JPH0243030A - Manufacturing method of flexible honeycomb core - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION "Field of Industrial Application" The present invention relates to a method for manufacturing a flexible honeycomb core. That is, the present invention relates to a method of manufacturing a flexible honeycomb core for forming a curved surface, which is suitable for forming a curve into a complicated curved surface such as a cubic surface.

"Technical background" First, we will discuss its technical background.

Honeycomb cores generally have the characteristics of being easy to manufacture and having a high strength-to-weight ratio.As shown in FIG. It consists of a flat collection of.

By the way, when attempting to curve a conventional honeycomb core 3 having regular hexagonal cells 2, etc. into a curved surface, the following will occur.

In other words, when the stretching direction W (or ribbon direction L) is curved along the curved surface, the ribbon direction L perpendicular to this direction
(or the direction of expansion W) is conversely warped upwards and distorted into a saddle shape, which does not follow the curved surface and does not fit. Further, if force is applied to the cell wall 1 to make it fit along a curved surface, the cell wall 1 may break or peeling may occur at the joint.

As described above, conventionally, it has been extremely difficult to use a general honeycomb core 3 to form a curve into a complex curved surface such as a cubic curved surface.

Therefore, firstly, an over-extended core has been conventionally provided.

That is, this overextended core is made of a planar assembly of substantially rectangular cells obtained by further expanding the above-described general honeycomb core 3 in the expansion direction W by a predetermined amount.

When this overextended core is curved in the ribbon direction along a curved surface, no problem occurs. However, if you try to curve the direction of expansion along a curved surface, the direction of expansion will be as if it were a straight line.
The cell walls are located like a plate and have high bending rigidity, making it extremely difficult to curve the expansion direction along a curved surface. Therefore, even if such an overextended core is used, it is difficult to accurately curve a complex curved surface such as a cubic curved surface.

Therefore, secondly, an improved version of the overextended core has been conventionally provided.

In other words, this improved honeycomb core holds the overextended core fixedly on one side in the direction of expansion,
It is formed by gradually applying a uniform predetermined load in the direction of the ribbon from the other side, and the cell walls in the stretching direction are slightly bent inward midway, so that the cells form an approximately drum shape.

With this honeycomb core, it has become possible to form curves into complex curved surfaces such as cubic surfaces with high precision, regardless of whether it is in the ribbon direction or the stretching direction.
It has been pointed out that the manufacturing problem is that the molding is troublesome as described above.

Especially when the thickness of the overextended core before molding is thin or its size is large, it is extremely difficult to gradually apply a predetermined load, which is a fatal flaw in that the shape of each cell becomes uneven. was pointed out.

The technical background is as above.

"Prior Art" Therefore, as a third conventional technique, a flexible honeycomb core 4 shown in FIG. 6 has been provided.

That is, in this flexible honeycomb core 4, each cell wall 5 is entirely bent in the middle, and each cell 6 has a rounded, substantially convex shape, and its protrusion has a shape close to a substantially triangular shape. ing. Since the flexible honeycomb core 4 has such a shape, it is extremely flexible and can be curved into a complex curved surface such as a cubic curved surface with high precision in any direction.

"Problems to be Solved by the Invention" By the way, the following problem has been pointed out in such a conventional flexible honeycomb core 4.

That is, this flexible honeycomb core 4 is produced by corrugating a flat plate material, first preparing a corrugated sheet material in which a predetermined shape with special unevenness is continuously bent, and then stacking a plurality of such corrugated sheet materials. They were formed by laminating them together and bonding them together at predetermined parts.

In other words, as mentioned above, the flexible honeycomb core 4 has a special shape in which each cell wall 5 is bent in the middle, each cell 6 is rounded and has a substantially convex shape, and the protrusion is almost triangular. In order to obtain high quality, uniform and stable shapes, the stretching method was considered difficult. Conventionally, corrugated sheets of a predetermined shape were first made as described above, and then they were bonded together one by one to form the corrugated sheet.

