KR960008687B1 - Honeycomb panel having inserts for fixing a member in an opening in the panel and method of producing the same - Google Patents

Abstract

None.

Description

Honeycomb panel with insert for fixing member to opening of honeycomb panel and manufacturing method

1 is a perspective view showing a honeycomb panel of a first embodiment of the present invention.

2 is a cross-sectional view of the honeycomb panel shown in FIG.

3 is a perspective view showing an outline of a vehicle body structure using the honeycomb panel shown in FIG.

4 is a process chart for explaining the manufacturing method of the honeycomb panel shown in FIG.

5 is a perspective view for explaining the shape of the insert used in the honeycomb panel shown in FIG.

6 is a plan view of a main part of a honeycomb core having an insert of FIG. 5 positioned in some cells of the honeycomb core during manufacture of the honeycomb panel according to the manufacturing method of FIG. 4;

7 is a sectional view of the main parts of the honeycomb panel during the manufacturing process by the manufacturing method of FIG.

8 is a sectional view of a main portion of a honeycomb panel during manufacturing by the manufacturing method of FIG.

9 is a sectional view showing main parts of the honeycomb panel shown in FIG.

10 is a process chart for explaining the manufacturing method of the honeycomb panel of the second embodiment to the present invention.

FIG. 11 is a sectional view of a main portion of an intermediate product during manufacture by the manufacturing method shown in FIG.

FIG. 12 is a plan view of a main portion of a honeycomb core having the insert of FIG. 5 positioned in some cells of the honeycomb core during the manufacture of the honeycomb panel according to the manufacturing method shown in FIG.

FIG. 13 is a sectional view of a main portion of an intermediate product during manufacture by the manufacturing method shown in FIG.

FIG. 14 is a sectional view of principal parts of an intermediate product during manufacture by the manufacturing method shown in FIG.

FIG. 15 is a plan view of main parts of a honeycomb core having an insert positioned in a core during manufacture of a honeycomb panel according to a third embodiment of the present invention. FIG.

Figure 16 is a plan view of the main part of the intermediate product prepared during the manufacture of the honeycomb panel of the fourth embodiment of the present invention.

FIG. 17 is an enlarged cross-sectional view of the main portion of the intermediate product shown in FIG. 16; FIG.

* Explanation of symbols for main parts of the drawings

10, 42: honeycomb panel 12: opening

14 coupling member 28,30 face plate

32: honeycomb core 34: frame member

36: insert 38: cell

40: circular cut line 50: spare hole

52a, 52b: cutting line 56: preliminary rectangular hole

58: cutting line 61, 62: face plate

65 insert 70 frame member

75 opening 76 cut line

BACKGROUND OF THE INVENTION Field of the Invention The present invention generally relates to a honeycomb panel and a method for manufacturing the honeycomb panel, and more particularly, a honeycomb panel having an opening to which another structural member is fixed and a method for manufacturing the honeycomb panel. It is about.

BACKGROUND ART A brazing aluminum honeycomb panel in which a honeycomb core is sandwiched between two face plates and brazed on these two face plates is known.

One example of such an aluminum honeycomb panel is proposed in Japanese Patent Laid-Open Publication No. 64-44268 and Japanese Utility Model Publication No. 1-131668.

Aluminum honeycomb panels of this kind are relatively light in weight, have high strength and weldability, and are therefore used in automobile bodies, railway vehicle structures, and building structures.

Aluminum honeycomb panels for various structural applications have openings formed for windows or doors or for piping, wiring, etc. Typically, a suitable member, such as a frame supporting a window pane, is secured to such openings by welding or other suitable means. In addition to the frame member fixed to the opening, another frame member is attached to the periphery of the honeycomb panel, and the honeycomb panel is connected to the other structural member.

On the other hand, the face plate and the honeycomb core of the aluminum honeycomb panel have a very small wall thickness in order to reduce the weight of the honeycomb panel. Moreover, the upper end portion of the volume of the honeycomb core provided between the face plates is constituted by a void.

Therefore, it is extremely difficult to provide the solid portion with an area large enough to allow welding of the frame member provided in the opening formed by the cut surface of the honeycomb cell to the solid portion of the honeycomb core. As a result, the honeycomb core does not provide sufficient welding strength of the frame member.

In order to improve the bonding strength of the frame member to the aluminum honeycomb panel, it is conceivable to install a welded reinforcement member on the outer surface of the panel. Installing such a reinforcing member is not particularly desirable when a honeycomb panel having a smooth outer surface is required.

The reinforcing member is not preferable in view of the weight reduction of the honeycomb panel.

Therefore, the honeycomb panel using the reinforcing member for welding the frame member cannot be suitably used as a structural member for forming the surface of the structure, and particularly has a smooth surface to reduce air resistance and noise and improve appearance. It cannot be suitably used as a railway vehicle and vehicle body structure required to be. Honeycomb panels with inserts installed in cells of honeycomb cores are also known to improve the strength of the panels as proposed in Japanese Utility Model Publication No. 64-25514 and Japanese Patent Publication No. 2-25325. have.

However, this honeycomb panel is unsatisfactory in terms of bonding strength to the panel of the frame member or the structural member.

In summary, the present invention is as follows.

It is a first object of the present invention to provide a honeycomb panel which can sufficiently secure the bonding strength of a frame member or another structural member to a honeycomb panel.

It is a second object of the present invention to provide a honeycomb panel suitable for a vehicle body structure having an opening for a window or other purpose and capable of securing a sufficiently high strength at one portion around the opening.

It is a third object of the present invention to provide a method for efficiently or economically manufacturing a honeycomb panel in order to secure sufficient bonding strength between the honeycomb panel and the frame member or other structural members.

The first object of the present invention is a honeycomb panel comprising two face plates, a honeycomb core positioned between two face plates and bonded to at least two face plates, and an insert provided on a honeycomb of a honeycomb core. Wherein the frame member is located in an opening formed through a portion of the honeycomb panel in the thickness direction of the panel, the opening being formed by a cut surface of the honeycomb in which the insert is installed, According to a first aspect of the present invention, there is provided a honeycomb panel, which is butt welded to one of the face plates of the hawk and the insert. Each insert height can be substantially equal to the thickness of the honeycomb core. Each insert can be bonded to both face plates.

For example, the opening is formed through the inside of the panel not including the outer periphery of the honeycomb panel.

Each insert is preferably composed of two horizontal portions respectively joined to two face plates and a vertical portion connecting the two horizontal portions.

In the honeycomb panel according to the first aspect of the present invention described above, the insert is installed in a honeycomb arranged along the edge of the opening in which the frame member is fixed with the face plate or the weld butt welded thereto, so that the honeycomb panel is It may be connected to the third member through the frame member. Therefore, the bonding strength of the third member to the honeycomb panel is increased as compared with the case where the third member is bonded only to a thin plate. Moreover, the frame member is effective for attaching the third member to the panel at the opening even when the opening is formed inside the panel, that is, when the opening is closed when the plane of the panel is observed and not open to the outside of the panel.

In a honeycomb panel comprising a honeycomb core and an insert provided on a honeycomb of a honeycomb core and a honeycomb core positioned between two faceplates and bonded to at least two faceplates. Has a cut surface of the face plate and a surface cooperating with the honeycomb cell to form an opening formed through a portion of the honeycomb panel in the thickness direction of the panel, and the surface of the insert is viewed in a direction perpendicular to the thickness direction of the panel. A honeycomb panel is provided according to a second aspect of the present invention, wherein the honeycomb panel is substantially aligned with the cut surface of the face plate.

In the honeycomb panel according to the second aspect of the present invention, the insert accommodated in the honeycomb cell of the honeycomb panel is perpendicular to the cut surface of the face plate forming the opening and the surface of the insert forming the edge of the opening. The openings are exposed to substantially align when viewed in a phosphorus direction. Thus, the predetermined third member, such as the frame member, can be easily fixed to the opening by joining the third member to the substantially mating surface of the insert and the face plate.

The surface of the insert that is substantially aligned with the cut surface of the face plate may be a cut surface obtained by cutting the panel to form an opening. Each insert has a channeled shape (such as a U or I shape) in a plane cross section parallel to the thickness direction of the panel, and is joined to opposite surfaces of two face plates while facing each other in the thickness direction. It has two parallel parts. In this arrangement, since the insert is joined not only to the two face plates but also to the third member, the joining strength between the predetermined third member and the panel is increased.

