JPH08127090A - Soldered honeycomb panel unit and production thereof - Google Patents

Abstract

PURPOSE: To ensure the rigidity of the vertical frame material of a soldered honeycomb panel while enhancing dimensional accuracy by forming a notch part to the vertical frame material and fitting a horizontal frame material in the notch part. CONSTITUTION: A notch part 5 is provided to a vertical frame material 3 and a horizontal frame material 4 such as an intermediate horizontal material 4 is fitted in the notch part 5 to be temporarily welded thereto to form the frame member of a soldered honeycomb panel unit. It is desirable to make the size of the notch part 5 as equal as possible to the cross-sectional dimension of the intermediate horizontal frame material 4a to be fitted. If the width of the notch part 5 is smaller than that of the horizontal frame material 4, the contact part of the vertical and horizontal frame materials 3, 4 is built up at the time of fitting and soldering inferiority is induced. It is pref. to make the depth of the notch part 5 slightly large in order to correct the strain of the horizontal frame material 4 or to absorb the dimensional error thereof. Further, a peripheral edge horizontal frame member is also attached to the vertical frame material in the same way by providing a notch part to the vertical frame material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a brazed honeycomb panel unit for a structure, and more particularly to a brazed honeycomb panel unit suitable for forming a vehicle structure and a method for manufacturing the same.

[0002]

2. Description of the Related Art The structure of a vehicle such as a passenger train or a monorail is a side structure that constitutes a vehicle side wall, a roof structure that constitutes a roof,
It is formed by manufacturing the end frame and the underframe that form the end of the vehicle as a unit panel, and joining these unit panels.

Recently, from the viewpoint of vehicle weight reduction, aluminum brazed honeycomb panels have been attracting attention as a constituent element of a vehicle structure, and various improvements have been made for application to a vehicle structure. A brazed honeycomb panel made of aluminum (including aluminum and aluminum alloy; the same applies hereinafter) has a honeycomb core 6 formed by brazing and joining a plurality of aluminum brazing sheets 16 to each other as shown in FIG. Aluminum face plates (not shown in FIG. 6) are joined by brazing to the upper and lower surfaces of 6.

Conventionally, in order to manufacture a unit panel of a vehicle structure using an aluminum brazed honeycomb panel, first, as shown in FIG. 7, a large number of vertical frame members (S frames) are used.
19, peripheral edge horizontal frame member 17, intermediate horizontal frame member 17a (W frame)
Is temporarily welded at point w to form the frame body 1, and the honeycomb core 6 is arranged flush with the upper and lower surfaces of the frame body at the opening of the frame body 1, and aluminum face plates are arranged on the upper and lower surfaces. After that, heating and brazing are performed to form a brazed honeycomb panel unit, which is joined to form a vehicle structure unit panel. The reason why temporary tack welding is used to form the frame body is that the frame body is given a degree of freedom of deformation during heating for brazing to suppress the occurrence of distortion in the panel unit integrated with brazing, and it may be due to the distortion. This is to prevent defective attachment. Further, the provision of the intermediate lateral frame member is for giving strength.

FIG. 8 shows a frame body for forming a vehicle structure having a curved surface. Similarly, a plurality of vertical frame members 19 (S frames) and a peripheral lateral frame member 18 having a predetermined curvature and an intermediate horizontal frame member are provided. 18a
(R frame) is temporarily welded at point w to form.
The aluminum honeycomb core 6 is attached to the frame body 1,
Aluminum face plates are provided on both upper and lower surfaces, heated, and integrally brazed and joined together to form a brazed honeycomb panel unit. By joining the units, a vehicle body unit panel used for a curved surface portion is formed.

However, in the production of the conventional panel unit, as shown in FIGS. 7 and 8, the frame is formed only by temporarily fixing and welding a large number of short vertical frame members and horizontal frame members. Therefore, sufficient rigidity cannot be ensured, and when the honeycomb core is mounted and the face plate is arranged and heated and brazed, it is deformed and affects the dimensional accuracy of the manufactured panel unit. In particular, during heating, brazing, and during warpage correction after brazing, the joint between the temporary frame welded vertical frame member and horizontal frame member is likely to open, and as a result, the wall thickness of the face plate at this portion becomes thin. There is a possibility that the face plate may crack.

