JP4544672B2 - Method for manufacturing sandwich panel and sandwich panel obtained thereby - Google Patents

Description

【００９９】
表 ２

【０１００】
その後、かくして得られた１種類が１０枚ずつの１２種類のサンドイッチパネル（パネルＮｏ．１〜１２）におけるそれぞれの種類のものにおいて、真空加熱炉内で、最上段（上から１段目）と最下段（上から１０段目）と中央段（上から６段目）に位置する組付け体から得られた３枚のサンドイッチパネルを、それぞれ適当な位置で二つに切断し、そして、その切断部位におけるそれぞれのもののパネル厚さを、それが最大となっている部位と最小となっている部位において測定して、各サンドイッチパネルにおけるパネル厚さのバラツキの範囲を調べる一方、各サンドイッチパネルの切断部位における波形コアと面板とのろう付け接合部分のろう付け状態を目視により調べた。その結果を下記表３〜表５に示した。
なお、それら表３〜表５におけるろう付け状態の評価において、接合不良の発生が確認されたものについては、ろう合金の溶融不足が認められ、また、コアの倒壊が確認されたものについては、著しいエロージョンの発生が認められた。
【０１０１】
表 ３

【０１０２】
表 ４

【０１０３】
表 ５

【０１０４】
上記表３〜表５の結果からも明らかなように、それぞれのサンドイッチパネルを与える組付け体の真空加熱炉内での積層位置の違いによる各組付け体の加熱温度（ろう付け温度）の差異に拘わらず、Ｓｉの含有量が６重量％若しくは９重量％で、且つＭｇを含まないＡｌ−Ｓｉ系ろう合金にて波形コアと面板とが一体的にろう付けされてなる、本発明に従うサンドイッチパネル（パネルＮｏ．４とパネルＮｏ．７）は、パネル厚さのバラツキが、０．１ｍｍまたは０．２ｍｍで、極めて小さな値となっているばかりでなく、ろう付け接合する前の組付け体に対する厚さの減少量が極めて小さくなっており、また、波形コアと面板とのろう付け状態が、良好となっている。
【０１０５】
これに対して、本発明で特定されるＡｌ−Ｓｉ系ろう合金とは異なるろう合金にて、波形コアと面板とが一体的にろう付けされてなるサンドイッチパネル、つまり、Ｓｉの含有量が６重量％若しくは９重量％ではあるものの、Ｍｇを０．６重量％若しくは１．２重量％の割合で含むろう合金にてろう付けされたサンドイッチパネル（パネルＮｏ．５，６，８，９）と、Ｍｇは含まないものの、Ｓｉの含有量が４重量％若しくは１１重量％であるろう合金にてろう付けされたサンドイッチパネル（パネルＮｏ．１，１０）と、Ｓｉの含有量が４重量％若しくは１１重量％であり、且つＭｇの含有量が０．６重量％若しくは１．２重量％であるろう合金にてろう付けされたサンドイッチパネル（パネルＮｏ．２，３，１１，１２）にあっては、極く一部のものを除き、殆どのものが、パネル厚さのバラツキと、ろう付け接合する前の組付け体に対する厚さの減少量が大きい値となっており、また、波形コアと面板との接合部において、ろう合金の溶融不足による接合不良や、エロージョンの発生による波形コアの変形若しくは倒壊が生じており、それら波形コアと面板とのろう付け状態が、不良となっている。
【０１０６】
このことから、本発明によれば、真空ろう付け法によって、厚さの薄い組付け体が健全なろう付け状態をもってろう付け接合され得、それによって、厚さの薄いサンドイッチパネルが、所望の厚さと高い面精度とをもって、容易に製造され得ることが、明確に認識され得るのである。
【０１１６】
以上、本発明の具体的な構成について詳述してきたが、これはあくまでも例示に過ぎないのであり、本発明は、上記の記載によって、何等の制約をも受けるものではなく、当業者の知識に基づいて種々なる変更、修正、改良等を加えた態様において実施され得るものである。そして、そのような実施形態が、本発明の趣旨を逸脱しない限り、何れも、本発明に範囲内に含まれるものであることは、言うまでもないところである。
【０１１７】
【発明の効果】
以上の説明からも明らかなように、本発明に従うサンドイッチパネルの製造方法によれば、コア厚さが薄くされて、パネル全体の厚さも薄くされ、それによって、軽量化が効果的に図られてなるサンドイッチパネルが、生産性及び経済性の低下を何等招くことなく、工業的に有利に製造され得るのである。そして、そのようにして得られる厚さの薄いサンドイッチパネルを構成する２枚の面板と波形コアとが、接合不良やコアの変形、倒壊乃至は潰れ等のない健全なろう付け状態とをもって、容易に且つ確実に真空ろう付けされ得るのであり、それによって、厚さの薄いサンドイッチパネルにおいて、優れた品質と高い面精度とが極めて有効に確保され得るのである。
【０１１８】
また、本発明に従うサンドイッチパネルにあっては、品質や面精度の低下を招くことなく、パネル全体の厚さが容易に薄く為され得て、更なる軽量化が効果的に達成され得るのであり、それによって、一般的な机の天板やドアの面板、棚板、或いは所定の筐体からなる梱包資材の側板や底板等、従来のハニカムパネルの如きサンドイッチパネルでは到底適用され得なかった薄くて軽い板材等に対しても、十分に適用され得て、その適用範囲が、効果的に広げられ得ることとなるのである。
【図面の簡単な説明】
【図１】本発明に従うサンドイッチパネルの一例を示す分解斜視説明図である。
【図２】図１に示されるサンドイッチパネルの縦断面説明図である。
【図３】本発明に従うサンドイッチパネルの別の例を示す図２に対応する図である。
【図４】本発明手法に従ってサンドイッチパネルを製造する工程の一例を示す説明図であって、複数の組付け体を成形装置にセットした状態を示している。
【図５】本発明に従うサンドイッチパネルの更に別の例を示す図１に対応する図である。
【図６】図５に示されるサンドイッチパネルの縦断面説明図である。
【図７】本発明に従うろう付けサンドイッチパネルの他の例を示す図１に対応する図である。
【図８】図７に示されるサンドイッチパネルの縦断面説明図である。
【図９】本発明に従うサンドイッチパネルの更に他の例を示す縦断面説明図である。
【図１０】本発明に従うサンドイッチパネルの別の例を示す一部分解斜視説明図である。
【符号の説明】
１０ サンドイッチパネル １２，１４ 面板
１６ 波形コア １８ 成形装置
２２ 上側成形治具 ２６ 下側成形治具
３４ 中間板 ３６ 枠材[0001]
【Technical field】
  The present invention relates to a method for manufacturing a sandwich panel and a sandwich panel obtained thereby, and in particular, an aluminum core is sandwiched between two face plates made of aluminum and integrated with the face plates.vacuumThe present invention relates to a novel method of manufacturing a sandwich panel formed by brazing and a characteristic sandwich panel obtained thereby.
