JPH07279306A - Honeycomb core and honeycomb panel and those manufacture - Google Patents

Abstract

PURPOSE:To join a number of corrugated boards simultaneously by thermal fusion of thermoplastic resin films with each other, manufacture a honeycomb core and an entrance door effectively, and equip the resultant door with an enhanced anti-corrosiveness and durability. CONSTITUTION:A band of laminate steel plate formed by laminating thermoplastic resin films on both surfaces of a metal plate is folded zigzag at a certain pitch so that a corrugated board 10 is formed, and a plurality of such corrugated boards are joined together to construct a honeycomb core 2, wherein the bottoms of one board are fastened to the crests of the adjoining board by means of hot fusion attachment of the thermoplastic films with each other, and further a frame member 1 is installed around the obtained honeycomb core 2. A facial plate 3 and a rear plate 4 are furnished on the two surfaces so that an entrance door (honeycomb panel) A is accomplished.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb core, a honeycomb panel using the same, and a method for manufacturing them.

[0002]

2. Description of the Related Art Conventionally, as a metal entrance door, a so-called steel door, a metal honeycomb core is placed inside a metal (particularly surface-treated steel plate) frame member, and metal plates are provided on both front and back surfaces thereof. A bonded honeycomb panel is used. A honeycomb core used for such a honeycomb panel is formed by cutting a steel plate (particularly a surface-treated steel plate) into a hoop shape with a slitter and bending the corrugated plate to a corrugated plate at this pitch. Manufactured by arranging so that the peaks of the plates fit together, joining them by welding or adhering with each other, and then sequentially joining the third and subsequent corrugated plates in the same manner. ing. Further, the honeycomb panel is manufactured by further mounting a metal frame member around the honeycomb core or accommodating the metal frame member inside the frame member and joining other metal plates to both front and back surfaces.

[0003]

In the above-mentioned conventional honeycomb core, since corrugated sheets are aligned one by one and joined together, it takes a lot of time and labor to manufacture, and a frame member is attached around the completed honeycomb core. It is troublesome to adjust the dimensions when putting it inside the frame member. An object of the present invention is to provide a honeycomb core and a honeycomb panel which can be easily manufactured, and a simple manufacturing method thereof.

[0004]

The honeycomb core of the present invention comprises a plurality of corrugated plates formed by alternately bending a strip-shaped plate made of a metal plate laminated with a thermoplastic resin film on both sides, at the same pitch, It is characterized in that the valley portion of each corrugated sheet and the peak portion of another corrugated sheet adjacent to the corrugated sheet are joined by thermal fusion of the thermoplastic resin films.

In the honeycomb panel of the present invention, a frame member, the honeycomb core having the same width as the frame member, which is held inside the frame member, are joined to the front surface side and the back surface side of the frame member. It is composed of a front plate and a back plate.
In such a honeycomb panel, a laminated plate in which a thermoplastic resin film is laminated on one side of a metal plate is used as the front plate and the back plate, and the front plate and the back plate and the corrugated plate are made of a thermoplastic resin film. Those joined by fusion are preferred.

In the method for manufacturing a honeycomb core of the present invention, a metal plate laminated on both sides with a thermoplastic resin film is cut to form a band-shaped plate, and the band-shaped plate is alternately bent at the same pitch to form a plurality of plates. Forming a corrugated sheet, contact the troughs of each corrugated sheet and the crests of another corrugated sheet adjacent to the corrugated sheet, and heat-bond the thermoplastic resin films to each other at the abutting section. It is characterized by doing.

In the method for manufacturing a honeycomb panel of the present invention, a metal plate laminated on both sides with a thermoplastic resin film is cut to form a band-shaped plate, and the band-shaped plate is alternately bent at the same pitch to form a wave. A plate is formed, and a plurality of the corrugated plates are arranged inside a separately formed frame member so that the troughs of the corrugated plates and the peaks of other corrugated plates adjacent to the corrugated plate are in contact with each other. The thermoplastic resin films are heat-melt-bonded to each other, and the front and back plates are joined to both surfaces of the frame member.

Another aspect of the method for manufacturing a honeycomb panel of the present invention is to cut a metal plate laminated with a thermoplastic resin film on both sides to form a band-shaped plate, and bend the band-shaped plate alternately at the same pitch. To form a corrugated plate, and a plurality of the corrugated plates are brought into contact with a trough portion of each corrugated plate and a peak portion of another corrugated plate adjacent to the corrugated plate inside a separately formed frame member. In this manner, the front surface plate and the back surface plate made of a laminate obtained by laminating a thermoplastic resin film on one side of a metal plate are abutted on both sides of the frame member, and the whole is heated to form the thermoplastic resin film. It is characterized in that they are fusion-bonded to each other.

