JPH0716963A - Aluminum honeycomb panel having curved-surface and its manufacture - Google Patents

Abstract

PURPOSE:To provide a honeycomb panel and its manufacture which is easy to manufacture, superior in productivity, free from generation of a distortion or a pleat in a face sheet, possesses sufficient soldered state and a curved surface state having favorable accuracy and is superior in strength properties. CONSTITUTION:A pair of top and bottom aluminum alloy face sheets 2, 3 possessing a fixed curved surface, a plurality of aluminum alloy honeycomb core material 5 which are interposed between those face sheets 2, 3 and arranged so that the neighbouring ones come into contact with each other and a core material 6 made of an alluminum alloy which is inserted into a wedgy gap S to be formed between the honeycomb core materials 5 adjoining to each other are constituted by soldering integrally. Therefore, since the face sheets 2, 3 are free from generation of a distortion or a pleat by differing from a case where a curved-state honeycomb panel 1 is obtained while bending the honeycomb core 5 or the face, the honeycomb panel 1 which possesses sufficient soldered state and a curved state having favorable accuracy and is superior in strength properties is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curved aluminum honeycomb panel used as a structural material for ships, vehicles, buildings and the like, and a method for manufacturing the curved aluminum honeycomb panel. More specifically, it has sufficient brazing performance and good accuracy. The present invention relates to a curved aluminum honeycomb panel capable of obtaining a curved state and a manufacturing method thereof.

[0002]

2. Description of the Related Art Generally, an aluminum honeycomb panel is brazed with surface plates on both sides of a honeycomb core having a structure in which a large number of cylindrical chambers (cells) defined by thin plates of aluminum alloy are connected in a honeycomb shape. It is used as various structural materials for construction because it is light and has high strength. In using this honeycomb panel as various structural materials, it is desired to have a curved surface.

Conventionally, in order to obtain a curved honeycomb panel, a flat plate-shaped honeycomb panel is forcibly processed into a curved shape by roll bending or the like.

[0004]

However, in the above-mentioned honeycomb panel, since the one which is difficult to be bent itself is forcibly bent, the upper and lower surface plates are apt to be distorted or creases, and the strength characteristics are apt to be deteriorated. Not only that, there is a problem that it is difficult to obtain a curved surface state with good accuracy. In order to easily manufacture a curved honeycomb panel,
A honeycomb core, which is a flexible core material that can be deformed into a curved surface, is processed into a tapered cross section by plane cutting, and an outer plate is placed on both surfaces of the honeycomb core on a curved surface die and pressure-bonded to obtain a desired curved surface. Although a method for obtaining a shaped panel has been proposed (see Japanese Patent Publication No. 60-5174), this method has a problem that the number of steps is large and the productivity is low because cutting is performed.

The present invention has been made in view of the above circumstances. It is easy to manufacture and has excellent productivity, and the surface plate is free from distortion and creases. It is an object of the present invention to provide a honeycomb panel having excellent strength characteristics and a method for manufacturing the same.

[0006]

In order to achieve the above object, a curved aluminum honeycomb panel of the present invention includes a pair of upper and lower surface plates made of aluminum alloy having a predetermined curved surface, and interposed between these surface plates. Honeycomb core material made of a plurality of aluminum alloys arranged so that adjacent ones on the lower surface plate are in contact with each other, and an aluminum alloy gap inserted into a wedge-shaped gap formed between the adjacent honeycomb core materials It is characterized by being integrally brazed with a core material for use.

Further, according to the method of manufacturing a curved aluminum honeycomb panel of the present invention, a lower surface plate made of an aluminum alloy is placed on a lower mold having a predetermined convex curved surface, and a plurality of aluminum pieces are placed on the lower surface plate. After arranging the honeycomb core material made of an alloy so that the adjacent honeycomb core materials are in contact with each other and after inserting the core material for the gap made of the aluminum alloy into the wedge-shaped gap formed between the adjacent honeycomb core materials, the aluminum is formed on the gap core material. An upper mold having a predetermined concave curved surface is placed via an alloy upper surface plate, and the upper and lower surface plates and the core material are heated under pressure via the upper mold and the lower mold. The feature is that these are brazed together.

[0008]

According to the curved aluminum honeycomb panel of the present invention configured as described above, a plurality of honeycomb core members are adjacent to each other on the lower surface plate between a pair of upper and lower surface plates which are formed in a predetermined curved shape in advance. Are placed so that they contact each other, and the core material for the gap is inserted into the wedge-shaped gap formed between the adjacent honeycomb core materials, and these are integrally brazed together. Unlike the case of obtaining a curved honeycomb panel while bending the face plate,
It is possible to obtain a honeycomb panel excellent in strength characteristics, which has a sufficient brazing state and a curved surface state with good accuracy without causing distortion or folds on the surface plate.

