JP2623295B2 - Honeycomb structure and manufacturing method thereof - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb structure used as a core of various structural materials and a method for manufacturing the same.

More specifically, the present invention particularly relates to a honeycomb structure used as a core material of a structural material having excellent heat insulation properties, sound insulation properties, and the like, and a method for manufacturing the same.

"Conventional technology", "Problems to be solved by the invention" A core material of a structural material that is excellent in flatness and also excellent in heat insulation and sound insulation without impairing the characteristics of being extremely lightweight. A honeycomb structure in which each cell of the honeycomb core is filled with a foamed plastic material such as hard urethane has been conventionally used because it is easily obtained.

However, a honeycomb structure filled with a foamed plastic material such as hard urethane in each cell of a conventional honeycomb core is formed of a foamed plastic material having a predetermined thickness on the honeycomb core, for example, for ease of molding. Are formed by pressing and filling a foamed plastic material at a predetermined position in each cell of the honeycomb core with a press or the like.

Therefore, at the time of press-fitting and filling,
The honeycomb core is filled while being cut by the upper end of the cell wall constituting each cell. Therefore, the foamed plastic material filled in each cell was filled in an independent state for each cell.

Therefore, when the honeycomb structure receives a shock or vibrates, the foamed plastic material filled from some cells may drop out, or the filling position may shift or eat out even if it does not drop out. Since it is easy to occur, for example, the transfer to the surface plate attaching process must be performed very carefully, so that the handling of the honeycomb structure is troublesome, and the filled foamed plastic material is dropped or filled. It has been pointed out that it is necessary to correct those points, for example, when the position shifts, and that the correction work is extremely troublesome and takes a long time, resulting in extremely poor work efficiency.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a honeycomb structure formed by temporarily filling a predetermined position in each cell in a honeycomb core with a foamed plastic material having a predetermined thickness. Even when the body is shocked or vibrated, the foamed plastic material filled in each cell may drop out of some cells, or the filling position may be shifted and eaten out of the cells. There is no need for troublesome correction work due to the fact that the filled foamed plastic material falls out or eats out,
An object of the present invention is to propose a honeycomb structure in which each cell in a honeycomb core is easily filled with a foamed plastic material, and a method for manufacturing the same.

"Means for Solving the Problems" The present invention has been made to achieve the above object, and the technical solutions thereof are as follows.

First, the honeycomb structure of claim 1 is as follows.

The honeycomb structure includes a honeycomb core formed of a planar assembly of cells having a predetermined shape, and a foamed plastic material having a predetermined thickness filled at predetermined positions in each cell of the honeycomb core.

At one end of a cell wall constituting each cell in the honeycomb core, a cutout having at least one predetermined depth is formed, and a cutout is filled at a predetermined position in each cell. A portion of the foamed plastic material having a predetermined thickness is filled so as to be continuously located at a portion corresponding to the cutout portion.

The cutout portion is formed at a joining portion having a double structure by being bonded to the cell wall via an adhesive. In addition, the foamed plastic material, which is formed in advance to have a thickness smaller than the thickness of the honeycomb core while matching the size of the honeycomb core, is overlapped from the side of the honeycomb core where the cutout portion is formed. Pressed by a press or the like. In the foamed plastic material, a portion cut at one end of the cell wall in which the notch is formed is press-fitted and filled independently for each of the cells, and the notch is The part that has not been cut due to the presence of the filler is filled in a continuous state through the notch. Thus, this honeycomb structure is used as a core material of various structural materials, but the surface plate is not yet attached.

Next, a method for manufacturing a honeycomb structure according to a second aspect is as follows.

That is, in this manufacturing method, first, a notch provided with at least one predetermined depth is formed at one end of a cell wall constituting a hollow columnar cell having a predetermined shape. A honeycomb core having a portion formed thereon, and a foamed plastic material which has been previously formed in a thickness suitable for the size of the honeycomb core and smaller than the thickness of the honeycomb core are prepared. Then, the foamed plastic material is overlaid on the surface of the honeycomb core on which the cutouts are formed, and then pressed by a press or the like. Thus, the foamed plastic material is press-fitted and filled with the cut portion at one end of the cell wall where the cutout portion is formed in an independent state for each of the cells and the cutout portion. The portion that has not been cut due to the presence of is filled in a continuous state through the notch. Accordingly, the foamed plastic material of the honeycomb core is filled in a predetermined position in each of the cells so that a part thereof is continuously located at a portion corresponding to the cutout portion, and is used as a core material of various structural materials. A honeycomb structure can be obtained which is used but the surface plate is not yet attached.