A first object of the present invention is a honeycomb panel comprising a honeycomb core positioned between two faceplates and two faceplates and bonded to two faceplates, wherein the honeycomb panel is formed in the thickness direction of the panel. An opening formed through the interior, an insert inserted into a honeycomb of the honeycomb core which is opened to the opening, and a frame member positioned in the opening and butt welded to the insert at least one of the two face plates. According to a third aspect of the present invention for providing a honeycomb panel.

In the honeycomb panel just described above, the insert is inserted into a honeycomb cell open to an opening formed by cutting the inside of the honeycomb panel having a conventional structure. Since the frame members are welded to the face plates or face plates as well as these inserts, the bonding strength of the frame members to the panel is effectively improved.

The first object is a honeycomb panel comprising a honeycomb core positioned between two faceplates and two faceplates and bonded to two faceplates, the honeycomb panel being in the thickness direction of the honeycomb panel. It consists of an opening formed through the inside of the insert and an insert inserted into the honeycomb of the honeycomb core which is open to the opening, each insert having a channel shape in a planar cross section parallel to the thickness direction of the honeycomb panel. According to a fourth aspect of the present invention for providing a honeycomb panel characterized in that it has a.

Each insert has a cross section that cooperates with the cross section of the faceplate to form the edge of the opening. The cross section of each insert is substantially matched when viewed from the cross section of the face plate and in a direction perpendicular to the thickness direction of the honeycomb panel.

In the honeycomb panel according to the fourth aspect of the present invention described above, each insert inserted into the honeycomb cell opened to the opening has a channel shape in cross section when viewed in a plane parallel to the thickness direction of the honeycomb panel. For example, having a U or I shape with bracketed grooves or grooves. Moreover, the cross section of each insert exposed to the opening substantially coincides with the cross section of the face plate exposed to the opening when viewed in a direction perpendicular to the thickness direction of the honeycomb panel. In this arrangement, the third member such as the frame member can be easily joined to the insert and the two face plates with sufficient bonding strength to the honeycomb panel.

The second object of the present invention is to provide at least a part of a vehicle body structure and a honeycomb panel having an opening formed through a part of the honeycomb panel in the thickness direction of the honeycomb panel. Honeycomb panel and the third member is positioned between the face plate and the third plate is positioned between the face plate so that the insert is exposed to the opening, the inner plate and the outer face plate, the inner plate and the outer face plate to provide an opening Consists of a frame member fixed to the opening for attaching to the opening, the frame member includes a cylindrical portion coupled to the opening and an outward flange portion extending radially outward from the cylindrical portion, the outward flange portion the inner surface of the inner plate A portion of the inner surface is adjacent to an edge of the opening, and the frame member is outer surface And it does characterized in that the insert is welded is achieved according to the fifth aspect of the present invention to provide a comb panel.

In the honeycomb panel for a vehicle body structure according to the fifth aspect of the present invention described above, the insert is installed to be exposed to the opening, and the frame member having an outward flange portion engaged with the outer face plate is joined to the inner face plate of the insert. have. Therefore, the strength of the honeycomb panel at one portion around the opening is increased.

A third object of the present invention is to prepare a non-bonded assembly in which (a) a honeycomb core and an insert are located between two face plates, and (b) prepare a bonded assembly in which a honeycomb core is bonded to two face plates. And (c) cutting the bonded assembly to form the opening through the thickness of the bonded assembly such that the insert is exposed to the opening to form the edge of the opening. According to a sixth aspect of the invention.

According to the above method, the insert is first installed in the honeycomb core between two faceplates, and then the honeycomb core is bonded to the faceplate. The joint assembly thus obtained is cut so that the insert is exposed to the opening. That is, the insert and the cut surface cooperate with the cut surface of the face plate and the honeycomb core to form an opening. According to this method, it is possible to manufacture a honeycomb panel having a high bonding strength by simply changing the conventional manufacturing process.

In one preferred aspect of the invention, the insert is joined to two face plates when the honeycomb core is joined to two face plates. In another preferred form of the method of the present invention, the step of cutting the joining assembly to form the opening consists of marking on the outer surface of one of the two face plates. This marking marks the cutting line, along which the insert is installed and the joint assembly is cut.

The present invention in the above preferred form may further comprise the step of positioning the frame member in the opening of the joint assembly so that the frame member is coupled to the insert, and the step of bonding the frame member to at least one face plate of the insert and the two face plates. . In this case, the method is a process of bending the bonded assembly at a predetermined curvature in a plane parallel to the thickness direction of the bonded assembly before the frame member is positioned in the opening, and substantially the curvature of the bonded assembly before the frame member is placed in the opening. The method may further include bending the frame member with the same curvature.

In another preferred form of the method of the present invention, the step of preparing the non-bonded assembly includes: in a honeycomb core of a honeycomb core, the honeycomb core is positioned along a cutting line in which the bonded assembly is cut to form an opening while the bonded assembly is cut along the cutting line. It consists of placing the insert in the selected cell.

The third object of the present invention is to prepare a non-bonded assembly in which a selected honeycomb is bisected by a predetermined cutting line and an insert is placed in a selected honeycomb of honeycomb cells of a honeycomb core in which an insert is positioned between two face plates. (B) preparing a joint assembly in which a honeycomb core is joined to two face plates, and (c) joining the joint assembly to remove openings therethrough and to form openings through the thickness of the joint assembly. According to a seventh aspect of the present invention, there is provided a method for producing a honeycomb core, which comprises a step of cutting an assembly.

In a preferred aspect of the present invention according to the above aspect of the present invention, each insert includes two horizontal portions in contact with two face plates and a vertical portion connecting two horizontal portions. In this case, the process of preparing the non-joined assembly consists of positioning each insert so that the vertical portion is located on one side of the preset cutting line away from the unnecessary portion.

In the method of the present invention according to the seventh aspect of the present invention, when the non-bonded assembly is assembled, a cutting line is determined, along which the joining assembly for the honeycomb panel is located.

The insert is positioned in a honeycomb that is positioned along or adjacent to the preset cutting line when preparing the non-joined assembly. The bonded assembly is cut according to this preset cutting line. By this configuration, the insert can be cut together with the honeycomb core and the face plate, whereby the cutting surface of the insert can be formed with high accuracy while substantially matching the surface of the honeycomb core and the face plate. Thus, a sufficiently high bonding strength to the bonded honeycomb panel through the insert of the desired member is ensured.

The third object of the present invention is to prepare a joint assembly in which (a) the honeycomb core and the honeycomb of the honeycomb core are selected from the honeycomb, wherein the insert is joined to one of at least two face plates, and (b) the insert. Cutting the joining assembly to form an opening through the joining assembly so as to expose the opening to the opening, (c) placing the frame member in the opening and welding the frame member to at least one of the insert and two face plates. According to an eighth aspect of the present invention, there is provided a method for producing a honeycomb panel.

In the method according to this aspect of the invention, the insert is exposed to an opening formed by cutting the joining assembly, and the frame member is welded to the insert and the faceplate or faceplates.

Since the cutting surface of the insert is matched with the cutting surface of the face plate by cutting, the frame member can be easily welded to the face plate or face plate and the cutting surface of the insert with a sufficiently high bonding strength.

The third object of the present invention is to prepare a joint assembly in which (a) a honeycomb core and a honeycomb insert positioned at a selected honeycomb are joined to at least one of two face plates, (b) Cutting the bonded assembly along the first cutting line to penetrate the thickness of the bonded assembly to form a preliminary hole, (c) determining the depth of the selected honeycomb cell that is open to the preliminary hole in a direction perpendicular to the cut line (D) determining the position of the second cut line parallel to the first straight cut line based on the selected depth of the selected honeycomb; (e) joining assembly along the second cut line to expose the insert. According to a ninth aspect of the present invention, there is provided a method for manufacturing a honeycomb panel, which is composed of a process of cutting a.

The method comprises determining a position of a third cut line adjacent to an edge of the bonded assembly and parallel to the second cut line based on the set position of the second cut line and trimming the bonded assembly along the third straight cut line. It may further include.

In the method according to the ninth aspect of the present invention, the position of the second cutting line is determined based on the measurement depth of the honeycomb that is open with respect to the preliminary hole formed by cutting the joint assembly along the first cutting line. Along the two cutting lines, the joint assembly is cut to expose the insert. According to this method, it is possible to precisely determine the position at which the insert is cut, so that the cutting surface of the insert forms the edge of the opening precisely, and the desired member is bonded to the insert in the opening.

