JP4418862B2 - Sandwich panel - Google Patents

Description

  The present invention relates to a honeycomb structure in which a cell space of a honeycomb material is filled with a filler such as a foam material and a sandwich panel using the same, and is technically novel in the fields of heat insulation, sound absorption and insulation, humidity control, environment, and the like. It offers the possibility.

  Honeycomb materials are used in various fields such as aircraft, railway vehicles and buildings because of their light weight and strength. However, in the conventional method, the honeycomb skeleton structure, that is, the honeycomb material structure is used as it is, and the cell space is often left unfilled.

  On the other hand, many attempts have been made to form a honeycomb structure by filling the cell space of the honeycomb material with a foam material or other fillers to provide a heat insulating / soundproofing function or the like.

  A conventional example of filling a honeycomb material cell with a filler can be found in, for example, Patent Document 1. FIG. 1A of the present application shows a configuration of a structure described in Patent Document 1 in which the vertical and horizontal dimensions of the honeycomb material 2 and the filler 1 are the same, and FIG. 1B is configured as shown in FIG. 1A. It shows how the filler is dropped from the cells at the end of the honeycomb material.

  The reason why the filler falls off is that a part of the hexagonal wall of the cell is cut off and opened at the end of the honeycomb material, and the filler cannot be stably held by the wall surface. In addition, when making a sandwich panel using such a structure as a core material, it is necessary to cut the dimensions of the core material to match the dimensions of the surface material, and the vertical and horizontal dimensions of the honeycomb material and the filler are the same. Then, since the cutting position is inevitably applied to the honeycomb material, the cells are cut at that position, and the dropout of the filler is inevitable.

  If an unfilled space is created at the end of the honeycomb material due to the falling off of the filler, the design performance such as heat insulation and soundproofing expected for the filler is lost at that portion, so the commercial value is impaired. Further, if the filler is dropped during the creation of the sandwich panel, the panel forming operation such as the dimension adjustment of the core material is hindered, and the work efficiency is lowered. Furthermore, the dropped filler cannot be left untreated and must be treated as waste.

  As a measure to prevent the filler from falling off, a method of fixing the filler by applying an adhesive to the honeycomb material is conceivable. However, the use of the adhesive causes an increase in cost and an increase in weight in addition to an increase in man-hours. The agent layer may reduce the heat insulation and sound absorption performance.

JP-A-7-88995

  The problem to be solved by the present invention is to prevent the filler from falling off from the end cell space of the honeycomb material, and to effectively prevent the occurrence of the above-mentioned various problems due to the filler falling off.

  In the honeycomb structure of the present invention, when the planar (longitudinal and lateral) dimensions of the sheet-form foam material before filling are larger than the planar dimensions of the honeycomb material, and the honeycomb material is pushed into the foam material, the peripheral edge portion of the honeycomb material is It is bordered by foam material and embedded.

  In the above honeycomb structure, the honeycomb material can be selected from paper, metal, resin, ceramics and other materials, and the filler can be a hard foam of synthetic resin such as phenol, urethane, styrene, etc. Can be used. When the honeycomb material and the filler are stacked and a load is applied by a press to press the honeycomb material into the filler, the cell space of the honeycomb material is filled with the filler and a honeycomb structure is completed.

  In the honeycomb structure, a projecting portion in which one end or both ends in the vertical direction of the honeycomb material are projected from the surface of the filler by a predetermined length may be provided.

  In the honeycomb structure, two filler sheets are filled into the cell space of the honeycomb material at a longitudinal interval, and an air layer in which no filler exists between the two filler layers inside the honeycomb material. May be provided.

  In the honeycomb structure, the two honeycomb materials are press-fitted from the upper and lower surfaces of the sheet-like filler having a thickness exceeding the total height of the two honeycomb materials, and in the middle portion in the thickness direction of the filler, You may provide the layer which consists only of a filler in which a honeycomb material does not exist.