Further, since a large number of vertical frame members are used, the number of temporary fixing welding spots increases, and the dimensional accuracy in the vertical direction becomes poor, which often causes deviation from the dimensional tolerance. Furthermore, since a large number of vertical frame members are used. However, there is also a drawback that an extremely large number of restraint jigs are required during temporary tack welding. When the vertical frame member 20 having a cross-sectional shape as shown in FIG. 9 is combined with the horizontal frame member 21 to form the frame body 1, after the brazing, the protruding portion 22 of the horizontal frame member 21 must be cut out for use. There are many things that must be done.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned conventional problems in a brazed honeycomb panel unit, and its object is to ensure the rigidity of the vertical frame member, Temporary fixing welding of the frame body without causing problems in accuracy and without creating a gap in the joint between the vertical frame member and the horizontal frame member during heating, brazing or during warpage correction after brazing A brazed honeycomb panel unit for a structure that can be easily worked, particularly a brazed honeycomb panel unit suitable for a vehicle structure,
And to provide a manufacturing method thereof.

[0009]

A brazing honeycomb panel unit according to the present invention for achieving the above object comprises:
A brazing honeycomb panel unit that is integrally brazed so that a honeycomb core is mounted on a frame body composed of a vertical frame material and a horizontal frame material, and face plates are provided on the upper and lower surfaces of the frame body and the honeycomb core. A structural feature is that a cutout portion is provided in the cutout portion, and the horizontal frame member is fitted into the cutout portion to form a frame body.

The horizontal frame member is formed by a suitable number of intermediate horizontal frame members provided at intervals in the longitudinal direction of the peripheral horizontal frame member and the vertical frame member, and a cutout is provided at least in the intermediate horizontal frame member mounting portion of the vertical frame member. A second feature of the configuration is that a frame is formed by providing a portion and fitting the intermediate horizontal frame member in the cutout portion.

Further, an aluminum extruded shape member having a cross section in which welding grooves are formed in the vertical direction by superposing in opposite directions is used as a vertical frame member, and an aluminum extruded shape is formed in a notch provided in the vertical frame member. A third feature of the configuration is that a frame body is configured by fitting a horizontal frame material made of a material.

In the method for manufacturing a brazed honeycomb panel unit according to the present invention, the upper surface is composed of the first horizontal surface portion, the second horizontal surface portion which is connected to the first horizontal surface portion and the inclined surface portion, and which is located above the first horizontal surface portion, and the lower surface. Is used as a vertical frame member, and an aluminum hollow extruded profile member formed in parallel with the upper surface is used as a vertical frame member. After the honeycomb core is attached to the frame body, face plates are provided on the upper and lower surfaces of the frame body and the honeycomb core, and they are integrally brazed, and then trimmed diagonally from the first horizontal surface portion to the lower surface of the frame body. It is characterized by doing.

In the frame body of the brazed honeycomb panel unit according to the present invention, as shown in FIG. 1, a vertical frame member 3 is provided with a notch 5, and a horizontal frame member such as an intermediate horizontal frame member 4a is provided in the notch 5. 4 is fitted and temporarily fixed and welded.
It is desirable that the size of the notch 5 be as equal as possible to the cross-sectional dimension of the intermediate horizontal frame member 4a to be fitted. If the width of the cutout is smaller than the width of the horizontal frame member to be fitted, the contact portion between the vertical frame member and the horizontal frame member may rise during the fitting, which may cause brazing failure around the cutout. It is preferable that the depth of the notch is slightly larger in order to correct the distortion of the lateral frame member to be fitted and to absorb a dimensional error. In addition, it is preferable that the peripheral horizontal frame member is also provided with a notch at the end of the vertical frame member and fitted and temporarily welded, but the peripheral horizontal frame member is provided in a butt state as before. May be.