A third object of the invention is to (a) a vertical connecting two horizontal parts and two horizontal parts such that the first part of the first face plate is divided from the second part of the first face plate by a channeled member. Positioning a channel member having a portion on the first portion of the first face plate, (b) bonding the channel member to the first face plate and the second portion, and (c) attaching the honeycomb core to the first face plate. Positioning the second face plate on the channel member and the honeycomb core, and (d) bonding the honeycomb core to the first and second face plates to prepare the joint assembly. Cutting the joining assembly to form the opening through the thickness of the joining assembly by removing the second portion of the first faceplate and the corresponding portion of the second faceplate so as to be exposed to the opening, and (f) the frame member in the opening. Position the frame member and the horizontal part And a do, which is composed of a step of welding the first and second face plates is achieved in accordance with the tenth aspect of the present invention to provide a method for producing the comb panel.

In the method according to the tenth aspect of the present invention, the channel member and the honeycomb core are positioned on the first face plate with respect to the opening to which the frame member is fixed to attach the desired member to the manufactured honeycomb panel. The channel member is joined to the first face plate at a portion of the first face plate to be removed in a subsequent cutting process. Thus, the channel member to which the frame member is welded can be accurately installed at a predetermined position, whereby the frame member can be welded to the channel member with a sufficiently high bonding strength.

The third object of the present invention is to (a) prepare a joint assembly in which a honeycomb core is positioned between two face plates and bonded to two face plates, and (b) an opening is formed through the thickness of the joint assembly. (C) inserting the insert into the honeycomb of the honeycomb core that is open to the opening, and (d) placing the frame member in the opening and placing the frame member into two face plates. According to an eleventh aspect of the present invention, there is provided a method for manufacturing a honeycomb panel, which comprises a process of welding to an insert.

In the method according to the first aspect of the invention, a conventional honeycomb panel without an insert is cut, with the result that the insert is inserted into a honeycomb cell that is open to an opening formed by cutting.

The frame member located in the opening can be welded firmly to the face plate and the insert.

A third object of the present invention is to prepare a joint assembly in which (a) a honeycomb core is positioned between two face plates and bonded to two face plates, and (b) a preliminary hole is formed through the thickness of the bonded assembly. Cutting the joining assembly as much as possible, (c) inserting the insert into the honeycomb of the honeycomb core that is open to the preliminary hole, and (d) the cutting surface of the insert in a direction perpendicular to the thickness direction of the joining assembly. In order to cut the insert so as to match the cutting surface of the honeycomb core and the face plate, a step of cutting the joint assembly to form an opening similar to or larger than a preliminary hole, (e) placing the frame member in the opening and placing the frame member in the face plate and the insert. According to a twelfth aspect of the present invention, there is provided a method for manufacturing a honeycomb panel, which is composed of a process of welding to a.

In the method according to the twelfth aspect of the present invention, after the insert is inserted into a honeycomb that is open with respect to the preliminary hole, an opening larger than the preliminary hole is cut, whereby the cutting surface of the insert is formed of the face plate and the honeycomb core. It can be precisely matched with the cut surface, so that the frame member of the opening can be butt welded to the face plate and the insert.

In one form of the method, each insert has a first portion held in intimate contact with an inner surface of a second portion of at least one of the two face plates, the second portion being adjacent to the opening.

The frame member is welded to the first portion of each insert and to the second portion of each face plate.

In this form of the method, the insert is welded to the inner surface of at least one of the two faceplates, thereby positioning them correctly. Thus, the frame member welded to the insert can be accurately and easily positioned relative to the insert.

The above objects, optional objects, features and advantages of the present invention will be better understood by reading the following description of the preferred embodiments of the present invention in connection with the accompanying drawings.

1 to 9, a first embodiment of the present invention will be described in detail.

1, 2 and 3, an aluminum honeycomb panel assembled and manufactured according to the present invention is shown generally at 10. An example of a vehicle body structure using the honeycomb panel 10 is shown in FIG. The honeycomb panel 10 constituting part of the railway car body structure is a rectangular flat member that is curved over the entire height dimension.

For example, the honeycomb panel 10 used for the side wall of the vehicle body structure has a circular window opening 12 in which a window member such as window glass is installed.

A plurality of honeycomb panels 10 are assembled to form side walls of the vehicle body structure.

As shown in FIG. 3, the honeycomb panel 10 has a plurality of honeycomb panels 10 connected to each other through the coupling member 14 (first and second views) in the longitudinal direction of the vehicle body. 16 is provided. In the characteristic example of FIG. 3, each side panel unit 16 is made up of four or five honeycomb panels 10 each having a width substantially equal to the distance between the openings 12 of adjacent panels 10. Is done. Some honeycomb panels 10 of some side panel units 16 do not have a window opening 12.

In addition, the vehicle body structure of FIG. 3 includes a plurality of roof panel units 18 composed of a plurality of honeycomb panels similar to the honeycomb panel 10 except that the vehicle body structure does not have a window opening 12. Since the plurality of side panel units 16 are assembled in the longitudinal direction of the vehicle body structure, side walls shown by reference numeral 20 as a whole are constituted in FIG.

Similarly, the roof framing 22 consists of a plurality of roof panel units 18 assembled together. The roof wall 22 and the two side walls 20 are fixed to each other by a pair of parallel cant rails 24. Typically, each can trail 24 extends in the longitudinal direction of the bodywork structure through the top of the corresponding sidewall 20. Similarly, a pair of parallel rocker rails 26 extend in the longitudinal direction of the vehicle body structure through the lower portion of the corresponding side wall 20. The lower frame 27 is installed between the rocker rails 26. Moreover, the two end walls 21 (only one end wall is shown in FIG. 3) are provided with side walls 20, roof walls 22, can trails 24, rocker rails 26 and underframes 27. It is formed so as to close the two opposing opening ends of the hollow body which is usually elongated. In this way, the vehicle body structure is constructed.

Referring to FIGS. 1 and 2, each honeycomb panel 10 includes two face plates 28 and 30, one honeycomb core 32, and an inner face plate 28 and an outer face plate 30. It includes four coupling members 14 interposed therebetween. These members 28, 30, 32, 14 are brazed together to form the honeycomb panel 10. The engaging member 14 is provided along four sides of the rectangular periphery of the panel 10. The honeycomb panel 10 further includes an annular frame member 34 welded to the circular window opening 12 and fixed thereto. The inside of the annular frame member 34 may be used as a window aperture. have. The face plates 28 and 30, honeycomb core 32, coupling member 14 and frame member 34 are all made of aluminum alloy. The frame member 34 serves to support the window glass or other suitable window material, and its cross-sectional shape is typically a hat, as shown in FIG.

A panel unit of a desired size can be obtained by welding the ends and ends of two or more honeycomb panels 10 together to the coupling member 14.

A method of manufacturing the aluminum honeycomb panel 10 having the window opening 12 as described above will be described with reference to the process diagram of FIG.

First, a process (S10) of preparing the face plates 28 and 30, the honeycomb member for the honeycomb core 32, and the coupling member 14 is performed.

The face plates 28 and 30 and honeycomb members are prepared in a manner known in the art.

In this particular example, the face plates 28 and 30 are 1 mm thick and the inner surface of each face plate 28 and 30 on the side of the honeycomb core 32 is a clad layer made of brazing material. Covered with The thickness of this brazing cladding layer is 5% of the thickness of the face plates 28 and 30.

On the other hand, the honeycomb members are corrugated members each having a thickness of 0.2 mm and a width of 28 mm (measured in the thickness direction of the honeycomb panel 10). Each corrugated member has a cladding layer composed of a brazing material, formed on opposite sides.

The thickness of each brazing cladding layer is 5% of the thickness of the corrugated member. Since each corrugated member has a recess, the recesses of the two adjacent corrugated members, as shown in FIG. 6, overlap the hexagonal honeycomb 38 when overlapped with each other so that two adjacent corrugated members face each other. To form. In the present embodiment, the nominal dimension of the hexagonal honeycomb 38 is 3/4 inch, which is the diameter of the inscribed circle of the hexagonal cell 38.

As shown in Fig. 2, the engaging member 14 has a U-shaped cross section, a thickness of 2 mm, a width of 28 mm (measured in the width direction of the corrugated honeycomb member), and the depth of the recess formed by the U-shaped wall. The depth measured in the direction is 15 mm.

In addition to the face plates 28, 30, honeycomb members and coupling members 14, a number of inserts 36 are prepared in step 100. These inserts are also made of aluminum alloy.

The insert 36 has a height dimension of 28 mm equal to the distance between the inner surfaces of the face plates 28 and 30 of the honeycomb panel 10, that is, the thickness of the honeycomb core 32 (the width of the corrugated honeycomb member above). Have

Insert 36 has dimensions acceptable to honeycomb 38. The insert 36 may have a variety of structures, but has a relatively large weld area in contact with the surface of the face plates 28 and 30 so that the insert can be welded to the face plates 28 and 30, and the weight is relatively high. It is preferable that it is light. Moreover, it is preferable that the said welding part of the insert 36 has sufficient thickness in the thickness direction (direction of the height dimension of the insert 36) of the honeycomb panel 10.