[Operation] The present invention comprises the above means, and operates as follows. That is, in this honeycomb structure and the honeycomb structure obtained by this manufacturing method, a part of the foamed plastic material having a predetermined thickness filled in a predetermined position in each cell in the honeycomb core constitutes each cell. At one end of the cell wall to be formed, a continuous state at a portion corresponding to the cutout having at least one notch having a predetermined depth, that is, the foamed plastic material filled in each cell is provided for each cell. Since the honeycomb structure is not in an independent state but has a configuration in which a portion of the foamed plastic material filled in adjacent cells is continuously filled with each other, the honeycomb structure may be subjected to, for example, impact or vibration. In some cases, even though the surface plate is still unattached,
It does not occur that the foamed plastic material filled from some cells drops out, or even if the foamed plastic material does not drop out, the filling position is shifted and eaten out of the cells.

Therefore, it is not necessary to perform extremely troublesome and time-consuming correction work that is necessary when the filled foamed plastic material is dropped off, and the handling of the honeycomb structure is easy. It is possible to improve work efficiency such as a transfer work to the attachment step.

In this honeycomb structure, when the cutout portion is formed at the joint portion forming the double structure of the cell wall of the honeycomb core, the formation of the cutout portion has little effect on the overall strength. There is.

"Example" Hereinafter, the present invention will be described based on the example shown in the drawings.

FIG. 1 is a perspective view of a main part of the honeycomb structure, and FIG. 2 is a sectional view taken along the line II-II of FIG.

In the figure, reference numeral 1 denotes a honeycomb structure, and 2 denotes a honeycomb core constituting a main body of the honeycomb structure 1. The honeycomb core 2 has a planar hexagonal hollow columnar cell 3 having a predetermined height. Consists of an aggregate. And
At the time of forming the honeycomb core 2, the cell walls 4 facing each other at one end (the upper end in the embodiment) of the cell walls 4 constituting the cells 3 along the extension direction W, A double structure formed by bonding adjacent base materials 5 to each other via an adhesive 6 applied in a striped shape having a predetermined width at each predetermined position of each base material 5 to form 4. At the approximate center of each of the cell walls 4 (joining portions 13 in FIG. 3 to be described later), the end sides of the cell walls 4 are opened to a predetermined depth, that is, a predetermined thickness to be described later. In a state where the formed hard urethane 7 is filled at a predetermined position in each cell 3, the bottom 8 a has a depth which is located at a position where the bottom 8 a enters the depth appropriately from the surface of the filled hard urethane 7. A rectangular cutout 8 set as described above is formed.

Reference numeral 7 denotes a hard urethane, and the hard urethane 7 is filled in substantially the center of the honeycomb core 2 in the thickness direction in each cell 3, and has a thickness smaller than the thickness of the honeycomb core 2. In the filled state, the surface of the notch 8 is set to have a thickness located above the bottom 8a of the notch 8 by a predetermined height.

Therefore, when the hard urethane 7 is filled into the honeycomb core 2, the hard urethane 7 is pressed into the honeycomb core 2 from the side where the cutout portion 8 is formed, so that the honeycomb core 2 is filled into a predetermined position in each cell 3. Hard urethane 7
Are filled in a continuous state at a portion corresponding to the notch 8.

 The honeycomb structure 1 is as described above.

Next, an example of a method for manufacturing the honeycomb structure 1 will be described.

FIG. 3 is a perspective view of a main part showing a state where the notch 8 is formed in the honeycomb core 12 in an unexpanded state.