Therefore, although this flexible honeycomb core 4 can be processed to be curved with high precision after the fact, it has been pointed out that the forming process is extremely troublesome and extremely costly, which is a fatal problem in manufacturing.

This point was pointed out in the conventional example.

In view of these circumstances, the present invention has been made to solve the problems of the conventional methods described above.The present invention is made by stacking triangular wave-shaped corrugated sheets in a predetermined manner and joining them together, and then stretching them. The purpose of the present invention is to propose a method for manufacturing a flexible honeycomb core that can easily and easily obtain a high-quality flexible honeycomb core with a uniform and stable shape.

"Means for Solving the Problem" The technical means of the present invention to achieve this object are as follows.

This manufacturing method includes the following preparation process, bonding material attaching process, laminating process, abutting process, bonding process, spreading process, etc.

In the preparation step, a corrugated sheet material in which triangular wave-like unevenness is continuously bent is prepared in advance.

In the bonding material application step, a bonding material is provided every other row on the top or trough portions of the corrugated sheet material.

In the lamination step, a plurality of corrugated sheet materials are stacked such that the positions where the bonding material is provided are alternately shifted between the upper and lower corrugated sheet materials.

In the abutting step, pressure plates are brought into contact with the stacked corrugated sheets from above and below, respectively, through pressurizing auxiliary bars that are fitted into the concavities and convexities of the stacked corrugated sheets.

In the joining step, the corrugated sheet material is pressed and heated by the upper and lower pressure plates, and is partially joined by the joining material.

In the stretching step, the joined corrugated sheet material is stretched by applying a tensile force in the stacking direction, so that each cell wall is bent in the middle, and each cell forms a rounded substantially convex shape. A flexible honeycomb core is formed.

"Function" Since the manufacturing method according to the present invention includes such means, it works as follows.

First, the corrugated sheet material prepared in the preparation step has a simple triangular wave shape and is continuously bent. In addition, in the step of attaching the bonding material, it is sufficient to simply provide the bonding material every other row on the top or trough portions of the corrugated sheet material. In the stacking of corrugated sheet materials in the lamination process, it is sufficient to simply shift the position of the bonding material from top to bottom. Further, in the abutting process, the pressurizing plate is smoothly abutted from above and below by fitting the pressurizing auxiliary bar.

In this way, each step is performed simply, easily and reliably.

Next, since the pressurization in the bonding process is performed by the pressurizing plate via each pressurizing auxiliary bar, it is carried out with a minimum pressure and a uniform pressurizing force, resulting in an extremely uniform shape.

In the final stretching step, a flexible honeycomb core in which each cell wall is bent in the middle and each cell has a rounded, substantially convex shape is obtained all at once by stretching without bonding them together one by one. In other words, a flexible honeycomb core with a special shape can be easily and stably obtained with a uniform shape.

Now, after the fact, such a flexible honeycomb core has 3
Curve formation processing is performed with high accuracy on complex curved surfaces such as curved surfaces.

"Example" The present invention will be described in detail below based on the example shown in the drawings.

Figures 1, 2, 3, 4, 5, and 6 are
FIG. 3 is an explanatory diagram for explaining an example of a method for manufacturing a flexible honeycomb core 4 according to the present invention. This manufacturing method is the next preparation step.

The process includes a bonding material attaching process, a laminating process, an abutting process, a joining process, an expanding process, etc.

First, let's talk about the preparation process.

FIG. 1 is a perspective explanatory view of a flat plate material 7 used in the preparation process. FIG. 2 is a perspective explanatory view of the corrugated sheet material 8 that has been bent in the preparation process.

In other words, in this preparation process, the flat plate material 7 shown in FIG. 1 is corrugated by passing it through a corrugating machine F (not shown), so that the corrugated sheet material 8 shown in FIG. is obtained.

As the flat plate material 7, ie, the corrugated plate material 8, which is the base material, aluminum, various alloys, other metal paper, thin plates such as plastic, foil, etc. are appropriately selected and used.

The preparation process is as follows.