As the vertical frame member and the horizontal frame member, for example, aluminum extruded shape members having various sectional shapes with a width of 20 to 50 mm and a height of 20 to 100 mm can be used, and they are formed as described above. For example, an aluminum honeycomb core 6 having a cell size of 5 to 50 mm is mounted on the frame body 1, and aluminum face plates made of, for example, a brazing sheet are disposed on the upper and lower surfaces of the frame body 1 and the honeycomb core 6 to perform brazing. Heat to temperature and braze together.

In this case, the honeycomb core mounted on the frame body may be assembled by brazing in advance and assembled, but the aluminum brazing sheet subjected to corrugated processing is formed in the shape of the honeycomb core in the frame body. It is also possible to form a brazed honeycomb panel unit by arranging the face plates and arranging face plates made of aluminum brazing sheets on the upper and lower surfaces and heating and brazing at once. The honeycomb core can also be formed by brazing and joining a bare material. The molded panel unit can be applied as various structural materials.

Vertical frame members are overlapped and welded to each other,
When brazing honeycomb panel units are to be joined together to form a unit panel for a structure such as a vehicle structure, as shown in FIG.
And a second horizontal plane section 11 which is connected to the first horizontal plane section 10 and the inclined plane section 12 and is located above the first horizontal plane section 10,
An aluminum hollow extruded shape member having a lower surface 13 formed in parallel with the upper surface is used as a vertical frame member 3, a cutout 5 is provided in the vertical frame member 3, and an intermediate horizontal frame member 4a made of the aluminum extruded shape member is provided in the cutout 5. While being fitted, peripheral edge horizontal frame members are arranged at the ends of the vertical frame members, and these are temporarily welded together to produce the frame body 1.
The notch 5 has a depth up to the end of the second horizontal surface portion 11 and is formed so as not to reach the inclined surface portion 12. The side surfaces 14 and 15 of the vertical frame member 3 may have various shapes depending on the panel unit to be manufactured.

Next, as shown in FIG. 2, the honeycomb core 6 is attached to the opening of the manufactured frame body 1, and the face plates 7 and 8 made of aluminum brazing sheets are provided on the upper and lower surfaces of the frame body 1 and the honeycomb core 6, respectively. To arrange. The end portion of the face plate 7 disposed on the upper surface is made to coincide with the end portion of the second horizontal surface portion 11 of the vertical frame member 3 on the inclined surface portion 12 side, and is heated to the brazing temperature to be integrally brazed.

After brazing, as shown in FIG. 2, from the first horizontal surface portion 10 to the lower surface 13 of the frame body, it is diagonally trimmed along the line X-X to obtain the brazed honeycomb panel unit 2 shown in FIG. To do. As shown in FIG. 2, first, the frame body 1 is formed by using the vertical frame member 3 made of an aluminum hollow shape member, and is formed into a vertical frame member having an open end as shown in FIG. 3 by trimming after brazing. In this case, the strength of the open end of the vertical frame member 9 can be kept sufficiently high. on the other hand,
When the frame body is constructed using the vertical frame member 9 having an open end as shown in FIG. 3 from the beginning, the strength of the open end is lowered during brazing and heating, and the rigidity of the vertical frame member is poor.

In the brazed honeycomb panel unit 2 thus produced, as shown in FIG. 5, the vertical frame members 9 are superposed in opposite directions to form a welding groove K on the upper surface and the lower surface, and welding is performed. By joining the panel units 2, a structural material such as a vehicle body is formed. In the structural material thus formed, the horizontal frame members are joined to each other and extended to form a strong skeleton. Note that when strength is not required so much, the frame body only needs to be temporarily welded to the vertical frame member and the horizontal frame member, but in the case of an application requiring sufficient strength such as a vehicle structure, As shown in FIG. 4, it is preferable that a fillet weld W is formed in the fitting portion between the vertical frame member 9 and the intermediate horizontal frame member 4a to reinforce the fitting portion.

