JPH09193267A - Curved surface honeycomb panel and its manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a curved surface honeycomb panel and its manufacturing method, with which highly accurate specified curvature exactly the same as the designed value is obtained and which is excellent in the aspect of cost such as the cost reduction burden of a mold or the like. SOLUTION: In the manufacturing method of a curbed surface honeycomb panel 10, first of all, an inner surface plate 4 is formed under pressure by means of a tensile forming or the like and, at the same time, a large number of cut-in groove-like slits S are formed on a flat outer surface plate 5. After that, the inner surface plate 4 and the outer surface plate, between which a honeycomb core 6 as a core material is pinched through adhesive, are heated and pressurized by means of a mold 7 equipped with the specified curvature. Thus, on both the inner and outer sides of the honeycomb core 6 as the core material, the inner surface plate 4 and the outer surface plate 5, both of which respectively act as using surfaces, are bonded together so as to obtain the curved surface honeycomb panel 10 equipped with the specified curvature as a whole and also a rigidity as a whole.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a curved honeycomb panel and a method for manufacturing the same. That is, the inner and outer surfaces of the honeycomb core, which is the core material, are bonded to the inner surface plate and the outer surface plate that form the use surface, and are provided with a predetermined curvature as a whole, for example, used as a parabolic antenna, a curved surface. The present invention relates to a honeycomb panel and a method for manufacturing the same.

[0002]

2. Description of the Related Art FIGS. 3 and 4 are provided for explaining a conventional curved honeycomb panel and a manufacturing method thereof. 3 (1) is a front explanatory view of the forming process of the inner surface plate, and FIG. 3 (2) is a front explanatory view of the formed inner surface plate.
(3) is a front explanatory view of the molding process of the outer surface plate, (4) is a front explanatory view of the molded outer surface plate, (5) is a front explanatory view of a raised float, etc. (6) The figure is an explanatory plan view of the floating or the like that has occurred. Further, FIG. 4 (1) is a front explanatory view of the prepared inner surface plate, outer surface plate, honeycomb core, etc.
(2) The figure is a front explanatory view of the process of heating and pressing these,
(3) FIG. 3 is a front explanatory view of the obtained curved honeycomb panel.

Now, the curved honeycomb panel 1 of this type is
It was manufactured as follows. That is, first, as shown in FIG. 3 (1), (2), (3), (4), etc., the inner surface plate 4 and The outer surface plate 5 and the outer surface plate 5 are pressure-molded with respective predetermined curvatures by stretch forming processing, that is, tensile molding or the like. And next, FIG. 4 (1) figure, (2) figure,
(3) As shown in the figure, between the inner surface plate 4 and the outer surface plate 5,
A predetermined curved honeycomb panel 1 is obtained by sandwiching a honeycomb core 6 as a core material while interposing an adhesive (not shown) and heating and pressurizing it using a mold 7 having a predetermined curvature. That is, the inner surface plate 4 and the outer surface plate 5 that form the use surfaces are formed on both the inner and outer surfaces of the honeycomb core 6, which is the core material.
Thus, the curved honeycomb panel 1 is obtained in which the and are bonded together and have a predetermined curvature as a whole. In FIG. 4 (2), 8 is an autoclave, which is an example of a heating and pressing device, and 9
Is the vacuum sheet.

[0004]

The following problems have been pointed out in such a conventional example. First of all, the inner surface plate 4 and the outer surface plate 5 are not easily fitted to the molds 2 and 3 when pressure molding is performed by tensile molding or the like. For example, as shown in FIGS. As described above, the float A was likely to occur. That is, with respect to the inner surface plate 4 and the outer surface plate 5, for example, residual stress or residual strain may remain due to heat generated by tensile molding, springback may occur after load is removed, or uneven distribution may occur. Inner surface plate 4 that fits molds 2 and 3 securely
It was difficult to obtain the outer plate 5. That is, it is difficult to obtain the inner surface plate 4 and the outer surface plate 5 having the predetermined curvature of the designed value, and when the load is removed, the float A on the inner surface plate 4 and the outer surface plate 5 is easily generated on the molds 2 and 3. . Therefore, with respect to the conventional curved honeycomb panel 1 in which the inner surface plate 4 and the outer surface plate 5 are bonded to the inner and outer surfaces of the honeycomb core 6 as a core material, the surface accuracy is poor and a high accuracy cannot be obtained. , A problem was pointed out in terms of accuracy.