Next, the process of attaching the bonding material will be described.

FIG. 3 is a perspective explanatory view of the corrugated sheet material 8 with the bonding material 9 provided on the top in the bonding material attaching step. That is, in this bonding material application step, the bonding material 9 is applied every other strip to either the front surface or the back surface of the top or valley portions of the corrugated sheet material 8 prepared in the above-mentioned preparation step. In the illustrated example, a bonding material 9 is applied to every other top surface of the corrugated sheet material 8.

As this bonding material 9, a brazing material or an adhesive is used.

The process of attaching the bonding material is as follows.

Next, the lamination process will be described.

FIG. 4 is an explanatory front view of the corrugated sheet materials 8 stacked in the stacking process. In other words, in this lamination process, the tops or valleys where the bonding material 9 was provided in the above-mentioned bonding material attaching process are alternately shifted left and right between each upper and lower corrugated sheet material 8, that is, each layer is stacked horizontally. A plurality of corrugated sheets 8 are stacked one on top of the other in a number of layers, shifting one peak at a time so that their unevenness, that is, the top and valley portions correspond to each other.

The lamination process is as follows.

Next, the contact process will be described.

Figure 5 shows pressure play from above and below in the contact process)10
It is a front explanatory view of the corrugated sheet material 8 with which etc. were abutted. In other words, in this contacting process, the pressurizing auxiliary bars 11 each having a triangular cross section are fitted from above and below into the irregularities at the top and bottom of the corrugated sheets 8 stacked in the above-described lamination process, respectively. Pressure plates 10 are brought into contact with each other.

The abutting process is as follows.

Next, the bonding process will be described.

In the joining process, the corrugated sheet material 8 is heated while being pressed by the upper and lower pressure plates 10, and is partially joined by the joining material 9.

For example, in this joining process, brazing is performed as a process. That is, first, the corrugated sheet material 8 is placed in a vacuum furnace, and the pressure plates 10 are abutted from above and below in the abutting step described above. Then, each corrugated sheet material 8 is pressurized via the pressurizing auxiliary bar 11 by the vertical movement of the pressure plate 1-10, and heated to the melting temperature of the brazing material that is the bonding material 9. Partially joined by

The joining process is as follows.

Next, we will discuss the expansion process.

The corrugated sheet material 8 joined in the above-mentioned joining process is appropriately cut and then stretched by applying a tensile force in the stacking direction, that is, the stretching direction. This stretching is carried out using, for example, a stretching device, by placing the joined corrugated sheet material 8 on the plate stand, inserting pins into the cells 6 at both ends, and then moving the bottle using a moving mechanism. It will be done.

In this manner, a predetermined tensile force is applied to the partially joined corrugated sheet material 8 by the joining material 9, and the opposing non-joined portions are deformed and separated to form a predetermined shape. FIG. 6 is an explanatory plan view of the flexible honeycomb core 4 formed by such a stretching process. In this flexible honeycomb core 4, each cell wall 5 is bent in the middle, each cell 6 has a rounded, substantially convex shape, and its protrusion has a shape close to a substantially triangular shape.

The expansion process is as follows.

The method for manufacturing a flexible honeycomb core according to the present invention includes:
It is as explained above.

The operation etc. will be explained below.

First, the corrugated sheet material 8 prepared in the preparation step has a simple triangular wave shape, and is easily and continuously bent from the flat sheet material 7 (see FIGS. 1 and 2).

In the process of attaching the bonding material, it is sufficient to simply provide the bonding material 9 every other thread on the top or trough of the corrugated sheet material 8 (see Figure 3).
.

When stacking the corrugated sheets 8 in the next lamination process, it is only necessary to make sure that the position of the bonding material 9 is shifted between the upper and lower corrugated sheets 8, and since the corrugated sheets 8 have a triangular wave shape, even a large number of corrugated sheets 8 will not collapse. (See Figure 4). Furthermore, in the abutting process, the pressurizing plate 10 is smoothly abutted from above and below by fitting the pressurizing auxiliary bar 11 (see Fig. 5).
.