In the present embodiment, insert 36 has a blank in which the U-shaped channel shown in FIG. 5 is formed (13, which is also referred to as a channel blank) in FIG. It is prepared by cutting to pitch. More specifically, each insert 36 is a channeled member (hereinafter referred to as a channel member) having a U-shaped groove, which is the thickness of the honeycomb core 32 (between the face plates 28 and 30). Vertical portion 36a having a height L1 equal to 28 mm) and two parallel horizontal portions 36b, 36c extending in a direction perpendicular to the vertical portion 36a from two opposite ends of the vertical portion 36a. ) Is included. The horizontal portions 36b and 36c have a length L2 of 13 mm measured perpendicular to the vertical portion 36a. The insert 36 has a dimension L3 of 13 mm and a wall thickness of 2 mm corresponding to the cutting pitch 13 mm measured in the direction perpendicular to the dimensions L1 and L2. The horizontal parts 36b and 36c serve as the welded parts, and the insert 36 has a honeycomb cell so that the upper and lower surfaces of the horizontal parts 36b and 36c contact the inner surfaces of the face plates 28 and 30, respectively. 38). In this embodiment, the insert 36 is prepared by cutting the U-shaped channel blank in the form of an extruded aluminum alloy member. However, the insert can also be prepared by machining or plasticizing other types of blanks. The cross section of the insert 36 is U-shaped, but may be other cross-sectional shapes such as I-shaped or Z-shaped.

After the step (S10), the corrugated honeycomb members are arranged and placed on the face plate 30 so that the honeycomb core 32 is formed as shown in FIG. 6, and the coupling member 14 is also on the face plate 30. The process (S20) is performed to be installed along four sides of the periphery of the honeycomb core 32.

The insert 36 is then inserted into a honeycomb 38 adjacent to the circular cut line 40, which is later described in step 550 by cutting the honeycomb core 32 along the cut line. One window opening 12 is formed. Moreover, the other faceplate 28 rests on the honeycomb core 32.

Thus, a non-brazing assembly is prepared in which the insert 36 is received in the selected honeycomb 38 along the cutting line 40. As described above, the annular frame member 34 is a window opening 12 to be formed by cutting the honeycomb core 32 along the cutting line 40 (along with the insert 36 inserted into the cell 38). It is fixed by welding in the inside. However, the actual cut line tends to deviate from the nominal cut line 40 in the radial direction of the circular opening 12 to be formed.

In this regard, the insert 36 is preferably inserted into every honeycomb 38 that is bisected by the nominal cutting line 40 or adjacent to the cutting line 4D.

For example, it is preferable to insert the insert 36 into the adjacent honeycomb 38 with the cutting line 40 extending therebetween. In this case the array of inserts 36 arranged along the cutting line 40 comprises the portion (s) in which the inserts 36 are installed in two rows of cells 38 as shown in FIG. Doing.

The insert 36 has a vertical portion 36a of each insert 36 positioned radially outward of the circular cutting line 40 (circular opening 12 to be formed) or intersecting the cutting line 40. So as to be positioned or oriented within each honeycomb 38. In the case where the vertical portion 36a intersects the cutting line 40, a portion of the vertical portion 36a is located radially outward of the cutting line 40.

For example, the insert 36 shown at the upper right of FIG. 6 is oriented so that the vertical portion 36a (indicated by the dotted line thickness) has a horizontal posture while the insert 36 shown at the lower left of FIG. 6 is vertical. 36a is oriented to have a vertical posture.

Appropriate markings are provided on the outer surface of the faceplate 30 to facilitate cutting along the cutting line 40 and to indicate the position of the honeycomb 38 in which the insert 36 is received.

This marking is done using colored paint so that it is very easily recognizable, and this marking is effective and marked on the inside of the cutting sheet 40 slightly in the circumferential direction of the opening 12. There is no marking left to avoid adverse effects of the paint in subsequent brazing processes.

The process S30 then heats the non-brazing assembly prepared in step S20 to the melting points of the cladding layer, the cladding layer, on the face plates 28 and 30 and the honeycomb core 32.

As a result, the corrugated honeycomb member is brazed to the honeycomb core 32 and the honeycomb core 32 is brazed to the face plates 28 and 30 and the coupling member 14. Moreover, the coupling member 14 is also brazed to the face plates 28 and 30. The horizontal portions 36b and 36c of the insert 36 are also brazed to the face plates 28 and 30.

Following step S30, a step S40 of bending the brazed assembly obtained in step S30 to provide an assembly equal to the curvature of the honeycomb panel 10 is performed.

The step S50 of preparing the intermediate product 42 is performed by cutting the brazed assembly along the cutting line 40. The intermediate product 42 thus prepared has a window opening 12 formed over the entire thickness of the assembly.

Since the opening part 12 is formed in the intermediate product 42, all honeycombs 38 of the core 32 existing along the cutting line 40 are formed in the opening part 12 as shown in FIG. The opening 12 is exposed radially inward. In the exposed majority of honeycomb 38, a partially cut insert 36 is received and brazed to the inner surface of the exposed cell 38.

The cut surface of the insert 36 is combined with the cut surfaces of the face plates 28 and 30 to form the periphery of the window opening 12. In other words, the cut surface of the insert 36 is generally aligned with the cut surfaces of the face plates 28 and 30 as shown in the direction perpendicular to the thickness direction of the intermediate product 42.

Cutting of the brazed assembly in step S50 is carried out using a band saw, wire-cut electrodischarge machining process, or various known methods using plasma or laser cutting.

Step S50 Next, as shown in FIG. 8, a step of installing the annular aluminum alloy frame member 34 prepared in steps S210, S220, and S230 in the window opening 12 of the intermediate product 42 (S60). This is done. Next, as shown in FIG. 8 as an example, a step S70 of welding the frame member 34 to the insert 36 and the face plates 28 and 30 is performed.

In preparing the frame member 34, for example, the blank prepared by extruding in step S210 is bent to an appropriate curvature, cut to an appropriate size in step S220, and welded to have an annular shape. The annulus is then made into the curvature of the intermediate product 42 for the honeycomb panel 10 in step S230. In this way, the annular frame member 34 is manufactured.

The frame member 34 is hat-shaped in cross section as shown in FIG.

More specifically, with reference to FIG. 8, the frame member 34 has a cylindrical portion 44 which is slightly longer in length than the thickness of the intermediate product 42, and from the opposite end of the cylindrical portion 44 in the radial direction. The inner and outer flange portions 46 and 48 extend inwardly and outwardly. The frame member 34 is inserted into the window opening 12 in the direction from the inner face plate 30 to the outer face plate 28 so that the outer flange portion 48 contacts the outer face of the inner face plate 30, while The outer face of the inner flange portion 46 is flush with the outer face of the outer face plate 28. Under these circumstances, the upper end of the cylindrical portion 44 (outer peripheral surface of the inner flange portion 46) is butt welded to the peripheral end surface of the face plate 28 and the corresponding surface of the insert 36, thereby opening the opening 12. Is formed. Moreover, the outer flange 48 is fillet welded to the outer surface of the face plate 30.

In order to facilitate the welding of the frame member 34 in the step S70, the butt weld of the frame member 34 and the butt weld of the insert 36 are appropriately beveled or V-groove in the steps S50 and S230. Is formed.

In the present embodiment, the height dimension L1 of the insert 36 is equal to the thickness of the honeycomb core 32 (distance between two face plates 28 and 30). However, this dimension L1 should be smaller than the thickness of the honeycomb core 32. In this case, the insert 36 is welded to only one of the two face plates 28 and 30.

Since the frame member 34 is welded to both of the face plates 28 and 30 (and welded to the insert 36 when the height dimension of the insert is approximately equal to the distance between the face plates 28 and 30). The insert 36 does not need to be welded to both face plates 28 and 30.

The strength of the intermediate product 42 and the strength of the manufactured honeycomb panel 10 are that the frame member 34 is welded to the face plates 28 and 30 as well as the insert 36 and the two face plates 28 and 30. This is greatest when the insert 36 is welded, but the strength of the honeycomb panel 10 is not significantly reduced even if the insert 36 is welded to only one of the face plates 28 and 30.

