortion of the welded portion and its periphery, the face, It is possible to eliminate the occurrence of sheet undulations. In addition, in the honeycomb panel in which the face sheets are welded in this way, no welding mark is left on one of the face sheets.

Alternatively, when one face sheet is joined to the honeycomb core by joining the one face sheet to the honeycomb core from the inside of the core by the energy beam, the other face sheet is joined,
A V-shaped narrow groove is formed between the flange of the honeycomb core and the face sheet, and an energy beam is injected into this narrow groove portion to move the V-shaped groove portion for a while and to multiple-reflect the energy beam. It is also possible to manufacture a honeycomb panel by condensing the particles in the deep end of the narrow groove, welding the face sheet to the flange of the honeycomb core, and joining the face sheet to the honeycomb core (FIG. 8). At this time, by selecting the conditions for inputting the energy beam or by parallelizing the heat removal in the vicinity of the welded portion and controlling the maximum depth of the molten layer inside the face sheet to be equal to or less than the thickness of the face sheet, It is possible to eliminate the generation of welding marks, distortion in the welded portion and its periphery, and waviness of the face sheet. In addition, in the honeycomb panel in which the face sheets are joined in this manner, no welding marks are left on the face sheets on both sides.

Since the method of the present invention is to form a honeycomb panel by welding a honeycomb core to which a flange is added and a face sheet, unlike a honeycomb panel in which the core edge portion and the face sheet are joined by using an adhesive, It is characterized in that it does not break the joint below and has excellent heat resistance, and that it is excellent in strength due to the increase in the joint area between the honeycomb core and the face sheet due to the addition of the flange. Further, the present invention is to perform the formation of the honeycomb core and the joining of the face sheet and the honeycomb core in separate steps, and after performing positioning once when joining the two,
The face sheet and honeycomb core can be joined in a very short time by scanning the energy beam toward the weld at high speed or moving the face sheet and honeycomb core at high speed with respect to the energy beam. The performance is also greatly improved compared to the conventional method.

The honeycomb core according to the present invention may have any shape as long as it has a flange.
Therefore, the honeycomb core having the prismatic shape shown in the above-mentioned embodiment and the hexagonal prismatic shape described in the embodiment are not particularly concerned. Also, the location where the flange is present is not necessarily two sides, and it is possible to select the surface where the flange is present and its shape, and there is no particular limitation. Therefore, depending on the application of the honeycomb panel, for example, when it is used at a high temperature location, a material having an excellent heat insulating effect is used to improve the heat resistance effect. There is no problem even if the core edge portion and the face sheet are joined by an adhesive without applying the method and forming a flange to be the joined portion.

[0017]

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The embodiments described below are intended to explain the present invention in principle, and needless to say have no meaning to limit the invention. The core strip constituting the honeycomb core used in the examples is made of stainless steel and has a thickness of 100.
μm, so that the honeycomb core cell shape is an assembly of regular hexagonal prisms, one side is 4 mm, and the angle between adjacent sides is 6 mm.
It is a shape in which a 0-degree trapezoid is made continuous in succession. For the flange part, the sides parallel to the longitudinal direction of the core strip are alternately selected, and one side of the side is punched out by the press working, and the edge part is punched out. On the other hand, it was bent vertically to be molded (FIG. 3). The core strips are combined so that the flanges present on the sides parallel to the longitudinal direction are back-to-back (FIG. 4 (A)), and the core strips are pre-formed by lap welding between the core strips by irradiation with a YAG laser. (FIG. 2 (A)). YAG at this time
The laser was focused by a lens having a focal length of 100 mm and pulse energy of 500 mJ was irradiated at the focal position.

(1) YA, which is a typical energy beam for joining the above honeycomb core and face sheet
A G laser was used. The face sheet is made of stainless steel and has a thickness of 300 μm. The honeycomb core was placed on the face sheet, the honeycomb core flange portion was brought into contact with the face sheet, and the contact portion was irradiated with YAG laser from the flange side to weld the face sheet (FIG. 6). The YAG laser focused using a lens having a focal length of 100 mm, and the work piece had an irradiation energy of 900 mJ at the focal position.

A similar face sheet was used in which the other face sheet was joined to the honeycomb panel in which one face sheet was welded to the honeycomb core as described above. The face sheet was placed on the honeycomb core, the honeycomb core flange portion and the face sheet were brought into contact with each other, and this contact portion was irradiated with YAG laser from the face sheet side this time to join the face sheets (FIG. 7). . Y
The AG laser focused with a lens having a focal length of 100 mm, and the work piece had an irradiation energy of 1200 mJ at the focal position.

(2) Using the same honeycomb panel as in Example (1), one face sheet is joined by contacting the honeycomb core flange portion with the face sheet, and the YAG laser is applied to the contact portion from above the flange portion. On the honeycomb panel made by irradiating the face sheet and welding the face sheet to the other face sheet to form a V-shaped narrow groove between the honeycomb core flange and the face sheet. A YAG laser beam was focused on the inside of the narrow groove by welding while introducing the beam and moving the V-shaped groove part for a while, and was welded to the flange of the honeycomb core (FIG. 8). At this time, the YAG laser was introduced into the tapered groove portion from an angle of 7 ° above the flange surface.
The YAG laser energy was 250 mmJ, and the condenser lens had a focal length of 200 mm.