Further, according to the method for manufacturing the curved aluminum honeycomb panel, the honeycomb panel can be easily manufactured, and the productivity can be improved.

[0010]

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

In FIG. 1, reference numeral 1 is an aluminum honeycomb panel, and this honeycomb panel 1 has a pair of upper and lower surface plates 2 and 3 made of an aluminum alloy and having a curved surface with a predetermined curvature. In this case, the lower surface plate 3 is curved so that its upper surface is convex, and the upper surface plate 2 is curved so that its lower surface is concave.

A panel frame 4 assembled by welding in a square shape by an aluminum extruded shape member having a U-shaped cross section is interposed between the two surface plates 2 and 3, and is divided by the panel frame 4. A plurality of honeycomb core materials 5 made of an aluminum alloy, which are arranged on the lower surface plate 3 so as to be adjacent to each other, are interposed between the surface plates 2 and 3. Then, as described above, the gap core material 6 made of an aluminum alloy is provided in the wedge-shaped gap S formed between the adjacent honeycomb core materials 5 by being arranged adjacent to each other on the convex lower surface plate 3. The upper and lower surface plates 2 and 3, the panel frame 4, the honeycomb core material 5 and the gap core material 6 are integrally brazed.

More specifically, as shown in FIG. 3, the panel frame 4 comprises vertical frames 4a located at both ends of the surface plates 2 and 3 in the circumferential direction, and horizontal frames 4b connecting the vertical frames 4a. The lateral frame 4b is previously curved and formed in an arch shape so as to follow the curved surfaces of the surface plates 2 and 3. In addition, the cross-sectional shape of the aluminum extruded profile forming the panel frame 4 is not limited to the U-shape,
It may be H-shaped or hollow. The honeycomb core material 5 is formed by laminating a number of thin plates 7 and adhering them in a zigzag manner (adhesive portions are denoted by reference numerals 7a), and pulling them from both sides in the laminating direction to form a large number of hexagonal cells 8. It is configured.

The honeycomb core material 5 is formed in such a size that it can be accommodated in the panel frame 4, and the surface plates 2 and 3 are formed.
Is divided into a plurality in the circumferential direction. Therefore, between the honeycomb core members 5 arranged adjacent to each other on the lower surface plate 3, a wedge-shaped gap S that expands upward is formed as shown in FIG.
Since it is formed continuously in the direction parallel to a,
In order to fill these gaps S, the gap core material 6 is inserted into each gap S. As shown in FIG. 4, the gap core material 6 is formed of a plate material or an extruded shape so as to follow the shape of the gap S and has a V-shaped cross section. Moreover, the gap core material 6 does not necessarily have to be a longitudinal through-hole along the gap S, and may be a piece.

According to the honeycomb panel 1 having the above-mentioned structure, a plurality of honeycomb core materials 5 are arranged on the lower surface plate 3 so as to be adjacent to each other between the pair of upper and lower surface plates 2 and 3 which are formed in a predetermined curved shape in advance. The honeycomb cores are arranged so as to be in contact with each other and intervened, and the core material for gap 6 is inserted into the wedge-shaped gap S formed between the adjacent honeycomb core materials 5 to integrally braze them. Unlike the case where a curved honeycomb panel is obtained by bending a surface plate or a curved surface plate, the surface plates 2 and 3 do not have distortion or creases, and have excellent strength characteristics in a sufficiently brazed state and a curved surface state with good accuracy. The honeycomb panel 1 obtained is obtained.

Next, a method of manufacturing the honeycomb panel 1 will be described. As shown in FIG. 5, first, the lower surface plate 3 made of aluminum alloy is placed on the lower mold 9 having a predetermined convex curved surface. The panel frame 4 is placed on the lower surface plate 3. Next, a plurality of aluminum alloy honeycomb core materials 5 are formed on the lower surface plate 3 partitioned by the panel frame 4.
Are arranged so that they are in contact with each other, and the gap core material 6 made of aluminum alloy is inserted into the wedge-shaped gap S formed between the adjacent honeycomb core materials 5. Then
An upper mold 10 having a predetermined concave curved surface is placed on the upper surface plate 2 made of aluminum alloy, and the upper and lower surface plates 2 and 3 are placed via the upper mold 10 and the lower mold 9. Then, the core materials 5 and 6 are heated under pressure to integrally braze the surface plates 2 and 3, the panel frame 4, the honeycomb core material 5 and the gap core material 6.

In this case, it is preferable that the surface plates 2 and 3 be formed in a curved shape in advance. However, when the surface plates 2 and 3 are thin, the lower mold 9 and the upper mold 10 are combined. You may make it form a curved surface directly. Moreover, a brazing material is applied in advance to at least one of the contact portions of the surface plates 2 and 3, the panel frame 4 and the core members 5 and 6 which are in contact with each other. Further, the lower mold form 9 and the upper mold form 10 are clamped from the vertical and horizontal directions by a tightening device (not shown), and in this clamped state, they are inserted into a furnace such as a heating furnace and heated.