[0009]

In the honeycomb core of the present invention, since the corrugated plates are made of a thermoplastic resin laminated plate, a large number of corrugated plates are stacked in a predetermined state, and then the corrugated plates are wholly heated or partially heated in sequence. It can be manufactured simply by doing. Therefore, the work is significantly easier than the case of joining them one by one, and automation is also easy. Further, since the assembling work and the joining work are separate, each corrugated plate can be freely moved at the time of assembling, so that the accuracy of the whole corrugated plate combination is high. Furthermore, since each corrugated sheet is laminated with a resin film, the durability is high.

In the method for manufacturing the honeycomb core of the present invention, since the corrugated plates are joined by fusing the thermoplastic resin film, the manufacturing process is simplified even when a large number of corrugated plates are integrated. Easy to manufacture. Also, by forming a large number of corrugated sheets all in the same shape and alternately stacking them one by one in an opposite direction, the corrugated sheets of adjacent corrugated sheets can be easily assembled in a state where they are in contact with each other. be able to.

The honeycomb panel of the present invention and the method for manufacturing the same can be easily manufactured by simply inserting a large number of corrugated plates into a frame member manufactured in advance and then heating the contact portion.
In that case, both ends of the corrugated plate can be aligned by the frame member only by sequentially inserting the corrugated plate inside the frame member, so that the assembling work is simple. If all the corrugated sheets have the same shape and are piled up while being turned upside down, the peaks and the valleys can be naturally brought into contact with each other. If the frame member is installed vertically, a load is applied to the abutting portion by the weight of the corrugated sheet, so that the fusion of the resin films is ensured.

[0012]

EXAMPLES Next, a honeycomb core, a honeycomb panel and a method for manufacturing them according to the present invention will be described with reference to the drawings. FIG. 1 is a partially cutaway perspective view showing an embodiment of an entrance door adopting a honeycomb panel of the present invention, and FIGS. 2a and 2b are a partially enlarged front view of a honeycomb core in the entrance door of FIG. 1 and its P portion, respectively. FIG. 3 is an enlarged cross-sectional view, FIG. 3 is a front view of a main part showing another embodiment of the honeycomb core of the present invention, and FIG.
FIG. 5 is a process diagram showing one embodiment of the method of manufacturing the entrance door of FIG. 1 in that order, and FIG. 6 is a perspective view showing another embodiment of the entrance door employing the honeycomb panel of the present invention.

The entrance door A shown in FIG. 1 is a so-called steel door having soundproofing and semi-fireproof properties, and has a rectangular frame member (inner bone) 1, a honeycomb core 2 incorporated therein, and their front sides. And a front surface plate 3 and a rear surface plate 4 joined to the back side, respectively, and a locking mechanism 6 having a door knob 5. This front door A is an application example of the honeycomb panel of the present invention as a whole, but the honeycomb panel of the present invention is applied to various decorative panels, architectural or structural panels, etc. in addition to the front door A. sell.

Of the entrance door A, the frame member 1, the front plate 3, the rear plate 4 and the locking mechanism 5 are conventionally known. For example, the frame member 1 is formed by combining four upper, lower, left and right members made of steel having a U-shaped or rectangular cross section, and finally joining the corners by welding or screwing. The front plate 3 and the back plate 4 are made of flat steel plates or partially embossed steel plates. If fire resistance is not required, decorative plywood or the like may be used. The inner honeycomb core 2 is a main part of the present invention, and as shown in FIGS. 2a and 2b, a strip-shaped laminated steel plate 9 in which thermoplastic resin films 8 and 8 are laminated on both front and back surfaces of a base material 7 made of a steel plate. A large number of corrugated plates 10 each having a trapezoidal shape or a corrugated shape formed at the same pitch are stacked and joined.

Adjacent corrugated plates 10a and 10b are bent in the same shape by the same metal mold and the like, and they are alternately stacked one by one upside down, and the troughs 11 in that state.
And the mountain portion 12 are joined by heat-sealing the resin films 8 and 8 to each other. The corrugated sheets formed in different shapes may be alternately stacked one by one. The resin films 8 and 8 are easily joined by being heated to a temperature close to the melting temperature of the resin by, for example, heating in a high-temperature heating furnace, blowing hot air, or applying a soldering iron, and pressing each other. You can. The shape of the corrugated plate 10 that constitutes the honeycomb core 2 may be a curve in which trapezoids are alternately continuous as shown in FIG. 2 or a curve Q in which curved lines are continuous as shown in FIG.