(3) A honeycomb sheet was manufactured by welding a face sheet having a plate thickness of 5 mm to the same honeycomb core as that used in Example (1) above. First, one face sheet was joined to the honeycomb core from the core side by lap welding with the flange portion using a YAG laser beam (FIG. 9 (A)). Furthermore, when welding the other face sheet to this honeycomb panel, first, the plate thickness 3
Place a 00μm stainless steel plate on the honeycomb core,
The flange portion was superposed and welded with a YAG laser beam to bond the stainless steel plate to the honeycomb core (FIG. 9 (B)).

A face sheet having a plate thickness of 5 mm,
A V-shaped narrow groove is formed between the stainless steel plate joined to the honeycomb core, and a YAG laser beam is injected into this narrow groove to move the V-shaped groove portion for a while, and multiple reflection is performed on the laser. The beam was focused on the inner side of the narrow groove and the stainless steel plate and the face sheet were joined together to manufacture a honeycomb panel (FIG. 9 (C)). In this way, a honeycomb panel having a thick face sheet could be manufactured by welding. In this example, a thin honeycomb steel plate was joined to both surfaces of the honeycomb core to form a preliminary honeycomb panel, and a V-shaped narrow groove was formed between the stainless steel plate and the face sheet. It is also possible to apply a YAG laser beam to the groove, multiple-reflect it, focus the laser beam on the inner side of the narrow groove, and join the preliminary honeycomb panel and the face sheet (FIG. 9 (D)). .

(4) From the appearance test after welding on the honeycomb panel of Example (1), YA was measured from the core side.
No welding mark, welding distortion, or waviness could be confirmed on the surface of the face sheet welded by G laser irradiation.
Also, on the face sheet surface welded from the face sheet side, although there were welding marks with a diameter of 500 μm, welding distortion and waviness could not be confirmed. In addition, in the honeycomb panel of Example (2), neither welding marks, welding distortion nor waviness could be confirmed on the surface of both face sheets.

(5) As an evaluation of the mechanical properties of the honeycomb panel, a honeycomb panel having a side of about 75 mm was formed and subjected to a compression test. As a result, the maximum load resistance was about 6 tons, and peeling from the face sheet was observed. I could not admit. Further, as a heat resistance test, the sample was left to stand in an electric furnace at 1400 ° C. for about 15 minutes for gradual cooling, but similarly, no peeling between the core flange portion and the face sheet was observed. Therefore, it was confirmed from these tests that the honeycomb panel was superior in strength and heat resistance as compared with the conventional honeycomb panel.

It is also possible to form the above-mentioned honeycomb core by using the same core strip and combining them so as not to contact the flanges existing on the sides parallel to the longitudinal direction (FIG. 4 (B)). Also in this case, it is possible to form a honeycomb core having a feature that a flange exists on only one of the front surface and the back surface of the honeycomb core (FIG. 2).
(B)). Then, face sheets can be joined to such a honeycomb core by the same method.

Further, in the core strip used in this embodiment, the flange portion is bent to the opposite side at both ends thereof. This means that the joint portion of the face sheet and the honeycomb core is as uniform as possible in the honeycomb panel, That is, it is performed so that the strength becomes uniform. Since it is possible to have the flange on any side of the hexagon forming the honeycomb core by providing the flanges on the opposite sides at both ends of the core strip as in the present embodiment, the strength of the honeycomb panel is improved. Can be improved.

[0027]

EFFECTS OF THE INVENTION By using an energy beam for joining a honeycomb core having a flange and a face sheet,
Compared with conventional bonding, it can be manufactured stably at a higher speed, it can be used even in high temperature because it is not bonded by conventional adhesive, and by adding a flange, the contact area between the core and face sheet increases, It is possible to provide a strong honeycomb panel.

[Brief description of drawings]

Figure 1 is a conceptual diagram of joining the face sheet and honeycomb core,
2A is a schematic diagram of the honeycomb core, FIG. 2B is a schematic diagram of the honeycomb core, FIG. 3 is a schematic diagram of the core strip, and FIG.
(A) is a diagram of an example of a combination method of core strips, FIG. 4 (B) is a diagram of an example of another combination method of core strips, FIG. 5 is a conceptual diagram of joining a face sheet and a honeycomb core, and FIG. 6 is a face. FIG. 7 is a conceptual diagram of joining of the sheet and the honeycomb core, FIG. 7 is a conceptual diagram of joining of the other face sheet and the honeycomb core, FIG. 8 is a conceptual diagram of joining of the other face sheet and the honeycomb core, and FIG. FIG. 10 is an explanatory diagram of a method for manufacturing a honeycomb panel, FIG. 10 is an explanatory diagram of an example of a method for joining a honeycomb core and a face sheet, and FIG. 11 is an explanatory view of a conventional method for manufacturing a honeycomb panel.