  A sandwich panel may be manufactured by using any of the honeycomb structures as a core material and bonding a surface material thereto. In that case, what apply | coated the adhesive agent to the back surface of a surface material can be pressed and adhered to the surface of a core material, or the protrusion part which protrudes from this surface.

  According to the honeycomb structure of the present invention, since the planar dimension of the filler is larger than the planar dimension of the honeycomb material, the filler is filled in the peripheral portion of the honeycomb material even after the filler is filled into the cell space of the honeycomb material. Since the integrity is maintained without being cut apart and the peripheral portion of the honeycomb material is embedded, the effect that the filler does not fall off is exhibited.

  According to the honeycomb structure provided with the protrusions described above, an effect is obtained that the surface of the filler is protected by the protrusions.

  According to the honeycomb structure in which the air layer in which no filler is present is provided in the intermediate portion in the height direction of the above-described honeycomb material, it is effective for sound absorbing applications corresponding to the entire region from low frequency to high frequency.

  According to the honeycomb structure in which the filler layer (intermediate layer) in which the honeycomb material does not exist is provided in the intermediate portion in the thickness direction of the filler layer, heat conducted through the honeycomb material wall is blocked by the intermediate layer. The foam material constituting the layer becomes a heat insulating layer. If the intermediate layer is thickened, the heat insulating performance is improved. The honeycomb material layers located on both surfaces serve as protective layers for the foam material.

  When manufacturing a sandwich panel by using the honeycomb structure provided with the above protrusions as a core material and bonding a surface material to it, attach an adhesive only to the tip of the protrusion and adhere to the surface of the filler. A method of manufacturing a sandwich panel in which no agent is attached is possible.

  Further, when the honeycomb structure of the present invention is used as a core material of a sandwich panel, the filler is exposed around the core material, so that the processing is easy, the end faces are easily aligned, and the finished appearance is good.

  In addition, as a post-processing, a buried plate is partially inserted around the sandwich panel and bonded to the surface material to create a reinforcing seat for mounting parts, etc., or a plywood or resin plate is inserted into the four surroundings of the panel. Even when bonded to the material, the processing is easy due to the flexibility and ease of cutting of the filler exposed at the periphery of the core material.

  The best mode for carrying out the present invention will be described through the following several examples.

2A and 2B are a sectional view and a perspective view showing a honeycomb structure including a foam material 1 and a honeycomb material 2 as a first embodiment of the present invention. In this embodiment, a hard open-cell phenol foam material having a density of 30 kg / m ³ or less and a length, width, and thickness of 1030 × 1030 × 28 mm in a sheet material is used as the foam material 1, and the honeycomb material 2 A paper honeycomb material with a length, width and thickness of 1000 x 1000 x 30 mm and a cell size (dimension between parallel sides of the cell) of 12 mm was used. Since the used phenol foam material has a low density and is hard and has a hardness that can be easily cut by the honeycomb material cell, the filling property into the honeycomb material cell is good.

  2A and 2B show two features of the honeycomb structure described above. The first feature is that the vertical and horizontal dimensions of the foam material 1 are 30 mm larger than the dimensions of the honeycomb material 2, so that the periphery of the honeycomb material 2 is surrounded by a border 3 having a width of 15 mm. This is a characteristic directly derived from the problem solving means of the present invention.

  Another feature is a structure in which the protrusions 4 of the honeycomb material 2 are formed on the surface of the foam material 1. In order to form this protrusion 4, for example, a honeycomb material 2 having a thickness of 30 mm placed on the upper surface of a foam material 1 having a thickness of 28 mm is pressed with a press so that the lower surface of the foam material 1 and the lower surface of the honeycomb material 2 are aligned. If pushing is stopped at that point, a structure in which the upper end of the honeycomb material 2 protrudes 2 mm from the surface of the foam material 1 is obtained. The protruding portion 4 of the honeycomb material 2 is useful for protecting the surface of the foam material 1 and is bonded only to the tip of the protruding portion 4 when the honeycomb structure is bonded to the surface material as a core material and a sandwich panel is manufactured. A manufacturing method is possible in which an agent is attached and no adhesive is attached to the surface of the foam material 1.