Secondly, not only the inner surface plate 4 which forms the use surface of the curved honeycomb panel 1, but also the outer surface plate 5 is
It has been pointed out that the cost burden is large because the material is pressure-molded by stretch forming, that is, tensile molding. That is, since the inner surface plate 4 and the outer surface plate 5 have slightly different predetermined curvatures, respectively, as shown in FIGS. While being used, it is pressure-molded by tensile molding or the like. For example, two types of molds 2 and 3 must be prepared, and the cost burden of the molds 2 and 3 is large. It was pointed out.

In view of such circumstances, the present invention has been made to solve the problems of the above-mentioned conventional example, and by adopting an outer surface plate having a large number of slits in the form of cut grooves, Secondly, it is an object of the present invention to propose a curved honeycomb panel and a method for manufacturing the same, which is excellent in surface accuracy and secondly excellent in cost.

[0007]

The technical means of the present invention for solving such a problem is as follows. First, claim 1 is as follows. That is, this claim 1
The curved honeycomb panel of No. 2 has an inner surface plate and a outer surface plate to be used surfaces to be bonded to both inner and outer surfaces of a honeycomb core, which is a core material, and has a predetermined curvature as a whole. A large number of slit-shaped slits are formed in the outer surface plate.

Next, claim 2 is as follows. That is, according to the manufacturing method of claim 2, the inner surface plate and the outer surface plate that form the use surface are bonded to both the inner and outer surfaces of the honeycomb core that is the core material, and the inner surface plate and the outer surface plate are provided with a predetermined curvature. The present invention relates to a method for manufacturing a curved curved honeycomb panel. Then, first, while using a mold having a predetermined curvature, the inner surface plate having a predetermined curvature is pressure-molded by tensile molding or the like, and a plurality of slit-like slits are formed in the flat outer surface plate. By sandwiching the honeycomb core, which is a core material between the inner surface plate and the outer surface plate while interposing an adhesive, and heating and pressurizing using a mold having a predetermined curvature, the curved honeycomb panel can be obtained. Characterize.

Then, in this curved honeycomb panel and the manufacturing method thereof, firstly, as the outer surface plate, one having flexibility provided by a slit is used, and it can be easily deformed to a predetermined curvature. . Therefore, a curved honeycomb panel having a predetermined curvature can be easily obtained as a whole. Secondly, since the outer plate is used by slitting a flat plate as described above, the cost burden of the mold is reduced correspondingly, and the overall cost is excellent.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail based on embodiments of the invention shown in the drawings. 1 and 2 are provided for explaining an embodiment of the present invention. (1) of FIG. 1 is a front explanatory view of a slit processing step, and (2) is a diagram showing a formed slit inverted inside and outside. Plan view,
(3) FIG. 3 is a front sectional view showing various aspects of the slit,
(4) FIG. 4 is a front explanatory view of a process of heating and pressing the inner surface plate, the outer surface plate, the honeycomb core and the like. 2A and 2B are front explanatory views of the obtained curved honeycomb panel, in which FIG. 1A shows a first example, FIG. 2B shows a second example, and FIG. 3C shows a third example. Note that FIG. 5 (1) is a front cross-sectional explanatory view showing an example of use as a parabolic antenna, and (2) is a perspective view of a honeycomb core.

First, a method of manufacturing the curved honeycomb panel 10 will be described. In this manufacturing method, first, a mold 2 having a predetermined curvature is used, and the inner surface plate 4 for the inside having a predetermined curvature is used.
Is subjected to pressure molding by tensile molding or the like, and a large number of slits S in the form of cut grooves are formed in the flat outer surface plate 5 for outside.

These will be described in more detail. First, the mold 2 for the inner surface plate 4 is, for example, a curved jig also called a mandrel as shown in FIG.
The mold surface has a predetermined curvature, for example, a parabolic surface, a hemispherical surface, other quadric surface or cubic surface, and in the illustrated example, a convex curved surface, but a concave curved surface is also possible. As a material for the inner surface plate 4, a metal material such as aluminum or aluminum alloy, aramid paper or other reinforced paper, vinyl chloride or other plastic material, fiber reinforced plastic (FRP) material, or other composite material is used. Then, a plate material made of such a material is heated and pressed using the mold 2 to obtain an inner surface plate 4 having a predetermined curvature, as shown in, for example, FIG. To be For example, the inner surface plate 4 can be obtained by performing stretch forming processing that applies a tensile force, that is, tensile forming while accommodating the heated plate material in the forming mold 2. The wall thickness of the inner surface plate 4 is, for example, about 1 mm.