Next, referring to FIG. 4 and FIG.
The manufacturing method of the front door A of No. 1 will be described. This manufacturing method is an embodiment of the method for manufacturing the honeycomb panel of the present invention. Figure 4
As shown in the first step S <b> 1 of the above, first, the four shape steels 13 cut into predetermined dimensions are joined in a frame shape to form the frame member 1. On the other hand, a laminated steel sheet 14 having thermoplastic resin laminated on both sides is slit to the same width as the frame member 1 (second step S2), and the obtained narrow plate material 15 is processed into a corrugated plate 10 by press molding or the like. (Third step S3). Then, the corrugated plates 10 are alternately turned over inside the frame member 1 one after another (fourth step S4) to fill the frame member 1 up to the top. In this state, the frame member 1 is leaned up and heated in a heating furnace to a temperature at which the thermoplastic resin films are fused (fifth step S5).

As a result, the corrugated sheets 10 are bonded to each other to form the integrated honeycomb core 2, and at the same time, the frame member 1 having the honeycomb core 2 built therein is obtained. Then, as shown in FIG. 5, a front plate 3 and a back plate 4 made of steel plates are bonded to the front surface and the back surface with an adhesive or the like (sixth step S6). This allows the entrance door A shown in FIG.
Can be obtained. The locking mechanism 6 may be assembled at the same time when the frame member 1 is assembled. According to the manufacturing method of the present invention as described above, it is not necessary to bond the corrugated plates 10 one by one, but it is possible to bond the corrugated plates 10 at the same time by heating a large number of stacked corrugated plates 10.

In the above-mentioned embodiment, the front plate 3 and the back plate 4 are adhered with an adhesive, but as the front plate 3 and the back plate 4, a laminated steel plate obtained by laminating a thermoplastic resin film on one surface of a metal plate such as a steel plate. If you use
In step S6, the front plate 3 and the back plate 4 are arranged so that the film faces inside and the frame member 1 and the honeycomb core 2 are formed.
It can be easily joined by stacking it on both sides and heating it. Further, in the fourth step S4 of FIG. 4, the front plate 3 and the rear plate 4 are piled up in the same manner, and the front plate 3 and the rear plate 4 are put in a heating furnace in order to fuse the corrugated plates 10 to each other. The back plate 4 may be fused.
This product has higher production efficiency, and since the cut end face of the corrugated plate 10 is covered with the resin film of the front plate 3 and the back plate 4, the corrosion resistance and durability are higher.

The entrance door B shown in FIG. 6 is a back member 16 in which the back plate 4a and the frame member 1a are integrated, and the back member 16 thereof.
And the backing member 16 housed inside the
And a front member 17 that covers the outside of the. Front member 17
The surface plate 3a and the frame member 1b are integrated with each other. Each of the front member 17 and the back member 16 may be formed by cutting a corner portion of a single steel plate and raising the peripheral edge, or by drawing. As the honeycomb core 2, the same one as the above-mentioned embodiment shown in FIG. 1 can be adopted. Further, the frame member 1b may not be formed on the front member 17, and the same plate-shaped surface plate 3 as in the case of FIG. 1 or 5 may be adopted. The entrance door B configured in this way has the same effects as in the above case in manufacturing the honeycomb core 2, and the corrugated plate 10 arranged on the back member 16 is stably held by the back member 16. Therefore, the manufacturing efficiency of the entire front door B is increased.

In each of the above embodiments, the inside of the honeycomb core 2 is hollow, but it may be filled with a conventionally known heat insulating material or sound insulating material such as glass wool or rock wool. Further, the corrugated plates of the honeycomb panel in the above-mentioned examples all use a steel plate as a base material, but an aluminum plate is used as a base material for reducing the weight of the door, and various kinds of galvanizing or the like for improving durability. It is also possible to use a steel plate subjected to surface treatment. On the other hand,
As the thermoplastic resin, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-acrylic ester copolymer,
Olefin resin such as ionomer, polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polyester such as ethylene terephthalate / isophthalate copolymer, nylon 6,
Polyamide resins such as nylon 6.6, nylon 11 and nylon 12, polyvinyl chloride, polyvinylidene chloride and the like can be mentioned. The film made of these resins may be uniaxially or biaxially stretched or unstretched. The resin film may be joined to the metal plate by any of heat fusion, adhesion using an adhesive, and heat fusion through a low melting point thermoplastic resin film.