In the above embodiment, the case where the honeycomb panel 1 is formed by using the panel frame 4 has been described, but it is not always necessary to use the panel frame 4, and the upper and lower surface plates 2 and 3, the honeycomb core material 5 are used. It is also possible to form the honeycomb panel 1 with the gap core material 6.

According to the above method for manufacturing a honeycomb panel,
As described above, the honeycomb panel 1 which is excellent in strength characteristics in a sufficiently brazed state and a curved surface state with good accuracy can be obtained, and the honeycomb panel 1 can be easily manufactured to improve productivity.

Although the gap core material 6 is formed in a V-shaped cross section in the above embodiment, the gap core material 6 is formed by bending a plate material as shown in FIGS. 6 (a) and 6 (b). It may be formed in an inverted triangular cross section. Also,
The gap core material 6 does not necessarily have a V-shaped or inverted triangular cross-section, and is formed in a trapezoidal cross-section so as to engage above the wedge-shaped gap S as shown in FIG. 7A, for example. Alternatively, it may be formed in a circular cross section as shown in FIG. Furthermore, the gap core material 6
In the case of forming the extruded profile, for example, as shown in FIG. 8A, the cross section is formed in an inverted A shape, and the thin plate portion 6b for cutting is formed on the horizontal plate portion 6a. When inserting into S, as shown in FIG. 8B, the horizontal plate portion 6a is cut off to form the gap core material 6 into the gap S.
The cross-sectional shape may be deformable according to the width of the.

Further, although the surface plates 2 and 3 are formed in the shape of an arch in the above embodiment, the surface plates 2 and 3 may be formed into a cubic curved surface having a large curvature. When the divided honeycomb core materials 5 are arranged on the lower surface plate 3, a gap S is generated between adjacent honeycomb core materials 5 not only in the horizontal direction but also in the vertical direction. The core material 6 may be inserted.

[0022]

As described above, according to the present invention, since it is configured as described above, the following excellent effects can be obtained.

1) According to the curved aluminum honeycomb panel of claim 1, a plurality of honeycomb core materials are contacted with each other on the lower surface plate between a pair of upper and lower surface plates which are formed in a predetermined curved shape in advance. Since the core material for the gap is inserted into the wedge-shaped gap formed between the adjacent honeycomb core materials and integrally brazed together, the honeycomb core and the surface plate are bent. Unlike the case where a curved honeycomb panel is obtained, a honeycomb panel excellent in strength properties having a sufficient brazing state and a curved surface state with good accuracy can be obtained without causing distortion or folds on the surface plate.

2) According to the method for manufacturing a curved aluminum honeycomb panel of claim 2, the honeycomb panel can be easily manufactured and the productivity can be improved.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a curved aluminum honeycomb panel of the present invention.

FIG. 2 is an enlarged cross-sectional view of a honeycomb core material portion in the panel of FIG.

FIG. 3 is a plan view of a honeycomb core material portion of FIG.

FIG. 4 is an enlarged cross-sectional view of a wedge-shaped core material.

FIG. 5 is a schematic cross-sectional view for explaining a method for manufacturing a curved aluminum honeycomb panel.

FIG. 6 is a cross-sectional view showing another embodiment of the wedge core material.

FIG. 7 is a cross-sectional view showing another embodiment of the wedge core material.

FIG. 8 is a cross-sectional view showing another embodiment of the wedge core material.

[Explanation of symbols]

 1 Honeycomb Panel 2 Upper Surface Plate 3 Lower Surface Plate 5 Honeycomb Core Material 6 Gap Core Material 9 Lower Formwork 10 Upper Formwork S Wedge-like Gap

Claims (2)

[Claims] 1. A pair of upper and lower surface plates made of an aluminum alloy having a predetermined curved surface, and a plurality of aluminum alloys interposed between the surface plates and arranged so that adjacent ones are in contact with each other on the lower surface plate. Honeycomb core material of
A curved aluminum honeycomb panel, which is integrally brazed with an aluminum alloy gap core material inserted into a wedge-shaped gap formed between adjacent honeycomb core materials. 2. A lower surface plate made of an aluminum alloy is placed on a lower mold having a predetermined convex curved surface, and a plurality of aluminum alloy honeycomb core materials are brought into contact with each other on the lower surface plate. After inserting the core material for the gap made of aluminum alloy into the wedge-shaped gap formed between the honeycomb core materials adjacent to each other, the predetermined concave shape is formed on the core material through the upper surface plate made of aluminum alloy. An upper formwork having a curved surface is placed, and the upper and lower surface plates and the core material are heated under pressure via the upper formwork and the lower formwork, and these are integrally brazed. Method for manufacturing curved aluminum honeycomb panel.