On the other hand, as the outer plate 5, unlike the ones shown in FIGS. 3 (3) and (4) described above, a plate member that remains flat is prepared. 1)
Slitting is performed as shown in the figures, (2) and (3). In the example shown in FIG. 1 (1), the outer surface plate 5 is fixed on the suction hole U of the vacuum table T, and an NC machine or the like from the upper side with respect to such outer surface plate 5,
A large number of slits S are formed. The slit S has a groove shape and is formed to give flexibility to the entire flat outer surface plate 5, that is, deformability to a predetermined curvature, and such a function (and how much surface accuracy is required). Various depths, widths, shapes, directions, numbers, and pitches are used according to the degree of accuracy required. The slit S shown in (1) of FIG. 1 has a substantially concave cross section, and the slit S shown in (2) of FIG.
It is formed by crossing in both X and Y directions (of course, it is possible to use only one direction regardless of this). In FIG. 1 (3), a V-shaped cross section, a substantially V-shaped flat bottom surface, and a substantially cross-sectional shape are shown. Each concave slit S is shown. The outer plate 5 is made of the same material as the inner plate 4 described above, and is usually made of the same material. Further, the thickness of the inner surface plate 4 is similar to that of the inner surface plate 4.

In the manufacturing method, the honeycomb core 6 is separately prepared in advance. The honeycomb core 6 will be described in more detail. As shown in, for example, FIG. 5 (2), the honeycomb core 6 is composed of a planar aggregate of a large number of hollow columnar cells 12 divided into independent spaces by cell walls 11. The cross-sectional shape of the cell wall 11 and the cell 12 is typically the hexagonal shape shown in the figure, but trapezoidal, triangular, quadrangular, and other various shapes are also possible. As the base material of the cell wall 11 and the honeycomb core 6, according to the inner surface plate 4 and the outer surface plate 5 described above, aluminum, aluminum alloy or other metal foil, aramid paper or other reinforced paper,
PVC or other plastic sheet, fiber reinforced plastic (FRP) sheet, or other composite material sheet is used. It is known that the honeycomb core 6 is excellent in weight ratio strength, is lightweight, and has high rigidity and strength, and is also excellent in flatness accuracy, heat retention, heat insulation, sound insulation, and the like. In addition, since the honeycomb core 6 used in this manufacturing method is required to be bent and deformed to have a predetermined curvature, the honeycomb core 6 is sliced to have a predetermined thickness, and in addition, slit processing is performed on the opening end face side of the cell wall 11. Or the cross-sectional shape of the cell wall 11 and the cell 12 is a special shape with a rounded and substantially convex shape, and when the expansion molding is performed, the cell wall 11 and the cell wall 11 are not expanded or over-expanded. When the cell 12 has a vertically or horizontally long hexagonal cross-section, etc., the bending deformation to a predetermined curvature described below is further smoothed.

Next, in this manufacturing method, as shown in FIG. 1 (4), a honeycomb core 6 as a core material is interposed between an inner surface plate 4 and an outer surface plate 5 with an adhesive (not shown). Then, the curved honeycomb panel 10 is obtained by sandwiching it and heating and pressurizing it while using the mold 7 having a predetermined curvature.

The heating and pressing step will be described in more detail. That is, the inner surface plate 4 formed as described above and having a predetermined curvature and the outer surface plate 5 having a large number of slits S and having flexibility are prepared as described above and sliced into a wall thickness of, for example, about 50 mm. The deformable honeycomb core 6 is applied to both open end faces while applying and interposing an adhesive, respectively, and is stacked on a mold 7 which is a curved jig also called a mandrel and whose mold surface has a predetermined curvature ( As the mold 7, it is possible to use the mold 2 for molding the inner surface plate 4 described above). That is, an inner surface plate 4 having a predetermined curvature, a honeycomb core 6 as a core material, an outer surface plate 5 with a slit S, and the like are stacked in this order on the mold 7 from the bottom side, and in the illustrated example, the outer surface plate 5 is further stacked.
A vacuum sheet 9 of an autoclave 8 which is an example of a heating and pressing device is put on the top. Then, after the periphery of the vacuum sheet 9 is attached to the mold 7 with tape or the like and sealed, the inside is suctioned and vacuumed through the hose 13, the adjusting valve 14 and the like, and heating and pressurization from the outside is performed. By these, the inner and outer face plates 4 and 5 which are front and back face materials and skin materials are integrally bonded to both open end faces of the honeycomb core 6 which is the core material, and the honeycomb core 6 and the outer face plate 5 which are the core material are bonded together.
However, the curved honeycomb panel 10 is bent along the mold 7 and the inner surface plate 4 etc., and thus has a predetermined curvature as a whole.
Is obtained. In addition, as such a heating and pressurizing device,
In addition to the autoclave 8, a vacuum oven, a hot press, etc. can be used as appropriate.