In this way, the preparation process, bonding material attachment process, lamination process, abutment process, etc. are performed simply, easily, and reliably.

Next, pressure in the bonding process is applied using upper and lower pressure plates 10.
This is done through the upper and lower pressurizing auxiliary bars 11. Therefore, the pressure plate 10 only needs to function with the minimum pressure, and the pressure auxiliary bar 11 applies a uniform pressure to the top and bottom of the corrugated sheet material 8, so that the corrugated sheet material 8 has an extremely uniform shape. keep.

Then, in the final expansion step, each cell wall 5 is bent in the middle, and each cell 6 has a rounded, substantially convex shape, and the protrusion of the flexible honeycomb core has a shape close to a substantially triangular shape. 4 can be obtained all at once by stretching without bonding them one by one. In other words, the specially shaped flexible honeycomb core 4 can be obtained easily and extremely stably with the cells 6 etc. having a uniform shape and density (see FIG. 6). Further, in the lamination process, as described above, a large number of corrugated sheets 8 can be piled up, so that a large flexible honeycomb core 4 can also be freely formed.

Now, the flexible honeycomb core 4 has a special shape in which each cell wall 5 is bent in the middle, and each cell 6 has a rounded, substantially convex shape. Regardless of whether it is in the stretching direction or in the ribbon direction, complex curved surfaces such as cubic curved surfaces can be curved with high precision.

The above is the explanation of the operation, etc.

"Effects of the Invention" The method for manufacturing a flexible honeycomb core according to the present invention includes:
As explained above, the following effects are achieved by stacking and joining triangular wave-shaped corrugated sheets in a predetermined manner and then stretching them.

In other words, a flexible honeycomb core with a special shape that can be processed to form curves on complex curved surfaces such as cubic surfaces with high precision is easy to obtain and is cost-effective, and the shape of its cells is also uniform and stable. The manufacturing problems that existed in conventional examples of this type are eliminated, etc.
The effects of the present invention are remarkable and significant.

[Brief explanation of the drawing]

Figures 1, 2, 3, 4, 5, and 6 are
FIG. 3 is an explanatory diagram for explaining an example of a method for manufacturing a flexible honeycomb core according to the present invention. FIG. 1 is a perspective explanatory view of a flat plate material used in the preparation process. FIG. 2 is a perspective explanatory view of the corrugated sheet material bent in the preparation process. FIG. 3 is a perspective explanatory view of a corrugated sheet material with a bonding material provided on the top in the bonding material attaching step. FIG. 4 is an explanatory front view of corrugated sheet materials stacked in the stacking process. FIG. 5 is an explanatory front view of the corrugated sheet material, which is abutted with pressure plates and the like from above and below in the abutting process. FIG. 6 is an explanatory plan view of a flexible honeycomb core formed by the stretching process. FIG. 7 is an explanatory plan view of a conventional honeycomb core. 4... 5... 6... 8... 9... 10... 1 l... Flexible honeycomb core cell wall section J corrugated sheet material bonding material Pressure plate Pressure auxiliary bar Diagram Figure Figure

Claims (1)

[Claims] A preparation step of preparing in advance a corrugated sheet material in which triangular wave-like irregularities are continuously bent, and a bonding material in which a bonding material is applied every other thread to the tops or valleys of the corrugated sheet material. an attaching step; a laminating step of stacking a plurality of corrugated sheet materials such that the position where the bonding material is provided is alternately shifted between the upper and lower corrugated sheet materials; On the other hand, a contacting step in which pressure plates are brought into contact with each other from above and below via pressure auxiliary bars that are respectively fitted into the unevenness, and the corrugated sheet material is pressurized and heated by the upper and lower pressure plates, A joining step of partially joining the joining material, and stretching the joined corrugated sheets by applying a tensile force in the stacking direction, so that each cell wall is bent in the middle and each cell is rounded. A method for producing a flexible honeycomb core, comprising: a stretching step of forming a flexible honeycomb core having a generally convex shape.