[0021]

INDUSTRIAL APPLICABILITY In the honeycomb core, the honeycomb panel and the manufacturing method thereof according to the present invention, the corrugated plates are joined together by
Since it is carried out by heat fusion of a thermoplastic resin film preliminarily laminated on a metal substrate, many corrugated plates are simultaneously
It can be joined efficiently and the production efficiency is high. Furthermore, since most of the corrugated sheet except the cut end face is laminated with a resin film, it has high corrosion resistance and durability. Further, in the honeycomb panel using the laminated metal plate for the front plate and the back plate and the manufacturing method thereof, the production efficiency of the entire panel is high. Furthermore, the corrugated sheet including the cut end face is covered with the resin film, and thus the corrosion resistance and durability are further enhanced.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an embodiment of an entrance door using a honeycomb panel of the present invention.

2a is a partially enlarged front view of a honeycomb core in the entrance door of FIG. 1, and FIG. 2b is an enlarged sectional view of a P portion thereof.

[Fig. 3] Fig. 3 is a front view of a main part showing another embodiment of the honeycomb core of the present invention.

FIG. 4 is a partial process diagram showing, in that order, one embodiment of a method of manufacturing the entrance door of FIG.

5 is a partial process diagram of the manufacturing method of the entrance door, which is subsequent to FIG. 4; FIG.

[Fig. 6] Fig. 6 is a perspective view showing another embodiment of an entrance door using the honeycomb panel of the present invention.

[Explanation of symbols]

 A entrance door 1 frame member 2 honeycomb core 3 front surface plate 4 back surface plate 7 base material 8 thermoplastic resin film 9 laminated steel plate 10 corrugated plate 10a corrugated plate 10b corrugated plate 11 valley part 12 mountain part 1a frame member B entrance door 16 backing member 17 Front member 1b Frame member

Claims (6)

[Claims] 1. A plurality of corrugated plates formed by alternately bending a belt-shaped plate made of a metal plate laminated with a thermoplastic resin film on both sides at the same pitch. The corrugated plate has a valley portion and the corrugated plate. A honeycomb core in which the corrugated portions of another corrugated plate adjacent to the above are joined by thermal fusion bonding of the thermoplastic resin films. 2. The frame member, the honeycomb core according to claim 1, which is held inside the frame member and has the same width as the frame member, and the surface plate joined to the front surface side and the back surface side of the frame member. And a honeycomb panel including a back plate. 3. A laminated plate in which a thermoplastic resin film is laminated on one side of a metal plate is used as each of the front plate and the back plate, and the front plate and the back plate and the corrugated plate are formed by heat fusion of the thermoplastic resin film. The honeycomb panel according to claim 2, which is joined. 4. A metal plate laminated with a thermoplastic resin film on both sides is cut to form a band-shaped plate, and the band-shaped plate is alternately bent at the same pitch to form a plurality of corrugated plates, A method for manufacturing a honeycomb core, wherein a trough portion of each corrugated sheet and a peak portion of another corrugated sheet adjacent to the corrugated sheet are brought into contact with each other, and the thermoplastic resin films at the contact portions are heat-sealed to each other. 5. A metal plate laminated on both sides with a thermoplastic resin film is cut to form a band-shaped plate, and the band-shaped plate is alternately bent at the same pitch to form a corrugated plate,
Inside the frame member formed separately, a plurality of the corrugated sheets are arranged and held so that the valley portions of the respective corrugated sheets and the peak portions of other corrugated sheets adjacent to the corrugated sheet are in contact with each other, and A method for manufacturing a honeycomb panel, wherein the abutting portion is heated entirely or sequentially to heat-bond the thermoplastic resin films to each other, and further, a front plate and a back plate are bonded to both surfaces of the frame member. 6. A metal plate laminated with thermoplastic resin films on both sides is cut to form a band-shaped plate, and the band-shaped plate is alternately bent at the same pitch to form a corrugated plate,
Inside the frame member formed separately, a plurality of the corrugated sheets are arranged and held so that the valley portions of the respective corrugated sheets and the peak portions of other corrugated sheets adjacent to the corrugated sheet are in contact with each other, and On both sides of the frame member, the front surface plate and the back surface plate made of a laminated plate obtained by laminating a thermoplastic resin film on one surface of a metal plate respectively are abutted, and the whole is heated to fuse and bond the thermoplastic resin films to each other in the honeycomb panel. Manufacturing method.