[0020]

According to the present invention, in the brazing honeycomb panel unit in which the honeycomb core is mounted on the frame body composed of the vertical frame member and the horizontal frame member, and the face plates are provided on the upper and lower surfaces to integrally perform the brazing, the vertical frame member is used. Since the frame body is formed by providing a cutout portion in the cutout portion and fitting the horizontal frame material into the cutout portion, it is not necessary to use a large number of divided vertical frame members, and the rigidity of the vertical frame member is improved and The frame material has good dimensional accuracy such as length accuracy, and the joint between the vertical frame material and the horizontal frame material opens during brazing heating, which reduces the thickness of the face plate and causes inconveniences such as cracks in the face plate. There is no. Such an effect can be exhibited by applying it to at least the intermediate lateral frame member, and the conventional butting method may be applied to the peripheral lateral frame member, but it is more effective if applied to the peripheral frame member. Further, the present invention can be applied to a frame body having only a peripheral frame member in which the intermediate horizontal frame member is omitted, and the dimensional accuracy can be made better than that of the conventional butting method.

Further, a frame body is formed by using an aluminum hollow extruded shape member having a cross-sectional shape as shown in FIG. 2 as a vertical frame member, and a honeycomb core and a face plate are arranged and brazed integrally, If the brazing honeycomb panel unit 2 is formed by trimming the frame material and forming the vertical frame material 9 having an open end as shown in FIG. 3, a panel unit having sufficient strength characteristics can be obtained. By uniting the vertical frame members 9 in opposite directions to form the welding groove K and welding, a unit panel that can be applied as a structural member for a structure, particularly for a railway vehicle structure is manufactured. However, the vertical frame member may be a quadrangle or the like.

[0022]

Embodiments of the present invention will be described below. Example 1 An aluminum hollow frame (material: 6063 alloy or 6N01 alloy, size: width 50 mm, height from bottom surface to second horizontal surface portion 80 mm, wall thickness 5 mm) having a cross-sectional shape as shown in FIG. Aluminum hollow frame made of the same material as the vertical frame (
The width was 50 mm, the height was 80 mm, and the wall thickness was 5 mm).

As shown in FIG. 2, in the frame, a cell size formed of a 0.2 mm thick aluminum brazing sheet in which BA4004 alloy is clad on both sides of a 3003 alloy core material
Aluminum brazing sheet with a 20 mm inch honeycomb core and the same face plate as the core material
(Thickness: 1 mm) was placed, and heated in a vacuum brazing furnace to 600 ° C. for brazing.

After brazing, trimming as shown by the line XX in FIG. 2 was carried out to produce a brazed honeycomb panel unit as shown in FIG. The fitting portion of the vertical frame member and the horizontal frame member of the frame body of this panel unit is reinforced by welding as shown in FIG. 4, and then the panel unit is polymerized in the opposite direction as shown in FIG. When the welding groove formed in the overlapping portion was subjected to MIG welding, a unit panel having sufficient strength and good dimensional accuracy without warpage was formed.

[0025]

As described above, according to the present invention, a dimensional change of a vertical frame member is provided in a warp correction during brazing heating or after brazing with a frame body having excellent rigidity and good length accuracy. Since the face plate does not have defects, a brazed honeycomb panel unit having sufficient strength characteristics can be obtained.

[Brief description of drawings]

FIG. 1 is a partial perspective view showing an arrangement of a vertical frame member and a horizontal frame member in forming a frame body of the present invention.

FIG. 2 is a partial perspective view showing an intermediate step of manufacturing a brazed honeycomb panel unit of the present invention.

FIG. 3 is a partially cutaway perspective view showing an embodiment of a brazing honeycomb panel unit of the present invention.

FIG. 4 is a cross-sectional view taken along the line AA of FIG. 3 showing the reinforcing welded portions of the fitting portions of the vertical frame member and the horizontal frame member.

5 is a partial perspective view showing a joined state of the panel unit of FIG.

FIG. 6 is a partial perspective view of a honeycomb core.

FIG. 7 is a perspective view showing a conventional frame body.

FIG. 8 is a perspective view showing another example of a conventional frame body.