[0002]
[Background]
In recent years, a sandwich panel has been developed in which an aluminum core is sandwiched between two aluminum face plates, and the two face plates and the core are integrally brazed, focusing on its light weight and high strength characteristics. It is used in a wide range of applications such as for structural materials, for design materials, for heat insulating materials, and for soundproofing materials. Among such sandwich panels, in particular, the so-called honeycomb panel in which the core sandwiched between two face plates is composed of a honeycomb core having a large number of honeycomb-shaped cells is a honeycomb core. In the height direction of the cell, since the two face plates are vertically supported, the compression strength and bending strength are high, and the rigidity anisotropy is small. It has been suitably used as a material, a strength member, and the like.
[0003]
However, in the honeycomb panel having such a structure, there is an inherent problem that the thickness (height) of the entire panel is inevitably increased (increased) for manufacturing reasons. there were.
[0004]
That is, in the conventional honeycomb panel, generally, a plurality of strip-shaped honeycomb forming materials obtained by corrugating, such as by continuously bending and deforming a flat plate made of aluminum material, A honeycomb core is formed between two face plates and arranged so that a large number of honeycomb-like cells are formed between the two face plates, and the honeycomb core and the two face plates are integrally brazed. It is manufactured. When such a manufacturing method is employed, if a honeycomb forming material having a narrow width is used, the core thickness can be reduced, and thus the thickness of the entire panel can be reduced. However, since the narrow-width honeycomb forming material is not stiff and not only easily bends and deforms, but also twists and warps, such a narrow-width honeycomb forming material is formed between the two face plates with a honeycomb-like shape. It is not easy to arrange cells so that a large number of cells are formed with a uniform shape, which takes a considerable amount of time and labor, resulting in a decrease in the productivity of the desired honeycomb panel, and thereby. This will cause a rise in manufacturing costs. Therefore, when manufacturing a honeycomb panel by the conventional method as described above, a narrow honeycomb forming material is not used. For this reason, the core thickness of the manufactured honeycomb panel and the entire panel The thickness was inevitably thick.
[0005]
Moreover, even if a thin honeycomb core is formed using such a narrow honeycomb forming material, the thin honeycomb core and the two face plates are integrally brazed according to a conventionally known method. Thus, when the desired honeycomb panel is manufactured, deformation, collapse, or collapse of the core may be caused when the honeycomb core and the two face plates are joined by brazing.
[0006]
Thus, in a sandwich panel such as a honeycomb panel, it has been extremely difficult to reduce the thickness of the entire panel, and therefore, it is difficult to further reduce the weight. It is rarely applied to thin and light plate materials such as general desk top plates, door face plates, shelf plates, side plates and bottom plates of packing materials consisting of a predetermined housing, and its use is thick. Is currently limited to thick and relatively heavy materials and members.
[0007]
[Solution]
Here, the problem to be solved by the present invention is that a sandwich panel in which the thickness of the entire panel is reduced and the weight is further reduced by reducing the core thickness is reduced in productivity and economy. It is possible to produce industrially advantageous without incurring any deterioration in the properties, and in the thin sandwich panel thus obtained, it will be healthy without any deformation, collapse or collapse of the core. An object of the present invention is to provide a method capable of easily securing the attached state. Further, in the present invention, it is also possible to provide a sandwich panel having a novel structure that can be easily reduced in thickness and weight, and can be advantageously applied as a thin and light plate material. It is a problem to be solved.
[0008]
[Solution]
In order to solve such a problem, the inventors of the present invention firstly, for the cause of core deformation, collapse, collapse, etc., when brazing the thin honeycomb core and the two face plates. Repeated examination. As a result, the following conclusions were obtained.
[0009]
  SnowChiIn order to obtain a target honeycomb panel according to a general brazing method, as a brazing alloy for brazing the honeycomb core and the face plate, generally, Al containing a relatively large amount of Si at a high ratio of about 10% by weight. -Si brazing alloyUsedUsed. However, according to the study by the present inventors, when the Al—Si brazing alloy containing a relatively large amount of Si is used for heat brazing of an aluminum material member, the brazing alloy is less than the melting point. However, when heated and melted at a high temperature of about 30 ° C. or higher, so-called erosion occurs in which the aluminum component in the aluminum material to be joined is excessively dissolved in the molten brazing alloy. It became clear thatThe
[0010]
From these facts, when obtaining the target honeycomb panel according to a general brazing method using a flux, when brazing the honeycomb core and the face plate, the high temperature region in the tunnel type continuous heating furnace is used. It was concluded that erosion occurred at the position where the honeycomb core and the face plate were located, and that the thin erosion core was deformed, collapsed or crushed at the portion where the erosion occurred.
[0011]
Further, for example, when a target honeycomb panel is obtained in accordance with a vacuum brazing method without using a flux, as is well known, as a brazing alloy for brazing a honeycomb core and a face plate, Mg is generally used. Al-Si brazing alloy containing 1.2 to 1.5% by weight is used, and this is done by brazing and heating the honeycomb core and the two face plates in a vacuum heating furnace. The Al-Si brazing alloy containing Mg is melted, and Mg is evaporated from the brazing alloy. At this time, the oxide film formed on the joint surface between the honeycomb core and the two face plates is destroyed. In addition, the joint surface is prevented from being reoxidized. However, according to the study by the present inventors, when a thin honeycomb core is used and disposed between two face plates, the distance between the two face plates becomes narrow, and the two face plates Since the space between the two face plates is narrow and the space between the two face plates is reduced, only a slight amount of Mg in the braze alloy is evaporated during brazing heating between the honeycomb core and the two face plates. The space is filled with Mg vapor, so that the Mg in the brazing alloy remains in the brazing alloy with little evaporation, resulting in a substantial decrease in the melting point of the brazing alloy. However, it became clear.