The outer diameter of the outer flange portion 48 of the annular frame member 34 is at least one honeycomb between the circumferential end faces of the face plates 28 and 30 forming the window opening 12 and the outer circumferential surface of the outward flange portion 48. It is determined that the comb 38 can be present. This arrangement ensures that the surface area of the overlapping area of the outer flange portion 48 on the honeycomb panel 10 is relatively large, which is associated with the face plate 30 (outward flange portion 48 from the face plate 28 (inward). It is effective to minimize the possibility of breakage of the honeycomb panel 10 at the portion adjacent to the window opening 12 when subjected to considerable force acting in the direction toward the flange portion 46.

After the welding of the frame member 34 is completed in step S70, in order to improve the surface finish of the intermediate product 42, the step of grinding the weld portion of the intermediate product 42 as shown in FIG. 9 (S80). This is finally done. Thus, as shown in FIG. 1 and FIG. 2, an aluminum honeycomb panel 10 having a frame member 34 welded to and fixed to the window opening 12 is manufactured.

In the honeycomb panel 10 manufactured as described above, the frame member 34 in the window opening 12 is formed on each insert 36 as well as on a relatively thin wall of the face plate 28 on which the honeycomb core 32 is brazed. It is also welded to the thick portion of the horizontal portion 36b and / or the vertical wall 36a. Moreover, inserts 36 are mounted on each honeycomb 38 and fixed by welding, the horizontal parts 36b and 36c of which faceplates 28 and 30 provide an exposed surface of the honeycomb panel 10. ) Has a relatively large surface area where the insert 36 is brazed. Therefore, the honeycomb panel 10 has a sufficiently high bonding strength.

In addition, the insert 36 is accommodated in the majority of honeycomb 38 exposed to the window opening 12, so that the insert 36 increases the mechanical strength of the panel 10 at the window opening 12. It should be noted that it contributes to Moreover, this arrangement ensures uniform welding conditions along the entire circumference of the opening 12 and facilitates automatic welding of the frame member 34 to the insert 36 and the face plates 28, 30.

Since the height dimension L1 of the U-shaped insert 36 in this embodiment is substantially the same as the thickness of the honeycomb core 32 (the distance between the face plates 28 and 30), the horizontal portions 36b and 36c. Are both welded to the respective face plates 28 and 30. Moreover, since the insert 36 is oriented with respect to the honeycomb core 32, the vertical portion 36a is positioned radially outward (outward in the radial direction of the cutting line 40) of the window opening 12. do. According to this arrangement, the force acting on the butt welds of the honeycomb panel 10 can also be transmitted to the face plate 28, thereby increasing the strength of the panel 10.

It should be noted that the surface of the insert 36 exposed to the opening 12 is in the doyle plane with the peripheral end surface of the face plate 28 exposed to the opening 12. That is, the diameter of the circle formed by the exposed surface of the insert 36 is equal to the diameter of the peripheral end face of the face plate 28 forming the opening 12. Therefore, the annular frame member 34 can be easily welded to the insert 36 and the face plate 28 with a sufficiently large welding strength.

Furthermore, the horizontal portions 36b and 36c of the insert 36 in the form of U-shaped channel members provide a sufficiently large surface area for the insert 36 to be brazed to the face plates 28 and 30. Moreover, the U-shaped insert 36 is lighter than other solid bars used for the same purpose at the same height. The insert 36 received in the cell 38 of the honeycomb core 32 does not protrude from the outer surface of the honeycomb panel 10. In other words, the vehicle body structure using the honeycomb panel 10 has a smooth outer surface.

In the above method for manufacturing the honeycomb panel 10, the insert 36 is a honeycomb (suitable for assembling the face plates 28 and 30, the corrugated honeycomb member for the honeycomb core 32, and other members) 38). The assembly process of this invention is the same as the assembly process of a well-known brazed aluminum one comb panel. Therefore, the manufacture of the honeycomb panel 10 according to the present invention does not require any substantial change in the manufacturing equipment and the assembly process, but has the advantage of increasing the strength of the panel 10 at the window opening 12.

In the manufacturing method according to the present invention, since the insert 36 is assembled with the corrugated honeycomb member, the insert 36 is installed in the honeycomb 38 which is installed near or adjacent to a predetermined cutting line 40. do. Next, the assembly obtained by brazing the members is cut along the cutting line 40. According to this process, the cutting surface of the insert 36 accurately forms the circumferential circumference of the window opening 12 formed by the cutting, whereby the welding strength of the annular frame member 34 passes through the entire circumference of the frame member 34. Improved and stabilized

In the present method, the cutting line 40 is indicated by appropriate marking on the face plate 28 (or face plate 30), which allows the cutting of the brazed assembly while accurately following the intended cutting line 40. This is to improve cutting efficiency and accuracy accordingly.

Moreover, marking materials such as paints do not adversely affect the brazing material, since the markings are located radially inward of the cutting line 40 and are installed on the part of the faceplates 28 and 30 which are removed by cutting. Because it becomes.

In the present embodiment, the frame member 34 is fixed to the window opening 12 of the honeycomb panel 10. However, the window opening 12 of the honeycomb panel 10 can accommodate other members (called third members) other than the frame member 34. In other words, if the surface of the insert 36 exposed to the opening 12 is engaged with a third member of a particular shape and dimension, the frame member 34 is not essential in accordance with the principles of the present invention. In other words, the honeycomb panel in the form of the intermediate product 42 shown in FIG. 7 is considered to be the honeycomb panel of the present invention, which can be used for the vehicle body structure. Examples of the third member to be fixed to the window opening 12 include a window frame, a door frame, a frame for an inspection lid, and a support member for a current collector attached to an outer surface of the vehicle body structure. The third member of any shape may be at least partially secured to the opening 12 of a suitable shape and dimension formed by the exposed surfaces of the insert 36 and the face plates 28, 30. As long as it is adopted, it may be welded and fixed to the opening 12. Before the third member equivalent to the frame member 34 is attached to the honeycomb panel 42, the third member is secured to the structure or the structural member other than the vehicle body structure, which is partially formed by the honeycomb panel 42. . Therefore, the frame member 34 is preferably fixed to a part of the honeycomb panel 42 forming the opening 12 and may be replaced by another member, and the opening 12 may have an appropriate shape and size.

In the embodiment of the railway vehicle body structure of FIG. 3, the side wall 20 and the roof wall 22 are constructed using the honeycomb panel 10 described above. However, the honeycomb panel 10 can also be suitably used for the end wall 21 and the lower frame 27. The honeycomb panel 42 for the end wall 21 has an opening for the door and an appropriate frame member for the door or a suitable supporting member for the bellows or vestibule diaphragm is fixed to the opening. . The frame or support member can be easily welded to the honeycomb panel 42 with sufficient strength. The honeycomb panel 42 for the lower frame, such as a floor board, has an opening for the inspection lead or the wiring hole, and an appropriate frame is fixed to the inspection lead or the wiring hole.

Referring now to FIGS. 10-14, the faceplates 28, 30, honeycomb core 32 and insert 36 are not brazed together, but with faceplates 28,30 as in the first embodiment. After the comcores 32 are brazed together, a second embodiment of the invention is described in which the inserts 32 are installed in the cells 38 of the honeycomb cores 32.

10 to 14, the same structural members or functional processes as in the first embodiment are shown by using the same member numbers as in the first embodiment. For the sake of brevity, the process and members have not been described in detail.

In the present embodiment, the step (S10) for preparing the face plates 28 and 30, the corrugated honeycomb member and the coupling member 14 is then interposed between the face plates 28 and 30, these face plates 30 The comb member, and the coupling member 14 are assembled and brazed together under heating to produce a step S320 for producing the intermediate product 49 shown in FIG. 11, wherein the intermediate product is made of a known brazed aluminum honeycomb panel. similar. The process S320 corresponds to the processes S20 and S30 of the first embodiment but does not include a procedure for inserting the insert 36 into the honeycomb core 32.

In the next step S40, the intermediate product 49 is curved with the same curvature as that of the honeycomb panel to be manufactured.

After the step S40, as shown in FIG. 11 and FIG. 12, the intermediate product 49 is cut so that the round preliminary hole 50 concentric with the window opening 12 to be formed in the honeycomb panel 10 is formed. Process S340 is performed. The diameter of the preliminary hole 50 is shorter than the diameter of the window opening 12 by an appropriate length. As a result, the plurality of honeycomb cells 38 of the intermediate product 49 are exposed or open to the preliminary holes 50 over the entire circumference of the holes 50.

Next, as shown in FIG. 12 and FIG. 13, a step S350 of inserting the insert 36 into the selected cell of the honeycomb 38 that is open to the preliminary hole 50 is performed.

The insert 36 is secured to the face plates 28 and 30 with a suitable adhesive or bonding agent.