In the figure, reference numeral 12 denotes an unexpanded honeycomb core,
The honeycomb core 12 in the unexpanded state is provided with a predetermined number of base materials 5.
In order that the adjacent base materials 5 are alternately bonded at a position shifted by a half pitch, the base materials 5 to which the adhesive 6 is applied at a predetermined pitch and in a stripe shape of a predetermined width are sequentially applied in a predetermined manner. Are formed in such a manner that the base members 5 are superimposed on each other in the positional relationship described above.

 First, the step of forming the notch 8 will be described.

In the embodiment, when the honeycomb core 12 is formed in an unexpanded state, the notches 8 are formed so that the adjacent base materials 5 are separated from each other at a predetermined pitch via the adhesive 6 applied in the form of striations. One end (upper end in the figure) of each joint 13 formed by bonding and positioned along the direction of lamination
A square notch 8 having an open end is formed by cutting out a substantially central portion of the substrate at an appropriate width and a predetermined depth.

Therefore, each joint located in series in the lamination direction
Since the notches 8 can be formed in the holes 13 at the same time, their formation is easy.

Regarding the formation of the notch 8, especially in the case of a honeycomb core formed by corrugation forming means, not by stretch forming means, a corrugated base in which uneven portions are continuously formed alternately. It may be formed in the state of the material or after the honeycomb core is formed.

Next, after the notch 8 is formed, the honeycomb core in an unexpanded state is formed.
By stretching the base 12 in the overlapping direction, that is, the stretching direction W, each substrate 5 is bent along the edge of the joint 13 to form a double structure as shown in FIG. The honeycomb core 2 in which the square notch 8 having a predetermined depth is formed at substantially the center of each of the cell walls (joining portions 13 in FIG. 3) is obtained.

Next, the filling step of the hard urethane 7 will be described with reference to FIGS.

The honeycomb core 2 has the cutout 8 side as the upper part, and a hard urethane 7 of the same size as the honeycomb core 2 formed to a predetermined thickness is stacked on the honeycomb core 2 and pressed, for example, through a press-fitting buffer material. By pressing the hard urethane 7 into the honeycomb core 2 by, for example, the hard urethane 7 is
From the lower end thereof, the honeycomb core 2 is pressed into the cells 3 while being cut by the cell walls 4 of the honeycomb core 2. The honeycomb core 2 has a predetermined position in each cell 3, that is, as shown in FIG. Filled in the center. In this state,
The lower part of the filled hard urethane 7 is filled in an independent state for each cell 3, but the notch is formed so that the upper surface of the hard urethane 7 is located at a predetermined height above the bottom 8 a of the notch 8. 8 and the thickness of the hard urethane 7 are set, so that a portion corresponding to the notch 8 in the upper portion of the hard urethane 7 has a structure in each cell 3 positioned in series along the extension direction W. The hard urethane 7 filled in this portion is all filled in a continuous state at this portion.

In the above-described embodiment, the configuration in which the hard urethane 7 is filled is described. However, the material of the foamed plastic material to be filled is not limited to the hard urethane 7, but the application of the honeycomb structure 1 and the honeycomb core 2
May be selected depending on the compressive strength of the steel. The thickness of the foamed plastic material to be filled also depends on, for example, the material of the honeycomb core 2, the thickness of the surface plate attached to the honeycomb structure 1, the type of the adhesive used when the surface plate is attached, and the like. A foamed plastic material having substantially the same thickness as the core 2 may be filled.

Further, the number and the like of the cutouts 8 formed in the cell walls 4 of the honeycomb core 2 are not limited to those in the above-described embodiment. In the case of the honeycomb core 2 composed of substantially planar hexagonal cells 3 in the embodiment so that a part of the plastic material is continuous with all adjacent cells 3, the cell wall having a planar approximately regular hexagonal shape. A configuration in which the cutouts 8 are formed on all sides of FIG. According to such a configuration, the filling state of the filled foamed plastic material can be more stably maintained. Also, the shape of the notch 8 may be, for example, substantially V-shaped, inverted trapezoidal, or the like.

Also, the planar shape of the cells 3 of the honeycomb core 2 constituting the main body is not limited to a substantially regular hexagon.