[0012]
Therefore, when the honeycomb core and the face plate are integrally brazed by the conventional vacuum brazing method to obtain the target honeycomb panel, the honeycomb core and the face plate are placed in a vacuum heating furnace. When heated at a temperature in the vicinity of the melting point of the brazing alloy, the brazing alloy whose melting point has been substantially lowered due to the residual Mg is excessively melted at the joint portion between the honeycomb core and the face plate, thereby causing erosion. As a result, it was concluded that deformation of the thin honeycomb core, collapse or collapse occurred at the portion where such erosion occurred.
[0013]
  Thus, the present invention has been completed as a result of further earnest research based on such conclusions.Al-Mg-Si 6000 seriesaluminumalloyAt least between two faceplates of materialAl-Mg-Si 6000 seriesaluminumalloyAn assembly formed with a material core in betweenvacuumBy brazing and joining, at least the two face plates and the core are integrated.vacuumWhen manufacturing a sandwich panel that is brazed, a corrugated core having a corrugated shape in which the corrugated shape is continuously formed in one direction is used as the core, and the corrugated core is used between the two face plates. After sandwiching the core in the height direction of the corrugated shape to form the assembly, silicon (Si)6.0-9.0It is contained in a proportion by weight and the balance is made of aluminum (Al) and inevitable impurities.The maBy using an Al—Si brazing alloy not containing gnesium (Mg), the assembly isvacuumA method for manufacturing a sandwich panel is characterized by brazing and joining.
[0014]
In such a method for manufacturing a sandwich panel according to the present invention, a corrugated core having a corrugated shape formed continuously in one direction is sandwiched between two face plates in the height direction of the corrugated shape. Therefore, simply using a corrugated core having a low corrugated shape as the corrugated core facilitates the thickness (height) of the core and thus the overall thickness (height) of the panel. It is possible to reduce the weight of the sandwich panel finally obtained, which can be effectively achieved.
[0015]
Further, in the method of the present invention, the corrugated core used as a core sandwiched between two face plates is configured with an integral structure having a corrugated plate shape. Therefore, the corrugated core is sandwiched between two face plates. The time and effort required to form the attachment is not affected by the height of the corrugated shape in the corrugated core, that is, the difference in core thickness. Compared to the case of manufacturing a panel, when a panel is manufactured using a corrugated core having a small thickness, the productivity of the target panel is not lowered, and thus such a panel is not produced. Due to the difference in productivity, there is no difference in the manufacturing cost of the panel between the case of using the thick corrugated core and the case of using the thin corrugated core.
[0016]
  Moreover, in the method of the present invention, silicon (Si), aluminum (Al), and unavoidable impurities are used as a brazing alloy for brazing and joining an assembly composed of two face plates and a corrugated core.MaSince the Al-Si brazing alloy not containing gnesium (Mg) is used, the corrugated core is thinned, and the distance between the two face plates sandwiching it is reduced.Even trueWhen brazing such two face plates and corrugated cores by the empty brazing method, the residual melting point of the brazing alloy is substantially lowered by Mg remaining in the brazing alloy without evaporating. Therefore, even if the corrugated core and the two face plates are heated at a temperature close to the melting point of the brazing alloy, the brazing alloy is excessively melted at the joint portion between the corrugated core and each face plate. No erosion occurs at all. As a result, when the corrugated core and each face plate are brazed, deformation of the thin corrugated core, collapse or collapse, and the like can be effectively avoided.
[0017]
  In the method of the present invention, the Si content of the Al—Si brazing alloy used is9.0Is it kept at a relatively low rate of less than% by weight?The wavesWhen brazing the shaped core and the two face plates, the brazing alloyExcessively in a high temperature area in a vacuum heating furnaceEven when heated, the occurrence of erosion can be advantageously prevented, and the occurrence of deformation, collapse or collapse of the corrugated core can be effectively prevented. is there. In addition to that, the Si content of the Al—Si brazing alloy is6.0Since the amount of Si is limited to more than% by weight, the amount of Si is too small, resulting in insufficient melting of the brazing alloy and insufficient fluidity when heat brazing the corrugated core and the two face plates, resulting in poor bonding. This can also be prevented reliably.
[0018]
  Therefore, according to the method for manufacturing a sandwich panel according to the present invention, a sandwich panel in which the core thickness is reduced and the thickness of the entire panel is also reduced, thereby effectively reducing the weight. It can be advantageously produced industrially without causing any reduction in productivity and economy. And the two face plates and the corrugated core constituting the thin sandwich panel thus obtained,In case of adopting vacuum brazing methodIt can be brazed easily and reliably with a healthy brazed state without joint failure, core deformation, collapse or crushing, etc., and as a result, excellent quality in such thin sandwich panels High surface accuracy can be ensured extremely effectively.
[0019]
In addition, according to the method for manufacturing a sandwich panel according to the present invention, a thin sandwich panel having excellent quality and high surface accuracy can be obtained. Sandwich that can be applied to thin plate materials that could not be applied to sandwich panels such as conventional honeycomb panels, such as door plates, door plates, shelf plates, or side plates and bottom plates of packing materials consisting of a predetermined housing Panels can be provided, so that the expanded coverage of sandwich panels can be achieved very advantageously, and by expanding the coverage in such a way, more robust desks, doors, shelves Or it becomes possible to obtain packing materials.
[0020]
Further, in the method for manufacturing a sandwich panel according to the present invention, the face plate and corrugated core used as the components of the panel, and the brazing alloy for brazing and joining them are all made of an aluminum material. It is possible to easily obtain a characteristic sandwich panel that exhibits excellent properties in terms of heat resistance, heat resistance (fire resistance), chemical resistance, and workability, and that can be easily recycled. There are advantages that can be made.
[0021]
  In addition, the manufacturing method of such a sandwich panel according to the present inventionTo the lawAccording to this, both the face plate and the corrugated core are formed of an aluminum molded body formed using an Al—Mg—Si based 6000 series aluminum alloy. In the case of adopting such a configuration, since the two face plates and the corrugated core are made of an Al—Mg—Si based 6000 series aluminum alloy having excellent strength, the corrugated core is thinned. Thus, when obtaining a sandwich panel in which the overall thickness of the panel is reduced, the strength of the obtained sandwich panel can be ensured as much as possible, and two sheets that are brazed to each other can be secured. As the face plate and the corrugated core, those having the same characteristics in thermal properties such as the coefficient of thermal expansion are used. Therefore, at the time of heating brazing between the two face plates and the corrugated core, or after that, It is possible to advantageously avoid the occurrence of deformation or the like due to the difference in physical properties.