Insert 36 is prepared in step S100 as in the first embodiment.

If these cells 38 are deep enough when viewed in the radial direction of the hole 50, the honeycomb 38 into which the insert 36 is inserted is selected.

While the number of inserts 36 inserted into the cell 38 can be suitably determined, the circumference of the hole 50 is along the circumference to ensure high bond strength between the frame member 34 and the honeycomb core 32. It is preferable to maximize the number of inserts 36 provided at appropriate positions, preferably at least four. In particular, the honeycomb 38 into which the insert 36 is inserted is selected if the circumference of the opening 12 to be subsequently formed crosses the insert 36 provided in the cell 38.

However, the radially innermost surface of the insert 36 inserted into the appropriate cell 38 need not be coplanar with the periphery of the spare hole 50.

After the step S350, a step S50 of cutting the intermediate product 49 is performed such that a window opening 12 having a diameter larger than the diameter of the preliminary hole 50 is formed. That is, the cutting surface of the insert 36 forms the opening 12 together with the cutting surfaces of the face plates 28 and 30 and the honeycomb core 32.

Processes S60, S70 and S80 are then carried out to manufacture the honeycomb panel 10, where the frame members 34 prepared by the processes S210, S220 and S20 are prepared as in the first embodiment. The opening 12 is fixed by welding.

As in the method according to the first embodiment, the method according to the second embodiment ensures a sufficiently large welding area of the frame member 34 to the honeycomb core panel 10 in the presence of the insert 36 and thereby A sufficiently high weld strength of the frame member 34 against the panel 10 is ensured.

Since the insert 36 is inserted in the honeycomb 38 adjacent to the opening 12, the weld strength of the frame 34 to the panel 10 as well as the mechanical strength of the panel in the opening 12 also increase significantly. do. Moreover, as in the first embodiment, the insert 36 does not deteriorate the surface smoothness of the panel 10.

In the second embodiment, the insert 36 is inserted into a suitable honeycomb 38 which is open to the spare hole 50 and then the honeycomb panel 49 (intermediate product) is larger than the hole 50. The cut face of the insert 36 is coplanar with the cut face of the honeycomb core 32 and the face plates 28, 30 because it is cut to form the opening 12. Therefore, the frame member 34 is easily fixed to the opening 12 and is fixed to the insert 36 and the face plate 28 by welding.

Although in the second embodiment, it is adopted to first form the preliminary hole 50 for inserting the insert 36 into the cell 38 of the honeycomb core 32 before the opening 12 is formed, The formation of 50 can be omitted. More specifically, the intermediate product 49 is first cut to form the opening 12 and the insert 36 is inserted into a selected one of the honeycomb 38 that is open to the opening 12. Subsequently, the inserted insert 36 is cut along the edge of the opening 12 such that the cut faces of the insert 36 are coplanar with the cut faces of the face plates 28 and 30 and the honeycomb core 32. . The frame member 34 is then fixed to the opening 12 by welding.

According to the improved method just pointed out, the insert 36 protrudes radially in the opening 12 from the cut surfaces of the face plates 28 and 30 and the honeycomb core 32 so that the frame member 34 is inserted into the insert 36. Is welded to the innermost surface in the radial direction.

Referring to FIG. 15, a third embodiment of the present invention is described in which the honeycomb panel 10 is provided with a rectangular opening whose outer shape includes a straight portion.

In this embodiment, the insert 36 is selected as shown in FIG. 15 during assembly of the face plates 28 and 30, the corrugated honeycomb member and the coupling member 14 as in the process S20 of the first embodiment. It is inserted into the comb 38.

In Fig. 15, the member number 52a represents a cutting line which is a normal straight line for the window opening 12, where the cutting line extends in the transverse direction (horizontal direction in Fig. 15) of the honeycomb panel to be manufactured, respectively. Perpendicular to the extending direction (vertical direction in FIG. 15) of the corrugated honeycomb member. If the actual cut line 52b deviates from the nominal cut 52a in the longitudinal direction (vertical direction in FIG. 15), the actual cut line 52b does not intersect any part of the insert 36 or the insert ( Intersect the end portions of the horizontal portions 36b and 36c of 36).

In the former case, the insert 36 does not function to support the frame 34.

In the latter case, the attachment area of the insert 36 and the face plate 28 is extremely small and insufficient for welding the frame member 34 to the honeycomb panel. Therefore, the frame member 34 cannot be welded with sufficient welding strength because the actual cutting line 52b deviates significantly from the nominal cutting line 52a.

In the particular embodiment of FIG. 15, the inserts 36 are arranged in a zigzag fashion along a nominal straight cut line 54 extending in the longitudinal direction of the honeycomb panel. Therefore, at least all of the other inserts 36 zigzag along the straight cut line 54 are at the horizontal portions 36b and 36c, even though the actual cut line deviates from the nominal straight line 54 in the transverse direction. It is bisected by the actual cutting line. However, it is preferable that the horizontal portions 36b and 36c of almost all of the inserts 36 along the cutting line 54 are bisected by the actual cutting line.

Therefore, it is preferable that the nominal cutting line actually cuts the horizontal portions 36b and 36c of the insert 36 along the longitudinal and horizontal straight portions. This third embodiment will be described with respect to the cutting line 52a as an example. In the present embodiment, the honeycomb panel is cut along the nominal cutting line 52a so that the lower portions of the horizontal portions 36b and 36c of the insert 36 arranged along the nominal cutting line 52a are shown in FIG. Is cut as if.

First, the brazed assembly obtained in step S30 of FIG. 4 is inside the nominal cut lines 52a, 54 and eventually has a prerectangular hole 56 in a portion of the assembly that is removed to form the window opening 12. It is cut to form. As shown in FIG. 15, the cutting line 58 corresponding to the upper side of the rectangular hole 56 has at least one row of one coma 38 with a cutting line 58 and a transverse cutting line for the opening 12. Located between 52a).

After the preliminary rectangular hole 56 is formed, the depth Ls of the honeycomb 38 that is open in the hole 56 is measured with a suitable measuring instrument, which is inserted into the open cell 38 to measure the depth Ls. It may be a caliper with a triangular leg.

The position of the nominal cut line 52a is determined based on the measured depth Ls of the open cell 38 and the horizontal portions 36b and 36c of the insert 36 are actually cut along the cut line 52a.

According to the present invention, the distance between the cutting line 52a and the edge of the honeycomb panel 10 parallel to the cutting plane 52a depends on the position of the spare hole 56, more precisely the cutting line for the hole 56. It varies depending on the position of 58. Therefore, the outer periphery of the panel 10 must be trimmed to position the opening 12 at the desired position at the desired spacing up to the edge of the panel 10 parallel to the cutting line 52a.

The method for determining the position of the cut line 52a may be applied to the straight cut line 54 extending in the longitudinal direction of the honeycomb panel.

The method allows precise alignment of the frame member 34 of the insert 36 so that the outer peripheral edge of the flange 48 is generally aligned with the horizontal portion 36c of the insert 36. It is possible to form the outer flange portion 48 of 34 so that the outer flange portion 48 can be welded to the horizontal portion 36c via the face plate 30.

In the first and third embodiments of FIGS. 1 to 9 and 15, the honeycomb panel has a window opening 12 which is circular or generally rectangular.

However, the principles of the present invention are applicable to honeycomb panels having semicircular or rectangular cutouts in which one of the four sides of the panel is open. In this case, too, the insert 36 is inserted into the honeycomb 38 selected along the contour of the cutting portion, and the appropriate frame member is fixed to the cutting portion so that the appropriate member is supported by the frame member or the honeycomb panel is passed through the frame member. To be connected to another structure.

A fourth embodiment of the present invention will be described with reference to FIG. 16 and FIG.

In the fourth embodiment of FIGS. 16 and 17, two face plates 61 and 62 are formed such that the insert 65 in the form of a rectangular frame is arranged so that the four sides of the rectangle of the insert 65 align with a predetermined cutting line 76. It is installed in between. FIG. 16 is a plan view showing an intermediate product in which an insert 65 in the form of a frame is provided on the face plate 61 in a predetermined relationship with the cutting line 76.

FIG. 17 is a partial cross-sectional view of a part of the completed honeycomb panel, and as described in detail below, a frame member (not shown) adjacent to the other face plate 62, the honeycomb core 32, and the insert 65; 70 is shown.