  Depending on the purpose of use, the foam material and the honeycomb material may have the same thickness, and the honeycomb material may be finished flat without protruding.

  3A and 3B are a sectional view and a perspective view of a honeycomb structure having an air layer 5 in the middle as a second embodiment of the present invention. This honeycomb structure having the air layer 5 in the middle is effective for sound absorption applications corresponding to the entire region from low frequency to high frequency. In this example, the dimensions and materials other than the use of the honeycomb material 2 having a height of 50 mm and the two foam materials 1 and 1 ′ having a thickness of 20 mm are the same as those in Example 1 above. . The foam materials 1 and 1 ′ may be foam materials having a thickness of 15 mm and 25 mm, for example.

  When these two foam materials are pressed from both sides or one side of the honeycomb material with a press and filled with a vertical interval, the periphery of the honeycomb material in each foam material is bordered by the foam material with a width of 15 mm. An air layer 5 having a thickness of 10 mm is formed in the middle in the vertical direction of the sheet of foam material. 3 is a support member inserted between the upper and lower edge portions 3 in order to stably maintain the air layer 5 of 10 mm. The support member 3a may be manufactured by processing the foam material into a frame shape in advance, or inserting the prismatic foam material between the two foam materials from four directions.

  4A and 4B are a sectional view and a perspective view of a honeycomb structure as a third embodiment of the present invention. This honeycomb structure is an intermediate layer which is a foam material layer in which two honeycomb materials 2 and 2 'are interposed in upper and lower portions of a thick foam material 1 and no honeycomb material is present between the two honeycomb materials. 6. The dimensions and materials other than the foam material 1 having a thickness of 50 mm and the use of two honeycomb materials having a height of 20 mm are the same as those in Example 1. The honeycomb materials 2 and 2 ′ may be two honeycomb materials having a height of 15 mm and 25 mm, for example. Also in the present embodiment, the periphery of the honeycomb material is edged by the edge portion 3, and the protruding portions 4, 4 'of each honeycomb material are formed on both surfaces of the foam material.

  In the honeycomb structure of the present embodiment, the heat conducted through the honeycomb material wall is blocked by the intermediate layer 6, and the foam material constituting the intermediate layer 6 becomes a heat insulating layer. If the intermediate layer 6 is thickened, the heat insulation performance is improved. The honeycomb material located near both surfaces of the foam material serves as a protective material for the foam material.

  5A and 5B are a cross-sectional view and a perspective view of a sandwich panel having the honeycomb structure shown in FIG. 2 as a core as a fourth embodiment of the present invention. In the honeycomb structure constituting this sandwich panel, as shown in FIG. 2, the projecting portions 4 of the honeycomb material are formed on both surfaces of the foam material together with the edge portion 3, and the projecting portions 4 hold the adhesive 7. The surface materials 8 and 8 'on both sides are adhered to each other as an adhesive portion. Non-breathable 1.2 mm aluminum material was used on both surfaces for the surface materials 8 and 8 ′ of this example. To obtain sound absorption and humidity control functions, use a porous material with air permeability on one or both sides. The core material may be such that the protrusion 4 is formed only on one side of the foam material, or the core material does not have the protrusion 4 on both sides.

The sandwich panel of this example was manufactured according to the following procedure. A two-component epoxy adhesive 7 that is sufficiently stirred and mixed is applied to the surface of the two aluminum materials 8 and 8 'that have been subjected to surface treatment at a rate of 300 to 600 g / m ^2. The material end 4 is abutted and bonded. After the adhesive is cured, the panel edges are cut to finish according to the dimensions of the aluminum material of the face material. Since the panel end is covered with the edge 3 of the foam material, the processing is easy.