[0022]
  According to one of the advantageous embodiments of the method for manufacturing a sandwich panel according to the present invention, the face plateAl-Mg-Si based 6000 series aluminum alloyIt is composed of an aluminum molded body formed using a brazing sheet in which the Al-Si brazing alloy is clad on one or both sides of a plate material made ofFurthermore, the corrugated core is also composed of an aluminum molded body formed using such a brazing sheet.The As a result, the brazing operation between the face plate and the corrugated core can be performed more efficiently.
[0023]
Furthermore, according to one of the desirable aspects of the manufacturing method of the sandwich panel according to the present invention, a plate material made of aluminum or an alloy thereof between at least one of the two face plates and the corrugated core. The assembly is formed by further sandwiching a brazing sheet clad with the Al—Si brazing alloy or a sheet or plate made of the Al—Si brazing alloy on one or both sides thereof. . According to such a configuration, the brazing sheet sandwiched between the face plate and the corrugated core, or the sheet or plate material made of the Al—Si brazing alloy can be used as a reinforcing member, and thereby the final Therefore, it is possible to give superior strength characteristics to the sandwich panel obtained in terms of bending strength, compressive strength, and the like.
[0024]
Furthermore, according to another preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, a plurality of the corrugated cores are used, and the plurality of corrugated cores are laminated in the height direction of the corrugated shape in each. In addition, between the adjacent ones, the corrugated shape is formed so that the forming directions thereof are orthogonal to each other, and the plurality of laminated corrugated cores are sandwiched between the two face plates in the stacking direction, An assembly is formed. This makes it possible to easily obtain a sandwich panel in which bending stiffness and bending strength anisotropy are effectively eliminated or relaxed.
[0025]
According to another advantageous aspect of the method for manufacturing a sandwich panel according to the present invention, a plurality of the corrugated cores and at least one intermediate plate made of aluminum material are used, And laminating the at least one intermediate plate between the plurality of laminated corrugated cores, and further laminating the intermediate plate. A plurality of corrugated cores are sandwiched between the two face plates in the stacking direction to form the assembly, and the assembly is then brazed to join the two face plates to the plurality of face plates. And the at least one intermediate plate are integrally brazed to each other.
[0026]
According to such a method of the present invention, the intermediate plate sandwiched between the corrugated core and the corrugated core to be laminated can be used as a reinforcing member, thereby, with respect to the sandwich panel finally obtained, It becomes possible to give more superior bending strength and compressive strength. In addition, since the intermediate plate made of aluminum is used here, the above-mentioned advantages obtained by using the aluminum-made face plate, the corrugated core, and the braze alloy are impaired by the arrangement of the intermediate plate. However, there is also a feature that it can be advantageously avoided. In particular, a plurality of corrugated cores are laminated so that the corrugated shapes are formed in the adjacent ones, and the intermediate plate is sandwiched between the laminated corrugated cores and the corrugated cores. In this case, since any of the laminated corrugated cores is brought into contact with the intermediate plate by line contact, it is possible to effectively increase the bonding strength between the laminated corrugated cores. It becomes possible.
[0027]
Furthermore, according to another desirable embodiment of the method for manufacturing a sandwich panel according to the present invention, a plurality of the corrugated cores and at least one intermediate plate made of aluminum are used, and the corrugated cores are respectively connected to the corrugated cores. A plurality of corrugated cores laminated in the height direction of the corrugated shape in the object, and arranged so that the forming directions of the corrugated shape coincide with each other in all, and the at least one intermediate plate is laminated And sandwiching the intermediate plate between the two corrugated cores in the stacking direction to form the assembly, Using a pair of molding jigs having a pressurizing surface exhibiting a predetermined curved surface shape, the formed assembly is sandwiched between the pair of molding jigs and pressurized with the pair of molding jigs Under condition By brazing and joining, the face plate, the plurality of corrugated cores and the at least one intermediate plate are integrally brazed to each other, and they are formed into a curved surface shape corresponding to the pressing surface. It will be.
[0028]
According to the method of the present invention, among the sandwich panels in which the thickness of each core can be reduced and the thickness of the whole panel is also reduced, thereby advantageously reducing the weight. The so-called curved panel having a curved surface shape can be advantageously produced industrially in a uniform brazed state with no variation in bonding strength without causing any reduction in productivity and economy. I can do it.
[0029]
In the case of using the intermediate plate as described above, advantageously, the intermediate plate is a brazing sheet in which the Al—Si brazing alloy is clad on one or both sides of a plate made of aluminum or an alloy thereof. It is composed of a molded aluminum body. As a result, the brazing operation between the corrugated core and the intermediate plate to be stacked can be performed more efficiently.
[0030]
According to still another preferred embodiment of the method for manufacturing a sandwich panel according to the present invention, an aluminum frame material is used, and the frame material is arranged around the corrugated core so as to surround it. The frame member and the corrugated core are sandwiched between the two face plates in the height direction of the corrugated shape of the corrugated core to form the assembly, and then the assembly is brazed and joined. By doing so, the face plate, the corrugated core, and the frame member are integrally brazed to each other. By adopting such a configuration, it is possible not only to easily obtain a sandwich panel in which bending rigidity and bending strength anisotropy are eliminated or relaxed, but also to use the outer surface of the frame material as a joining surface such as welding. By doing so, independent panels can be welded to each other, and a large-sized panel or the like having a large area can be easily manufactured.
In addition, if such a frame material having a hollow shape is used, in the manufactured sandwich panel, the inside of the hollow portion of the frame material can be used, for example, as a refrigerant distribution path or an electrical wiring path. It becomes.
[0031]
  By the way, in the present invention, in order to solve the problems related to the sandwich panel, it is a sandwich panel obtained by the manufacturing method as described above,Al-Mg-Si 6000 seriesaluminumalloyAt least between two faceplates of materialAl-Mg-Si 6000 seriesaluminumalloyThe material core is sandwiched and at least the two face plates and the core are integrated.vacuumIn the brazed structure, the core is composed of a corrugated core having a corrugated shape in which the corrugated shape is continuously formed in one direction, and the corrugated core has a height of the corrugated shape. In a direction, silicon (Si) is sandwiched between the two face plates.6.0-9.0It is contained in a proportion by weight and the balance is made of aluminum (Al) and inevitable impurities.The maWith an Al-Si brazing alloy that does not contain gnesium (Mg),vacuumThe gist of the present invention is also a sandwich panel characterized by being brazed.