[Explanation of symbols]

 1 Frame 2 Brazed Honeycomb Panel Unit 3 Vertical Frame Material 4 Horizontal Frame Material 4a Intermediate Horizontal Frame Material 5 Notch 6 Honeycomb Core 7 Face Plate 8 Face Plate 9 Vertical Frame Material 10 First Horizontal Plane Section 11 Second Horizontal Plane Section 12 Sloping Section 13 Bottom surface 14 Side surface portion 15 Side surface portion 16 Blazing sheet 17 Peripheral lateral frame material 17a Intermediate lateral frame material 18 Peripheral lateral frame material 18a Intermediate lateral frame material 19 Vertical frame material K Welding groove W Reinforcement welding part w Temporary fixing welding part

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[Procedure amendment]

[Submission date] February 17, 1995

[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 partial perspective view showing an arrangement of a vertical frame member and a horizontal frame member in forming a frame body of the present invention.

FIG. 2 is a partial perspective view showing an intermediate step of manufacturing a brazed honeycomb panel unit of the present invention.

FIG. 3 is a partially cutaway perspective view showing an embodiment of a brazing honeycomb panel unit of the present invention.

FIG. 4 is a cross-sectional view taken along the line AA of FIG. 3 showing the reinforcing welded portions of the fitting portions of the vertical frame member and the horizontal frame member.

5 is a partial perspective view showing a joined state of the panel unit of FIG.

FIG. 6 is a partial perspective view of a honeycomb core.

FIG. 7 is a perspective view showing a conventional frame body.

FIG. 8 is a perspective view showing another example of a conventional frame body.

FIG. 9 is a perspective view showing a combination of a conventional vertical frame member and horizontal frame member.

[Explanation of Codes] 1 Frame 2 Brazing Honeycomb Panel Unit 3 Vertical Frame Material 4 Horizontal Frame Material 4a Intermediate Horizontal Frame Material 5 Notch 6 Honeycomb Core 7 Face Plate 8 Face Plate 9 Vertical Frame Material 10 First Horizontal Surface 11 Second Horizontal Surface portion 12 Sloping surface portion 13 Lower surface 14 Side surface portion 15 Side surface portion 16 Blazing sheet 17 Peripheral lateral frame material 17a Intermediate horizontal frame material 18 Peripheral lateral frame material 18a Intermediate horizontal frame material 19 Vertical frame material 20 Vertical frame material 21 Horizontal frame material 22 Projection part K Weld groove W Reinforcement weld w Temporary stop weld

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Claims (4)

[Claims] 1. A brazing honeycomb panel unit which is integrally brazed so that a honeycomb core is mounted on a frame body composed of a vertical frame member and a horizontal frame member, and face plates are provided on the upper and lower surfaces of the frame member and the honeycomb core. In the brazed honeycomb panel unit, the vertical frame member is provided with a cutout portion, and the horizontal frame member is fitted into the cutout portion to form a frame body. 2. The horizontal frame member is formed by a proper number of intermediate horizontal frame members that are provided at intervals in the longitudinal direction of the peripheral horizontal frame member and the vertical frame member, and at least the intermediate horizontal frame member attachment portion of the vertical frame member. The brazed honeycomb panel unit according to claim 1, wherein a cutout portion is provided in the cutout portion, and a frame body is formed by fitting the intermediate horizontal frame member into the cutout portion. 3. A vertical frame member is an aluminum extruded shape member having a cross section in which welding grooves are formed in the vertical direction by polymerizing in opposite directions to each other, and an aluminum extruded shape member is provided in a notch provided in the vertical frame member. The brazed honeycomb panel unit according to claim 1, wherein a horizontal frame member made of a material is fitted to form a frame body. 4. An aluminum hollow extrusion whose upper surface is composed of a first horizontal surface portion, a second horizontal surface portion which is connected to the first horizontal surface portion and an inclined surface portion and which is located above the first horizontal surface portion, and whose lower surface is formed parallel to the upper surface. A vertical frame member is used as a shape member, a horizontal frame member made of an aluminum extruded shape member is fitted into a notch provided in the vertical frame member, and temporary fixing welding is performed to form a frame body, and a honeycomb core is attached to the frame body. A brazed honeycomb panel unit characterized by being mounted, disposing face plates on the upper and lower surfaces of the frame and the honeycomb core, and integrally brazing, and then diagonally trimming from the first horizontal plane portion to the lower surface of the frame. Manufacturing method.