FIGS. 6A, B ₁ , B ₂ and C show three types of post-processing examples for a finished fourth embodiment sandwich panel as a fifth embodiment of the present invention. FIG. 6A shows an example in which the reinforcing seat 5a is partially inserted around the panel, and FIGS. 6B ₁ and 6B ₂ show a screw seat 5b1 for screwing the connecting plate 5b2 connecting the two panels. FIG. 6C shows an example in which the protective plate 5c is attached to the entire periphery of the panel.

  In each of the above embodiments, the example in which the vertical and horizontal dimensions of the foam material are both larger than the vertical and horizontal dimensions of the honeycomb material is shown. However, when only one of the vertical and horizontal dimensions of the foam material is larger than the vertical and horizontal dimensions of the honeycomb material, In effect, it has the same effect as the above examples.

Since the honeycomb structure of the present invention and the sandwich panel using the honeycomb structure as a core material can add characteristics such as heat insulation, sound absorption, humidity control, and non-combustibility of the foam material to the light weight and high strength characteristics of the honeycomb material, It is effectively used in various industrial fields such as railway vehicles, buildings, energy saving and environmental safety.

It is a figure (A) of a honeycomb structure shown in a prior application, and a figure (B) showing how a filled foam material falls off from a honeycomb material cell. They are sectional drawing (A) and perspective view (B) which show the 1st Example of this invention using a foam material with a dimension larger than a honeycomb material. It is sectional drawing (A) and perspective view (B) which show the 2nd Example of this invention which provided the air layer in the honeycomb material intermediate | middle. It is sectional drawing (A) and perspective view (B) which show the 3rd Example of this invention which left the foam material layer in the foam material middle. 2 is a diagram showing a fourth embodiment of the present invention as a sandwich panel in which the material is a core material and a surface material is bonded. A diagram showing a reinforcing seat partially placed around the panel (A), a diagram (B ₁ ) showing a connecting portion of two panels, a diagram B ( ₂ ), and the entire surface around the panel for protection and strengthening It is a figure (C) which shows the protective plate put in.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 1 ': Foam material 2, 2': Honeycomb material 3: The edge part 3a by a foam material: The support material 4 of an air layer, 4 ': The protrusion part 5 of an end of a honeycomb material: Air layer 5a: A part around a panel Reinforcing seat 5b1: Panel connecting plate mounting seat 5b2: Panel connecting plate 5c: Protective plate 6 placed around the entire periphery of the panel: Foam intermediate layer 7: Adhesives 8, 8 ': Surface material

Claims (2)

The honeycomb structure to the cell spaces of the honeycomb material formed by filling a sheet form material to a core material, bonding the surface material on both sides of the core material, vertically and horizontally length and width of the sheet-like foam material before filling of the honeycomb material It is a sandwich panel in which the peripheral edge of the honeycomb material is trimmed by a sheet-like foam material after being filled with a size ,
The core material is composed of two sheet-like foam materials which are vertically spaced by a support material to form a honeycomb material.
Filled into the cell space, no foam material exists between the two sheet-like foam materials
A sandwich panel provided with an air layer . The core material is a honeycomb structure that is formed by filling the cell space of the honeycomb material with a sheet-like foam material.
The surface material is bonded to both sides of the core material, and the vertical and horizontal dimensions of the sheet-like foam material before filling are determined as the honeycomb material.
After filling, the peripheral edge of the honeycomb material is made of sheet-like foam material.
It is a sandwich panel that is rimmed,
The core material overlaps two honeycomb materials, and has a thickness exceeding the total height of the two honeycomb materials.
The two honeycomb materials are press-fitted from the upper and lower surfaces of the sheet-form foam material
An intermediate portion in the thickness direction of the foam material, features and be Rusa command switch panel that honeycomb material is provided with a layer that does not exist.

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