[0032]
  In such a sandwich panel according to the present invention, two corrugated cores, which are obtained by the characteristic manufacturing method as described above, and are formed of a corrugated plate-like object in the height direction of the corrugated shape, are obtained. Because it is sandwiched between the face plates, the corrugated core, and thus the entire panel, can be easily made thin by simply constructing such a corrugated shape low and without the troublesome work, Also, such a corrugated core and two face platesBut MSince it is brazed with an Al-Si brazing alloy that does not contain g and the upper limit of the Si content is kept low, the bonding failure between the two face plates and the corrugated core, and the corrugation The occurrence of deformation, collapse or collapse of the core can be advantageously avoided.
[0033]
Therefore, in the sandwich panel according to the present invention, the thickness of the entire panel can be easily reduced without causing deterioration in quality and surface accuracy, and further weight reduction can be effectively achieved. . As a result, it cannot be applied to sandwich panels such as conventional honeycomb panels such as a general desk top plate, a door face plate, a shelf plate, or a side plate or a bottom plate of a packing material comprising a predetermined casing. The present invention can be applied sufficiently to thin and light plate materials and the like, so that the application range can be effectively expanded.
[0034]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, in order to clarify the present invention more specifically, the method for manufacturing a brazed sandwich panel according to the present invention and the structure of the sandwich panel obtained thereby will be described in detail with reference to the drawings. .
[0035]
First, FIG. 1 shows an exploded example of a brazed sandwich panel having a structure according to the present invention, and FIG. 2 shows a cross-sectional view of such a sandwich panel. As is clear from these drawings, the sandwich panel 10 has an upper surface plate 12 and a lower surface plate 14 which are arranged to face each other in the vertical direction. A corrugated core 16 having a corrugated plate shape is sandwiched between the upper surface plate 12 and the lower surface plate 14 and brazed integrally to the upper and lower surface plates 12 and 14 respectively. It is joined and configured.
[0036]
More specifically, the upper surface plate 12 and the lower surface plate 14 constituting the sandwich panel 10 are both made of an aluminum material made of an Al—Mg—Si based 6000 based aluminum alloy that exhibits excellent strength. It is configured. And they have a rectangular plate shape with a relatively thin wall thickness of about 0.8 mm and have the same size.
[0037]
On the other hand, the corrugated core 16 is made of an Al—Mg—Si based 6000 series aluminum alloy, and rectangular plate materials having a thickness of about 0.2 mm thinner than the upper and lower surface plates 12 and 14 are formed above and below them. The face plates 12 and 14 are formed into a corrugated plate having substantially the same size. That is, the corrugated core 16 has a rectangular corrugated shape in which corrugated shapes or corrugated shapes in which uneven portions (valley portions and mountain portions) are alternately arranged are continuously formed in one direction. It is composed of an integral body of an aluminum material to be exhibited. And in this corrugated core 16, each one of the convex part (mountain part) and the recessed part (valley part) which gives the corrugated shape or corrugated shape has a substantially triangular shape in which the apex portion has a curved surface shape. In addition, the distance between the respective apex portions of the uneven portions, that is, the height of the waveform shape is set to about 2.6 mm.
[0038]
Thus, the corrugated core 16 having such a low corrugated shape, that is, a thin corrugated core, is sandwiched between the upper surface plate 12 and the lower surface plate 14 in the height direction of the corrugated shape. In such an arrangement state, the upper and lower ends of the corrugated core 16 (the respective apex portions of the corrugated portions in the corrugated shape) are the opposing surfaces of the upper and lower plates 12 and 14. Are integrally brazed to each. As a result, the sandwich panel 10 is composed of the upper and lower face plates 12 and 14 and the corrugated core 16 and is made of an Al—Mg—Si 6000 series aluminum alloy having a hollow sandwich structure with a thin thickness as a whole. It is configured as an integrated product.
[0039]
  It should be noted that the thicknesses of the upper and lower plates 12 and 14 constituting the sandwich panel 10, the thickness of the plate material that gives the corrugated core 16, and the height of the corrugated shape are not limited to the above-described dimensions. Absent. The shape of the concavo-convex portion of the corrugated core 16 is not particularly limited, and may be, for example, a triangular shape, a rectangular shape, a polygonal shape such as a trapezoidal shape, or a U-shaped shape. Further, the materials constituting the corrugated core 16 and the upper and lower plates 12 and 14 can be appropriately selected from aluminum alloys and pure aluminum, but can be used at a high temperature during brazing heating. Prevent deformationIn doingThese materials include Al-Mg-Si-based 6000-based aluminum alloys.Money isAre preferably used.
[0040]
  Here, in particular, the brazing alloy that brazes the upper and lower plates 12 and 14 and the corrugated core 16 integrally is different from the commonly used Al—Si brazing alloy.6.0-9.0It is contained in a relatively low proportion such as% by weight and the balance is made of Al and inevitable impurities.The maIt is made of a special Al—Si brazing alloy containing no magnesium Mg.
[0041]
By the way, the sandwich panel 10 having such a structure is manufactured, for example, according to the following method.
[0042]
That is, first, the upper and lower two face plates 12 and 14 and the corrugated core 16 are prepared. Here, the upper and lower face plates 12 and 14 are made of Al-Mg-Si 6000 having excellent strength. Those formed of a rectangular flat plate having a thickness of about 0.8 mm made of an aluminum alloy are used.
[0043]
In addition, as the corrugated core 16, an aluminum molded body obtained by molding a plate material having the same material as the upper and lower surface plates 12 and 14 and having a thickness of about 0.2 mm into a corrugated plate shape is used. That is, the corrugated core 16 is formed of a thin plate material made of an Al—Mg—Si based 6000 series aluminum alloy, for example, by a predetermined forming operation such as press molding, and has a substantially triangular shape with the apex portion being curved. The waveform shape to be obtained is obtained by forming a corrugated plate having a height of about 2.6 mm and continuously formed in one direction. Of course, each shape of the convex portion (mountain portion) that gives the waveform shape is a polygonal shape such as a triangular shape, a rectangular shape, a trapezoidal shape, or a U-shaped shape, as illustrated above. In such a case, the plate material is formed into a corrugated plate shape so that a corrugated shape exhibiting a desired shape is obtained by the predetermined forming processing operation described above.
[0044]
It is to be noted that at least one of the aluminum alloy flat plate providing the upper and lower plates 12 and 14 and the aluminum alloy thin plate material providing the corrugated core 16 is advantageously clad with a brazing material on one side or both sides. It is composed of a brazing sheet made of an Al—Mg—Si based 6000 series aluminum alloy. As a result, brazing and joining of the assembly in which the upper and lower plates 12 and 14 and the corrugated core 16 described later are assembled to each other can be performed efficiently.