The honeycomb panel constructed and manufactured according to the fourth embodiment is suitably used for exterior wall panels of a building or building structure having a rectangular window opening 75 as shown in FIG. The insert 65 in the form of a rectangular frame is composed of four side portions 65U, 65D, 65L and 65R corresponding to the top, bottom, left and right sides of the window opening 75 as shown in FIG. The four side portions 65U, 65D, 65L and 65R are welded at their ends to form an insert 65 in the form of an integral rectangular frame. Such side portions 65U, 65D, 65L and 65R can be thought of as individual inserts. Each side portion 65U, 65D, 65L and 65R is formed of a U-shaped channel member consisting of one vertical portion 65a and two horizontal portions 65b and 65c as shown in FIG. The insert 65 is positioned such that the vertical portion 65a of each side portion is provided outside of the rectangular cutting line 76, that is, on the side of the cutting line 76 far from the window opening 65 to be formed. The frame member 70 fixed to the opening 75 has four side surfaces corresponding to the four side portions 65U, 65D, 65L and 65R of the insert 65 in the form of a frame. The frame member 70 is U-shaped in cross section with two horizontal portions.

The frame member 70 has two end faces of two horizontal plates 61 and 62 and end faces of the corresponding horizontal parts 65b and 65c of the insert 65 as shown in FIG. To be welded to. When the frame member 70 engages with the insert 65 in the form of a frame, a rectangular hollow region is formed therebetween.

Now, a method of manufacturing the honeycomb panel of FIG. 17 will be described.

First, the insert 65 in the form of a rectangular frame is mounted on the face plate 61 in alignment with the cutting line 76. The insert 65 is installed on the face plate 61 in the rectangular interior of the cutting line 76 and the joining member is installed along the four outer surfaces of the honeycomb core 32 formed by the corrugated honeycomb member. The corrugated honeycomb member and the joining member are similar to those used in the first embodiment.

Subsequently, the faceplate 62 is placed on the honeycomb core 32 and the insert 65 to form the non-brazing assembly. Then, in the same manner as in the first embodiment, a brazing assembly in which the face plates 61 and 62, the honeycomb core 32, the insert 65 and the joining member are brazed together is produced by heating the assembly. Moreover, this brazed assembly is cut along the cutting line 76 to form a window opening 75 and the frame member 70 is inserted into this opening 75 and fixed therein by welding. In this way, a honeycomb panel is manufactured.

According to the above method, the insert 65 can be easily installed in the opening 75 to be formed. Furthermore, in the present invention, since the corrugated honeycomb member for the honeycomb core 32 is not provided inside the rectangular insert 65, the material of the honeycomb core 32 can be saved. Since the frame member 70 to be welded to the insert 65 is thick at its weld, an automatic MIG (metal insert gas) welding technique can be easily employed to weld the frame member 70.

The face plates 61 and 62 are formed into rectangular openings corresponding to the cut lines 76 before being assembled.

Although the present invention has been described by the presently preferred embodiments, it is not limited to the details of these described embodiments and may be practiced with modifications, improvements and improvements by those skilled in the art under the above description.

For example, the shape and the number of the openings of the insert inserted into the honeycomb 38 are not limited to the shape and the number of the openings of the described embodiment depending on the required strength of the honeycomb panel, the size of the honeycomb 38, and other factors. Can be changed as appropriate.

Furthermore, if the insert inserted into the honeycomb 38 may be partially attached to the face plate, other types of inserts having different shapes and sizes may be used.

The insert may be I-shaped in cross section. In this case, however, care must be taken not to cut the vertical part of the insert. The insert may be in the form of a frame, such as a hexagonal shape, whose cross-sectional shape is substantially aligned with the hexagonal shape of the honeycomb 38.

The six faces of this hexagonal bar-shaped insert should be blazed on the corresponding face of the honeycomb 38. In this case, the insert has a significant increase in weld strength due to the increased attachment area between the insert and the honeycomb wall.

It is not essential to remove the weld beads from the face plate in step S80 because the volume of the beads between the frame member and the face plate is relatively small.

As described in the embodiment, the brazing process is adopted for welding the face plate, honeycomb core, insert and the like. However, various other metal bonding processes, such as electrical resistance welding or diffusion bonding techniques, can be employed to join the fast members together.

Where it is desirable to have a high surface smoothness at the outer periphery or at the hatch openings of the honeycomb panel, frame members having substantially the same thickness and height dimensions of the honeycomb panel face the insert and face plate (shown in the height direction). It is advisable that the welded and welded parts be properly surface finished to have the desired smoothness.

The honeycomb panel constructed and manufactured according to the present invention is suitably used as various structural members for a vehicle body and a building or a building structure as well as a vehicle body structure for a railway vehicle. In particular, this honeycomb panel is suitably and widely used for structural members having openings or holes formed therethrough for windows or doors or for piping, wiring, monitoring and the like.

It is apparent that various modifications, improvements and improvements can be made to the present invention without departing from the spirit of the present invention by those skilled in the art, and it is to be understood that such changes, improvements and improvements are within the scope of the present invention. Can be.

The honeycomb core 32 used in the described embodiment has a hexagonal cell 38, but the honeycomb core interposed between the face plates is not limited to the honeycomb of the embodiment described above. For example, a honeycomb core may have a cell that is quadrilateral or substantially triangular.

Honeycomb cores with quadrilateral cells can be prepared relatively easily, while honeycomb cores with substantially triangular cells produce honeycomb panels with a part-spherical shape. It is used properly. Honeycomb Core's various shapes of cells include LIGHT METALS (KENIKIN 20KU in Japanese), 1900, Vol. 40, no. 5. Described in P394. As used herein, the term honeycomb is interpreted to mean not only hexagonal but also cells having desired shapes such as quadrilateral and triangular. The term honeycomb includes at least one insert interposed between two faceplates, a honeycomb core connecting the two faceplates, and the two faceplates and fixed to these faceplates and the honeycomb cores. Is interpreted to mean a panel. Generally, a honeycomb core is composed of a plurality of strips joined to each other to form a honeycomb cell. The strip is assembled to extend in a direction substantially perpendicular to the face of the faceplate.

As already described, at least one honeycomb panel constructed and manufactured according to the present invention is provided along an opening in which the third member is fixed so that a third member such as a frame member is in contact with the insert (s) and the face plate. Has an insert.

By preparing the insert, a large bonding area of the third member to the honeycomb panel is ensured, and thus a sufficiently high bonding strength between the third member and the honeycomb panel is ensured.

Furthermore, the insert for strong bonding of the third member to the honeycomb panel can be easily installed in the cell of the honeycomb core without a difficult process during or after assembling the honeycomb panel. Therefore, the present invention makes it possible to manufacture honeycomb panels efficiently and economically.

Therefore, the honeycomb panel according to the present invention can be suitably used, for example, for a vehicle body structure having a window opening and requiring high mechanical strength at the window opening.

Claims (26)