[Explanation of symbols]

 1: Honeycomb panel 2: Honeycomb core 3: Face sheet 3 ': Dummy face sheet 4: Face sheet 4': Dummy face sheet 21-29: Honeycomb core strip 30-33: Flange portion 90: Electrode bar 92: Electrode Strip 94: Electrode strip 96: Core strip 98: Face sheet 100: Face sheet 102: Core strip 104: Electrode ring 106: Node welder LB: Laser beam

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[Procedure amendment]

[Submission date] August 17, 1993

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

[Brief description of drawings]

FIG. 1 is a conceptual diagram of joining a face sheet and a honeycomb core,

[Fig. 2] is a schematic view of a honeycomb core,

FIG. 3 is a schematic diagram of a core strip,

FIG. 4 is a diagram showing an example of a combination method of core strips,

FIG. 5 is a conceptual diagram of joining a face sheet and a honeycomb core,

FIG. 6 is a conceptual diagram of joining a face sheet and a honeycomb core,

FIG. 7 is a conceptual diagram of joining of the other face sheet and the honeycomb core,

FIG. 8 is a conceptual diagram of another joining of the other face sheet and the honeycomb core,

FIG. 9 is an explanatory view of a method for manufacturing a honeycomb panel of the embodiment,

FIG. 10 is an explanatory view of an example of a method for joining a honeycomb core and a face sheet,

FIG. 11 is an explanatory diagram of a conventional method for manufacturing a honeycomb panel.

[Explanation of Codes] 1: Honeycomb panel 2: Honeycomb core 3: Face sheet 3 ': Dummy face sheet 4: Face sheet 4': Dummy face sheet 21-29: Honeycomb core strip 30-33: Flange portion 90: Electrode bar 92: Electrode strip 94: Electrode strip 96: Core strip 98: Face sheet 100: Face sheet 102: Core strip 104: Electrode ring 106: Node welder LB: Laser beam

[Procedure Amendment 2]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

[Figure 1]

[Fig. 2]

[Figure 3]

[Figure 5]

[Figure 6]

[Figure 4]

[Figure 7]

[Figure 8]

[Figure 9]

[Figure 10]

FIG. 11 ─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] November 26, 1993

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0010

[Correction method] Change

[Correction content]

The honeycomb core used in the present invention has flanges on both sides thereof, which are joints with the face sheet (FIG. 2). The honeycomb core can be roughly classified into two types depending on the positions of the flanges on both sides thereof. The first type is a honeycomb cell having a flange on only one of both surfaces (FIG. 10B), and the second type is a honeycomb cell having a flange on both surfaces (FIG. 10C). A big difference between these two types of honeycomb cores occurs when the energy beam is injected from the core side for joining with the face sheet. The first type is characterized in that the flange does not block the energy beam, so the angle of incidence of the energy beam and the degree of freedom of position are large (Fig. 1).
0D). In the second type, the flange part becomes an obstacle and it is necessary to inject the energy beam at an angle (Fig. 10).
E).

Claims (4)

[Claims] 1. In a honeycomb panel comprising a face sheet and a honeycomb core having a flange, one face sheet is joined to the honeycomb core from the core side by lap welding of the flange portion with an energy beam, and the other face. A honeycomb panel manufactured by joining a sheet to the honeycomb core from the face sheet side by lap welding with the flange portion using an energy beam. 2. In a honeycomb panel comprising a face sheet and a honeycomb core having a flange, one face sheet is joined to the honeycomb core from the core side by lap welding of the flange portion with an energy beam, and the other face. A method for manufacturing a honeycomb panel, characterized in that the sheet is bonded to the honeycomb core from the face sheet side by lap welding with the flange portion using an energy beam, and is manufactured. 3. In a honeycomb panel comprising a face sheet and a honeycomb core having a flange, one face sheet is joined to the honeycomb core from the core side by lap welding of the flange portion with an energy beam, and the other face. The sheet and the honeycomb core are joined to each other by multiple reflection while moving the V-shaped groove portion for a while by introducing an energy beam into the V-shaped narrow groove portion formed between the flange portion and the face sheet. A honeycomb panel, which is manufactured by condensing light in the deep part of the narrow groove and welding the face sheet and the flange. 4. In a honeycomb panel comprising a face sheet and a honeycomb core having a flange, one face sheet is joined to the honeycomb core from the core side by lap welding of the flange portion with an energy beam, and the other face. The sheet and the honeycomb core are joined to each other by multiple reflection while moving the V-shaped groove portion for a while by introducing an energy beam into the V-shaped narrow groove portion formed between the flange portion and the face sheet. A method of manufacturing a honeycomb panel, which comprises manufacturing the honeycomb panel by condensing the light in a deep portion of the narrow groove and by welding the face sheet and the flange.