In this way, the curved honeycomb panel 10 has a predetermined curvature as a whole and also has a total rigidity.
Is obtained. That is, this curved honeycomb panel 10
Is formed by adhering an inner surface plate 4 that forms a use surface and an outer surface plate 5 having a large number of slits S in the form of cut grooves to both inner and outer surfaces of a honeycomb core 6 that is a core material. By such adhesion, it is possible to provide overall rigidity including the outer surface plate 5 and to provide a predetermined curvature as a whole.

A first example of the curved honeycomb panel 10 thus obtained is shown in FIG. 2 (1).
By the way, in the curved honeycomb panel 10 of the first example,
Although the slit S is formed on the inner surface side of the outer surface plate 5, that is, on the honeycomb core 6 side that is the core material, the present invention is not limited to this, and is shown in the third example of FIG. 2 (3). As described above, the curved honeycomb panel 10 in which the slits S are formed on the outer surface side of the outer surface plate 5, that is, the outer surface side is also possible. Further, in the curved honeycomb panel 10 of the first example of FIG. 2 (1), the slit S is formed only on the outer surface plate 5, but the slits S of FIG. 2 (2) and FIG. As shown in the second and third examples, the slit S is formed on the inner surface of the inner plate 4 together with the outer plate 5.
A curved honeycomb panel 10 in which the above is formed is also possible. In this case, the slit S on the inner surface plate 4 side is formed on the inner surface plate 4 after pressure molding, is formed on the inner surface plate 4 before pressure molding, and According to the outer face plate 5, various forms such as a form in which it is formed on the flat inner face plate 4 without being pressure-molded can be considered.

The present invention is constructed as described above. Then it becomes as follows. In this curved honeycomb panel 10 and its manufacturing method, as shown in FIG.
After sandwiching the honeycomb core 6 as a core material between the inner surface plate 4 pressure-molded to have a predetermined curvature and the outer surface plate 5 to which the rigidity is once finely interrupted by the plurality of slits S and the flexibility is imparted. By applying heat and pressure while using the mold 7 having a predetermined curvature, the spaces between these are bonded, and thus the curved honeycomb panel 10 shown in FIG. 2 is obtained. The curved honeycomb panel 10 has, for example, a substantially hemispherical shape as shown in FIG. 5 (1) and is used as a parabolic mirror of a parabolic antenna, and the inner surface plate 4 has a mirror surface / reflection surface which is a use surface thereof. Form. In FIG. 5 (1), numeral 15 indicates a radiator of a parabolic antenna, and numeral 16 indicates a radiated microwave. Now, according to this curved honeycomb panel 10 and its manufacturing method, the following first and second aspects are obtained.

First, as the outer surface plate 5, the one to which flexibility is imparted by the slit S is used, and the one formed by pressure molding is not used. Therefore, like the outer surface plate 5 of this type of related art shown in FIGS. 3 and 4 described above, a predetermined curvature cannot be obtained due to residual stress, residual strain, spring back, etc. due to pressure molding. (5) of 3
(See Fig., (6) Fig.)
It can be easily deformed to a predetermined curvature. Therefore, even if floating A or the like occurs in the pressure-formed inner surface plate 4 due to residual stress, residual strain, springback, etc., the honeycomb core is formed between the outer surface plate 5 and the mold 7. By pressing and heating via 6, the adverse effects on the inner surface plate 4 can be corrected or avoided, and as a whole, the curved honeycomb panel 10 having a predetermined curvature can be obtained.

Secondly, as described above, the outer plate 5 is used by forming the slit S in a flat one, and pressure molding such as tensile molding is not carried out. , The dedicated mold 3 (see FIG. 3 (3)) used in the conventional example of this kind in FIG. 4 is unnecessary, and the cost burden of the mold 3 is reduced accordingly, and this curved honeycomb panel 10 is also excellent in overall cost.