[0045]
Next, the corrugated core 16 is sandwiched from above and below in the height direction of the corrugated shape on the upper side and the lower side of the corrugated core 16, and the upper surface plate 12 is in contact with the upper and lower ends of the corrugated core 16. The bottom plate 14 is arranged and assembled. As a result, an assembly 17 composed of the corrugated core 16 and the upper and lower plates 12, 14 is formed (see FIG. 4).
[0046]
  At this time, when the assembly 17 is formed by using the upper and lower surface plates 12 and 14 and the corrugated core 16 which are not a brazing sheet but are simply formed of an aluminum alloy, as shown in FIG. Between the core 16 and the upper surface plate 12 and between the corrugated core 16 and the lower surface plate 14, an aluminum alloy brazing sheet 19 or a brazing alloy thin plate 21 clad with brazing alloy on both sides is interposed. , Place it. In this way, the brazing sheet 19 and the brazing alloy thin plate 21 sandwiched between the upper and lower surface plates 12 and 14 and the corrugated core 16 function as a reinforcing member, and finally the sandwich panel 10 obtained. The advantage that the bending strength and the compressive strength are advantageously increased is obtained. In addition, as the brazing alloy of the brazing sheet 19 or the brazing alloy thin plate 21 used for forming the assembly 17 or the brazing sheet brazing alloy that gives the upper and lower plates 12 and 14 and the corrugated core 16 described above, Si6.0-9.0Containing a low percentage by weight and the balance being made of Al and inevitable impuritiesMA special Al-Si brazing alloy containing no g is used.
[0047]
Thereafter, as shown in FIG. 4, the assembly 17 formed as described above is set in a molding apparatus 18 having a known structure. That is, in this step, generally, the upper molding jig 22 having the upper pressing surface 20 corresponding to the upper surface of the target sandwich panel 10 having the planar shape, and the lower surface of the sandwich panel 10 having the same planar shape are generally supported. The molding apparatus 18 including the lower molding jig 26 having the lower pressure surface 24 is used. Then, by placing the assembly 17 between the lower pressure surface 24 of the lower molding jig 26 and the upper pressure surface 20 of the upper molding jig 22, the assembly is assembled in the molding apparatus 18. The attachment body 17 is set.
[0048]
FIG. 4 shows an example of a technique for discontinuously brazing and joining the assembly 17 by a vacuum brazing method using a vacuum heating furnace (not shown). Therefore, here, for the purpose of improving productivity or the like, the upper and lower molding jigs 22 of the molding apparatus 18 in a state where a plurality of assembly bodies 17 are stacked so as to overlap in the vertical direction. 26. Then, when a plurality of assembly bodies 17 are stacked and set in the molding apparatus 18 as described above, the assembly located at the uppermost part of the assembly bodies 17 to be stacked is advantageously provided. Between the body 17 and the upper molding jig 22, between the assembly body 17 and the lower molding jig 26 located at the lowermost part, and between all the assembly bodies 17 to be stacked. The release material 28 made of carbon sheet or the like is sandwiched and positioned. Thereby, in the brazing process to be described later, the plurality of assembly bodies 17 can be brazed and joined together, and the assembly bodies 17 or the assembly bodies 17 and the upper and lower molding jigs 22, 26 can be advantageously prevented from being joined to each other by hot press welding or brazing of the brazing material.
[0049]
  Further, in this process, instead of using the release material 28 made of carbon sheet or the like, fine solid lubrication such as graphite powder or boron nitride powder is applied to the surfaces of the upper surface plate 12 and the lower surface plate 14 of each assembly 17. Even if the agent is applied, the same effect as that obtained by using the release material 28 can be obtained.The
[0050]
Next, in a state where the pressurizing mass 30 having a predetermined weight is placed on the upper molding jig 22 of the molding apparatus 18 and the lower molding jig 26 is placed on the support tray 32, these moldings are performed. The apparatus 18 and the plurality of assemblies 17 set therein are accommodated in a vacuum heating furnace (not shown). At that time, a pressing force corresponding to the total weight of the upper forming jig 22 and the pressure mass 30 placed on the upper forming jig 22 is applied to the assembly 17 so that the plurality of assemblies 17 have a certain amount of pressure. Each pressure is increased by pressure.
[0051]
  Thereafter, the inside of the vacuum heating furnace in which the plurality of assemblies 17 are set as described above is evacuated, and then the inside of the vacuum heating furnace is heated to a temperature approximately equal to the melting point of the brazing alloy. The brazing alloy present in the assembly 17 is heated and melted under a certain pressure based on the total weight of the upper forming jig 22 and the pressurizing mass 30, and the upper surface plate 12, the corrugated core 16, and The corrugated core 16 and the upper and lower surface plates 12 and 14 are brazed integrally with each other by flowing between the contact portions of the lower surface plate 14 and the corrugated core 16.The
[0052]
  Here, as described above, in the present embodiment, Si is used as a brazing alloy for brazing the corrugated core 16 and the upper and lower plates 12 and 14 integrally.6.0-9.0Containing a low percentage by weight and the balance being made of Al and inevitable impuritiesMA special Al—Si brazing alloy containing no g is used. Therefore, in such a brazing process, Mg does not evaporate from the heat-melted brazing alloy. Therefore, the assembly 17 has a thin corrugated core 16 having a corrugated height of about 2.6 mm. The space between the upper and lower surface plates 12 and 14 sandwiched between them is narrow, and the space between the upper and lower surface plates 12 and 14 is a narrow, substantially closed space, but remains in the brazing alloy without evaporating. It is avoided that the melting point of the brazing alloy is substantially lowered by Mg. As a result, when the corrugated core 16 and the upper and lower plates 12 and 14 are heated at a temperature near the melting point of the brazing alloy, the brazing alloy is bonded to the corrugated core 16 and each of the face plates 12 and 14. It is avoided that erosion occurs due to excessive melting, so that the corrugated core 16 is not deformed or collapsed or crushed.