Two face plates 28, 30, 61 and 62, a honeycomb core 32 positioned between the two face plates and bonded to at least two face plates, and the honeycomb core 38 of the honeycomb core. In a honeycomb panel including inserts 36 and 65 installed in the honeycomb panel, the frame members 34 and 70 are located in openings 12 and 74 formed through a portion of the honeycomb panel in the thickness direction of the honeycomb panel. And the opening is formed by a cut surface of the honeycomb 38 in which the insert is installed, and the frame member is butt welded to at least one of the face plates of the two face plates and the insert. Honeycomb panel. The honeycomb panel according to claim 1, wherein each of said inserts (36,65) has a height (L1) substantially equal to the thickness of said honeycomb core (36). The honeycomb panel according to claim 1 or 2, wherein each of the inserts (36,65) is bonded to both of the two face plates (28,30,61,62). The honeycomb panel according to claim 1, wherein the openings (12,75) are formed through the inside of the honeycomb panel which does not include the outer periphery of the honeycomb panel. 2. The insert 36, 65 of each of the two inserts 36b, 36c, 65b, 65c bonded to the two face plates 28, 30, 61, 62, respectively. Honeycomb panel, characterized in that it is composed of vertical parts (36a, 65a) connecting the two horizontal parts. Two face plates 28, 30, 61 and 62, a honeycomb core 32 positioned between the two face plates and bonded to at least two face plates, and a honeycomb core 38 of the honeycomb core. In a honeycomb panel including inserts 36 and 65 installed in the honeycomb panel, the inserts 36 and 65 form openings 12 and 75 formed through a portion of the honeycomb panel in the thickness direction of the honeycomb panel. In order to have a surface coupled to the cutting surface of the honeycomb 38 and the face plates 28, 30, 61, 62, the surface of the insert is viewed in a direction perpendicular to the thickness direction of the honeycomb panel Honeycomb panel, characterized in that substantially aligned with the cut surface of the face plate. 7. The insert of claim 6, wherein the insert has a cut surface that is substantially aligned with the cut surface of the face plate, each insert having a channel-shaped cross section in a plane parallel to the thickness direction of the honeycomb panel. And each of the inserts has two parallel portions that face each other in the thickness direction and are joined to opposite surfaces of the two face plates. In a honeycomb panel comprising two face plates 28, 30, 61, 62 and a honeycomb core 32 positioned between two face plates and bonded to two face plates, the honeycomb panel Openings 12 and 75 formed through the inside of the honeycomb panel in the thickness direction of the inserts, inserts 36 and 65 inserted into the honeycomb cells 38 of the honeycomb core 32 which are open to the openings; And a frame member (34,70) positioned in the opening and welded to at least one of the two face plates and the insert butt welded to the insert. In a honeycomb panel comprising a honeycomb core 32 positioned between two faceplates 28,30,61,62 and two faceplates and bonded to two faceplates, a honeycomb panel Openings 12 and 75 formed through the interior of the honeycomb panel in the thickness direction of the honeycomb panel, and inserts 36 and 65 inserted into the honeycomb cells 38 of the honeycomb core 32 in the openings. Each of the inserts has a channel-shaped cross section in a plane parallel to the thickness direction of the honeycomb panel, and each of the inserts forms the face plate 28, 30, 61, 62 to form a perimeter of the opening. Honeycomb panel characterized in that it has an end face coupled to the end face of the insert, and the end face of each insert is substantially aligned with the end face of the face plate when viewed in a direction perpendicular to the thickness direction of the honeycomb panel. . In a honeycomb panel having an opening 12 formed through a portion of the honeycomb panel in the thickness direction of the honeycomb panel and constituting at least a portion of the car body structure, an interior providing an inner and an outer surface of the car body structure, respectively. And an outer face plate 28 and 30, a honeycomb core 32 positioned between the inner and outer face plates, an insert 36 positioned between the two face plates such that an insert is exposed to the opening and bonded to the two face plates. And a frame member 34 fixed to the opening 12 for attaching a third member to the honeycomb panel, the frame member having a cylindrical portion 44 engaging with the opening and a radius from the cylindrical portion. An outer flange portion 48 extending outwardly in a direction, the outer flange portion being engaged with a portion of the outer surface of the outer face plate 30, and having an image on the outer surface. Some are adjacent to the periphery of the opening, the frame member do, characterized in that it is welded to the inner face plates 28 and the insert 36, the comb panel. Preparing a non-joined assembly in which the honeycomb core 32 and the inserts 36 and 65 are installed between the two face plates 28, 30, 61 and 62. The honeycomb core is the two face plates. The process of preparing a joint assembly bonded to the joint assembly and forming the openings 12 and 75 through the thickness of the joint assembly such that the insert is exposed to the opening to form the periphery of the opening. A method for producing a honeycomb panel, characterized by comprising a step of cutting. 12. The method according to claim 11, wherein the inserts (36, 65) are bonded to the two face plates when the honeycomb core (32) is bonded to the two face plates. 12. The process of claim 11, wherein the step of cutting the joining assembly to form an opening consists in providing a marking on the outer surface of one of the two face plates 28, 30, 61, 62, The marking is a method of manufacturing a honeycomb panel, characterized in that the insert is installed and the cutting line (40, 76) to mark the bonded assembly is to be cut. The method according to claim 12, wherein the frame members are positioned in the openings 12 and 75 of the joint assembly so that the frame members 34 and 70 engage with the inserts 36 and 65. And a step of bonding the insert and at least one of the two face plates to the face plate. 15. The process of claim 14, wherein the joining assembly is curved at a predetermined curvature in a plane parallel to the thickness direction of the joining assembly before positioning the frame member in the opening, and before placing the frame member in the opening. The method of manufacturing a honeycomb panel further comprises the step of bending the frame portion (34, 70) to a curvature substantially the same as the curvature of the bonded assembly. 13. The process of claim 12, wherein the step of preparing the non-bonded assembly comprises inserting the selected honeycomb of the honeycomb core 32 along the line through which the bonded assembly is cut to form the opening 12. Wherein 36 is made of a process, the joining assembly is a method for manufacturing a honeycomb panel, characterized in that the line is cut. An insert 36 is installed in a cell to be selected from the honeycomb 38 of the honeycomb core 32, which is located between two face plates 28 and 30 and bisected by a predetermined cutting line 40. Preparing a non-bonded assembly; Preparing a bonding assembly in which at least the honeycomb core is bonded to the two face plates; And cutting the bonded assembly to remove the unnecessary portion and penetrate the thickness of the bonded assembly to form the opening 12. 18. The vertical portion 36a according to claim 17, wherein each of the inserts 36 has two horizontal portions 36b and 36c attached to the two face plates 28 and 30, respectively, and a vertical portion connecting the two horizontal portions. And a step of preparing the non-joined assembly, wherein each of the inserts is positioned such that the vertical portion 36a is positioned on one side of the cutting line 40 away from the unnecessary portion. Honeycomb core manufacturing method. The process of preparing the joint assembly in which the insert 36 installed in the selected cell of the honeycomb core 32 and the honeycomb core 38 of this honeycomb core is joined to at least one faceplate of two faceplates 28 and 30 is prepared. ; Cutting the joint assembly to form the opening through the thickness of the joint assembly such that the insert is exposed to the opening 12; And positioning the frame member (34) in the opening to weld the frame member to at least one of the insert and the face plates of the two sheets. The process of preparing the joint assembly in which the insert 36 installed in the selected cell of the honeycomb core 32 and the honeycomb core 38 of this honeycomb core is joined to at least one faceplate of two faceplates 28 and 30 is prepared. ; Cutting the joint assembly along a first cutting line 58 to form a preliminary hole 50 through the thickness of the joint assembly; Measuring a depth of the selected honeycomb (38) open in the preliminary hole in a direction perpendicular to the cutting line; Determining a part of the second cutting line 52a that is flat to the first straight cutting line based on the measured depth of the selected honeycomb cell; And cutting the joint assembly along the second cutting line to expose the insert. 21. The method of claim 20, further comprising determining a position of a third cutting line adjacent to the junction assembly and parallel to the second cutting line based on the determined position of the second cutting line. The method of manufacturing a honeycomb panel further comprises the step of trimming the bonded assembly according to. On the first part of the first face plate, two horizontal parts 65b and 65c, such that the first part of the first face plate 61 is divided from the second part of the first face plate by the channel member 65. And positioning the channel member (65) having a vertical portion (65a) connecting the two horizontal portions, and joining the channel member to a second portion of the first face plate; Positioning a honeycomb core 32 on a first portion of the first faceplate, and placing a second faceplate 62 on the channel member and the honeycomb core, to prepare a joint assembly. Bonding the honeycomb core to a face plate and a second face plate; Cutting the joining assembly to form the opening by removing the second portion of the first face plate and the corresponding portion of the second face plate such that the channel member is exposed to the opening 75, and a frame member ( 70) is positioned in the opening, and the frame member is welded to the two horizontal portions of the channel member and the first and second face plates. Preparing a joint assembly in which a honeycomb core 32 is positioned between two face plates 28 and 30 and bonded to the two face plates; Cutting the bonded assembly to form the opening 50 through the thickness of the bonded assembly; Inserting an insert (36) into the honeycomb (38) of the honeycomb core (32) open to the opening; And positioning a frame member (34) in the opening and welding the frame member to the two face plates and the insert. Preparing a joint assembly in which a honeycomb core 32 is positioned between two face plates 28 and 30 and bonded to the two face plates; Cutting the joint assembly to penetrate through the thickness of the joint assembly to form a preliminary hole 50; Inserting an insert (36) into the honeycomb (38) of the honeycomb core which is opened in the preliminary hole (50); An opening similar to or larger than the preliminary hole 50 for cutting the insert such that the cutting surface of the insert is aligned with the cutting surface of the honeycomb core and the face plate when viewed in a direction perpendicular to the thickness direction of the joint assembly. Cutting the bonding assembly to form a 12; And positioning a frame member (34) in the opening and welding the frame member to the face plate and the insert. 24. The apparatus of claim 23, wherein each of the inserts has a first portion held in close contact with an inner surface of each second portion of at least one of the two faceplates, wherein the second portion is the opening. Adjacent to and welding the frame member to the first portion of each insert and to the second portion of each face plate. 25. The apparatus of claim 24, wherein each of the inserts has a first portion held in close contact with an inner surface of each second portion of at least one of the two faceplates, wherein the second portion is the opening. Adjacent to the frame member is welded to a first portion of each insert and a second portion of each face plate.