The honeycomb structure 1 and the method for manufacturing the same according to the present invention are as described above. Therefore, in the honeycomb structure 1, a part of a foamed plastic material such as a hard urethane 7 having a predetermined thickness filled in a predetermined position in each cell 3 in the honeycomb core 2 is formed on the cell wall 4. Since the portion corresponding to the notch portion 8 is filled in a continuous state, even when the honeycomb structure 1 receives an impact or vibrates, the hard urethane 7 or the like filled from some of the cells 3 can be used. Even if the foamed plastic material does not drop out, and even if the foamed plastic material does not drop out, the filling position will not be shifted and the honeycomb core 2 will not be eaten out.

[Effect of the Invention] As described in detail above, according to the honeycomb structure of the present invention and the honeycomb structure obtained by the manufacturing method of the present invention, the honeycomb structure receives, for example, an impact or vibrates. In some cases, the filled plastic material does not drop out of some cells, or the filling position is shifted even if it does not drop out. Extremely troublesome and time-consuming correction work that was necessary when the foamed plastic material dropped out became unnecessary, and the handling and transportation of the honeycomb structure was easy because the handling of the honeycomb structure was easy. Work efficiency of work and the like can be remarkably improved, and the effect exhibited by this type of honeycomb structure has been remarkably increased, for example, the problems of the conventional honeycomb structure have been eliminated.

In this honeycomb structure, when the cutout is formed at the joint without the double structure of the cell wall of the honeycomb core, the influence of the formation of the cutout on the overall strength is reduced.

[Brief description of the drawings]

1 and 2 show an embodiment of the present invention. FIG. 1 is a perspective view of a main part of a honeycomb structure, and FIG. 2 is a cross-sectional view taken along line II-II in FIG. FIG. FIG. 3 is a perspective view of a main part showing a state in which a cutout portion is formed in a honeycomb core in an unexpanded state, for explaining a method of manufacturing a honeycomb structure according to an embodiment of the present invention. DESCRIPTION OF SYMBOLS 1 ... Honeycomb structure 2 ... Honeycomb core 3 ... Cell 4 ... Cell wall 5 ... Base material 6 ... Adhesive 7 ... Hard urethane 8 ... Notch portion 12 ... Unexpanded honeycomb core 13 …… Joint W …… Extension direction

Claims (2)

(57) [Claims] 1. A honeycomb structure used as a core material of various structural materials, wherein a surface plate is in an unattached state, and each cell in a honeycomb core formed of a planar aggregate of hollow columnar cells having a predetermined shape. At one end of the cell wall constituting, a notch having at least one predetermined depth is formed, and at a portion corresponding to the notch,
A predetermined position in each cell is filled with a foamed plastic material having a predetermined thickness so that a part thereof is continuously located, and the cutout portion is bonded to the cell wall via an adhesive. The foamed plastic material is formed at a joint portion having a double structure by forming the honeycomb structure in advance to have a thickness smaller than the thickness of the honeycomb core while being suitable for the size of the honeycomb core. The core was overlaid and pressed with a press or the like from the side where the notch was formed, and the foamed plastic material was cut at one end of the cell wall where the notch was formed. A part is press-fitted and filled in an independent state for each of the cells, and a part that has not been cut due to the presence of the notch is filled in a continuous state via the notch. Also a honeycomb structure. 2. A notch comprising a planar assembly of hollow columnar cells having a predetermined shape and having at least one predetermined depth at one end of a cell wall constituting each cell. Is prepared, and a foamed plastic material which is formed in a thickness which is suitable for the size of the honeycomb core and which is smaller than the thickness of the honeycomb core in advance, is prepared. The foamed plastic material is cut at one end of the cell wall where the notch is formed by stacking the core on the surface of the cell where the notch is formed and then press-fitting with a press or the like. The cut portion is press-fitted and filled in an independent state for each of the cells, and a portion that has not been cut due to the presence of the notch portion is filled in a continuous state through the notch portion. Honeycomb core The foamed plastic material is filled at a predetermined position in each of the cells so that a part thereof is continuously located at a portion corresponding to the cutout portion, and is used as a core material of various structural materials. A method for producing a honeycomb structure, characterized in that a honeycomb structure not yet attached is obtained.