[0053]
Here, as described above, since the space between the upper and lower plates 12 and 14 is a narrow and substantially closed space, the joint surfaces of the upper and lower plates 12 and 14 and the corrugated core 16 are oxidized. Therefore, it is not necessary to include Mg in the brazing alloy in order to destroy the oxide films formed on the joint surfaces or prevent re-oxidation of the joint surfaces. That is, in other words, in this embodiment, when the assembly 17 is brazed and joined according to the vacuum brazing method without using a flux, brazing failure is caused by the absence of Mg in the brazing alloy. There is nothing to be done. It should be noted that, in the portion where the space between the upper and lower surface plates 12, 14 is an open space, such as the outer peripheral portion of the assembly 17, the solder will be oxidized by the respective joint surfaces of the upper and lower surface plates 12, 14 and the corrugated core 16. If there is a concern about the deterioration of the applicability, the concern can be easily eliminated by arranging Mg ingots, Mg powder, or alloy ingots containing a large amount of Mg in the heating furnace. Become.
[0054]
Furthermore, since the content of Si in the brazing alloy used here is 6% by weight or more, the Si amount is too small, resulting in insufficient melting of the brazing alloy. There is no occurrence of poor bonding between the face plates 12 and 14, and the upper limit of the Si content of the brazing alloy is 9% by weight, which is kept relatively low. In an excessively heated part of the assembly 17 located in a high temperature region or the like in the heating furnace, it is avoided that the amount of Si in the brazing alloy heated and melted becomes too large and erosion occurs. It is also advantageously prevented that the corrugated core 16 is deformed or collapsed or crushed.
[0055]
Incidentally, for example, the clad rate of the brazing alloy of the brazing sheet that gives the corrugated core 16 and the upper and lower plates 12, 14 may be reduced or disposed between the corrugated core 16 and the upper and lower plates 12, 14. If the thickness of the alloy thin plate is further reduced to reduce the amount of brazing alloy existing between the joint surfaces of the corrugated core 16 and the upper and lower plates 12, 14, it has been generally used. Even when an Al-Si brazing alloy, that is, a brazing alloy containing a larger amount of Si than that used in the present embodiment, is used, the amount of Si in the heat-melted state of the brazing alloy can be kept low. . However, as is well known, it is difficult to make the brazing alloy brazing ratio of the brazing sheet 5% or less, and the brazing alloy having a high Si content is easily cracked. It is more difficult to reduce the thickness of the brazing sheet than to reduce the cladding ratio of the brazing alloy of the brazing sheet. Therefore, in practice, a general Al-Si based brazing alloy as described above is used. Thus, it is almost impossible to braze the thin corrugated core 16 and the upper and lower plates 12, 14 soundly.
[0056]
Conversely, the brazing ratio of the brazing alloy of the brazing sheet that gives the corrugated core 16 and the upper and lower plates 12, 14 is increased, or is disposed between the corrugated core 16 and the upper and lower plates 12, 14. If the thickness of the brazing alloy thin plate is increased to increase the amount of brazing alloy existing between the joint surfaces of the corrugated core 16 and the upper and lower plates 12, 14, it is used in this embodiment. Even if a brazing alloy having a lower Si content than that obtained is used, it is considered that the lack of melting of the brazing alloy is resolved. However, the Al—Si brazing alloy having a low Si content has poor fluidity in a heated and melted state, and does not sufficiently flow between the contact portions of the corrugated core 16 and the upper and lower plates 12 and 14. Even if the clad rate of the brazing sheet clad with such an Al—Si brazing alloy having a low Si content is increased or the thickness of the thin plate made of such a brazing alloy is increased, the corrugated core 16 and It is difficult to eliminate the bonding failure between the upper and lower plates 12 and 14, and rather, when the thickness of the brazing alloy is increased, the reduction in the thickness of the brazing alloy accompanying heating and melting increases, thereby As a result, new problems such as hindering the bondability and dimensional accuracy between the corrugated core 16 and the upper and lower plates 12, 14 are brought about.
[0057]
Thereafter, the brazed assembly 17 is taken out from the vacuum heating furnace in the vacuum heating furnace while being sandwiched between the upper and lower molding jigs 22 and 26 under pressure, and is naturally Or by using a special cooling device to complete the brazing process. The brazed assembly 17 is taken out of the heating furnace after nitrogen gas or the like is introduced into the vacuum heating furnace and the pressure is restored. In addition, the cooling operation of the assembly 17 is preferably performed by a rapid cooling operation in order to improve the strength by quenching and shorten the manufacturing cycle.
[0058]
Then, after such cooling, the upper molding jig 22 and the lower molding jig 26 are opened, and the panel to which the assembly 17 is brazed is taken out, so that the corrugated core 16 and the upper and lower plate 12 are removed. , 14 having a thin thickness formed by brazing integrally, as shown in FIGS. 2, 6, and 8, to obtain the intended sandwich panel 10. In addition, since the some assembly | attachment body 17 is brazed jointly simultaneously here, the some sandwich panel 10 will be obtained at once.
[0059]
Thus, in the present embodiment, the corrugated core 16 sandwiched between the upper and lower surface plates 12 and 14 is thinned, so that the distance between the upper and lower surface plates 12 and 14 is advantageous. It can be made narrower and the overall thickness of the panel can be very thin.
[0060]
Moreover, in this embodiment, since the corrugated core 16 is comprised with the integral structure which consists of the molded object of the corrugated aluminum, the corrugated core 16 is assembled | attached by sandwiching between the upper and lower surface plates 12 and 14. At the same time, the labor, time, cost, and the like required for brazing and joining the assembly 17 obtained thereby can be advantageously made less dependent on the thickness of the corrugated core 16.
[0061]
Therefore, according to the present embodiment as described above, the sandwich panel 10 having a very thin thickness as compared with a relatively thick one generally used in the related art can be obtained without causing a decrease in productivity and economy. It can be easily manufactured, so that further weight reduction of the sandwich panel 10 can be achieved very effectively. The sandwich panel 10 thus obtained is a member or material conventionally made of cardboard from the viewpoint of lightness, for example, a side plate or a bottom plate of a packaging material made of a casing, or a light thin plate material. It can be applied as a general desk top plate, a door face plate, a shelf board, and the like, thereby not only widening the application range of the sandwich panel 10 but also such a sandwich panel 10. It is also possible to effectively improve the robustness of the members, materials, products, etc. to which the is applied.
[0062]
  Moreover, in the present embodiment, the corrugated core 16 and the upper and lower plates 12, 14 are integrally formed.vacuumAs a brazing alloy for brazing, Si is used.6.0-9.0Containing a low percentage by weight and the balance being made of Al and inevitable impuritiesMBy using a special Al—Si brazing alloy not containing g, the corrugated core 16 having a small thickness and the upper and lower surface plates 12 and 14 may be bonded poorly, deformed, collapsed, or crushed. The thin and lightweight sandwich panel 10 is extremely effective in ensuring excellent quality and high surface accuracy because it can be brazed easily and reliably with a sound brazing state without any problems. It can be done.