[0022]

As described above, the curved honeycomb panel and the method for manufacturing the same according to the present invention exhibit the following effects by employing the outer surface plate having a large number of slit-like slits.

First, the surface accuracy is improved. That is, according to the curved honeycomb panel and the method for manufacturing the curved panel, as the outer plate, the one whose rigidity is once finely cut off by the plurality of slits and which is imparted with flexibility is used. It is possible to easily obtain one with a curvature. That is, as in the above-described conventional example of this kind, the situation in which residual stress, residual strain, springback, etc., of which the predetermined curvature cannot be obtained and floating is likely to occur is improved, and these adverse effects are corrected, Avoided. Therefore, it becomes possible to obtain a highly accurate curved honeycomb panel having excellent surface accuracy, for example, mirror surface accuracy.

Secondly, it is excellent in cost. That is, according to the curved honeycomb panel and the manufacturing method thereof, the outer plate is used by slitting a flat one, and pressure forming such as stretch forming, that is, tensile forming is performed as in the conventional example of this kind described above. Therefore, the overall cost is excellent, for example, the cost burden of the mold is reduced accordingly. As described above, the effects exhibited by the present invention are remarkable and large, for example, the problems existing in this type of conventional example are surely solved.

[Brief description of the drawings]

FIG. 1 is a view for explaining a curved honeycomb panel and a method for manufacturing the same according to the present invention, in an embodiment of the invention,
(1) is a front explanatory view of the slit processing step, (2) is a plan explanatory view in which the formed slit is inverted inward and outward, and (3) is a front sectional view showing various aspects of the slit. Drawing (4) is a front explanatory view of the process of heating and pressurizing an inner face plate, an outer face plate, a honeycomb core, etc.

FIG. 2 is a front explanatory view of a curved honeycomb panel obtained by explaining the embodiment of the present invention, and (1) FIG.
An example, (2) shows a second example, and (3) shows a third example.

3A and 3B are used to describe a curved honeycomb panel of this type of conventional example and a method for manufacturing the curved honeycomb panel. FIG. 3A is a front explanatory view of an inner face plate forming step, and FIG. 3B is a front face of the formed inner face plate. Explanatory drawing, (3) is a front explanatory drawing of the molding process of the outer surface plate,
(4) is a front explanatory view of the molded outer surface plate, (5) is a front explanatory view of the generated floating or the like, and (6) is a plan explanatory view of the generated floating or the like.

FIG. 4 is a view for explaining the conventional example of the same kind. FIG. 4 (1) is a front explanatory view of the prepared inner surface plate, outer surface plate, honeycomb core, etc., and FIG. 4 (2) is a process of heating and pressing these. Front explanatory view, (3) is a front explanatory view of the obtained curved honeycomb panel.

FIG. 5 (1) is a front sectional view showing an example of use as a parabolic antenna, and FIG. 5 (2) is a perspective view of a honeycomb core.

[Explanation of symbols]

 1 curved honeycomb panel (conventional example) 2 type 3 type 4 inner surface plate 5 outer surface plate 6 honeycomb core 7 type 8 autoclave 9 vacuum sheet 10 curved surface honeycomb panel (of the present invention) 11 cell wall 12 cell 13 hose 14 regulating valve 15 Radiator 16 Microwave A Floating S Slit T Vacuum table U Suction hole

Claims (2)

[Claims] 1. A curved honeycomb panel in which an inner surface plate to be used surfaces and an outer surface plate are adhered to both inner and outer surfaces of a honeycomb core which is a core material and which has a predetermined curvature as a whole. A curved honeycomb panel characterized in that a number of slit-like slits are formed in the outer surface plate. 2. A curved honeycomb panel having a predetermined curvature as a whole, wherein an inner surface plate to be used surfaces and an outer surface plate are adhered to both inner and outer surfaces of a honeycomb core as a core material. In the method, first, while pressure-molding the inner surface plate having a predetermined curvature using a mold having a predetermined curvature by tensile molding or the like, forming a large number of slits in the form of cut grooves in the flat outer surface plate, Next, the honeycomb core, which is a core material, is sandwiched between the inner surface plate and the outer surface plate while interposing an adhesive, and heated and pressed using a mold having a predetermined curvature to obtain the curved honeycomb panel. And a curved honeycomb panel manufacturing method.