[0063]
In the present embodiment, since the corrugated core 16, the upper and lower plates 12, 14 and the brazing alloy for brazing them all are made of an aluminum material, strength, durability, heat resistance (fire resistance) ), Exhibiting excellent properties in both chemical resistance and processability, and having an advantage that a sandwich panel having the characteristics of being easily recyclable can be easily obtained.
[0064]
Furthermore, in this embodiment, the corrugated core 16 and the upper and lower plates 12, 14 are both made of an Al—Mg—Si based 6000 series aluminum alloy that exhibits excellent strength. Even though the corrugated cores 16 are thinned and the overall thickness of the sandwich panel 10 is thinned, high strength can be advantageously ensured, and the corrugated cores 16 and the upper and lower surface plates 12 can be secured. , 14 exhibit the same thermal properties such as the coefficient of thermal expansion, and the deformation due to the difference in the thermal physical properties of the corrugated core 16 and the upper and lower plates 12, 14 during heat brazing or the like. Such an occurrence can be advantageously avoided, whereby the superior quality and surface accuracy of the thin sandwich panel 10 can be more effectively ensured.
[0065]
By the way, the sandwich panel according to the present invention is not construed as being limited to the above-described exemplary structure, and various modifications can be made without departing from the gist of the present invention. Some examples are shown in FIGS. 5 to 10. 5 to 10, members and parts having the same structure as in the previous embodiment are denoted by the same reference numerals in the drawings, and detailed description thereof is omitted.
[0066]
That is, in FIG. 5 and FIG. 6, two corrugated cores 16 a and 16 b are stacked between the upper and lower plates 12 and 14 so as to be stacked in the opposing direction of the upper and lower plates 12 and 14, that is, in the vertical direction. An example of the resulting structure is shown. There, the upper corrugated core 16a positioned on the upper side of the two corrugated cores 16a and 16b and the lower corrugated core 16b positioned on the lower side have their respective waveform shape forming directions, in other words, waveforms. In a state in which the concave and convex portions (valley and peak) of the shape are overlapped with each other so as to be orthogonal to each other, they are sandwiched between the upper and lower surface plates 12 and 14 in the height direction of each corrugated shape. It is positioned.
[0067]
  In such an arrangement state, the laminated upper and lower corrugated cores 16a and 16b are integrally brazed and joined together, and the upper corrugated core 16a has its upper end (in the corrugated shape). At the apex portion of the convex portion), the lower corrugated core 16b is brazed integrally with the lower surface of the upper surface plate 12, and the lower corrugated core 16b is formed at the lower end portion (bottom portion of the concave portion in the corrugated shape). The upper surface of 14 is integrally brazed. Also in this case, the brazing alloy that brazes the upper and lower corrugated cores 16a and 16b to each other, and the brazing alloy that brazes the upper and lower corrugated cores 16a and 16b to the upper and lower plate 12,14. But all Si6.0-9.0It is contained in a relatively low proportion such as% by weight and the balance is made of Al and inevitable impurities.MIt is comprised by the special Al-Si type brazing alloy which does not contain g.
[0068]
In the sandwich panel 10 having such a structure, when the assembly 17 is formed, the upper corrugated core 16a and the lower corrugated core 16b are stacked in the vertical direction as described above, and the upper and lower plates 12, 14 are separated. The sandwich panel 10 is manufactured by the same method as the sandwich panel 10 shown in the first embodiment except that the sandwich panel 10 is disposed between the two.
[0069]
Thus, also in this embodiment, the corrugated core 16 made of aluminum alloy having a corrugated shape is sandwiched between the upper and lower surface plates 12 and 14 made of the same kind of aluminum alloy, and they are made of Si. Since the sandwich panel 10 is formed by brazing integrally with a special Al—Si brazing alloy having a low content and not containing Mg, the same effect as in the first embodiment can be obtained. Can be enjoyed effectively.
[0070]
In the present embodiment, the upper and lower corrugated cores 16a and 16b are stacked between the upper and lower face plates 12 and 14 so that the corrugated shape forming directions are orthogonal to each other. Since the upper and lower face plates 12 and 14 are integrally brazed to each other, the sandwich panel 10 has bending rigidity and bending strength anisotropy. Features that can be effectively eliminated can also be advantageously exhibited.
[0071]
Next, in FIGS. 7 and 8, the intermediate plate 34 is further sandwiched between the upper and lower corrugated cores 16 a and 16 b stacked between the upper and lower plates 12 and 14. An example of the structure is shown. In this case, the upper and lower corrugated cores 16a and 16b are laminated so that the corrugated shapes are orthogonal to each other as in the above-described embodiment. Further, the intermediate plate 34 sandwiched between the upper and lower corrugated cores 16a and 16b has a thin rectangular shape having the same size as the upper and lower face plates 12 and 14, and is based on Al-Mg-Si. 6000 series aluminum alloy. In addition, as this intermediate plate 34, what consists of a brazing sheet | seat by which the brazing | wax material was clad on one side or both surfaces is used as needed.
[0072]
In such an arrangement state, the upper corrugated core 16a and the lower corrugated core 16b are integrally brazed to each other via the intermediate plate 34, and the upper corrugated core 16a has an upper end portion thereof. The lower corrugated core 16b is integrally brazed to the upper surface of the lower surface plate 14 at the lower end thereof.
[0073]
  In this case as well, the brazing alloy for brazing the upper and lower corrugated cores 16a and 16b to each other via the intermediate plate 34, and the upper and lower corrugated cores 16a and 16b to the upper and lower corrugated plates 12 and 14 are used. All brazing alloys for brazing are made of Si.6.0-9.0It is contained in a relatively low proportion such as% by weight and the balance is made of Al and inevitable impurities.MIt is comprised by the special Al-Si type brazing alloy which does not contain g.
[0074]
Thus, the sandwich panel 10 having such a structure has the upper and lower corrugated cores 16a and 16b and the intermediate plate 34 between the upper surface plate 12 and the lower surface plate 14 when the assembly 17 is formed. From the bottom, except that the lower corrugated core 16b, the intermediate plate 34, and the upper corrugated core 16a are stacked in this order, and the upper and lower corrugated cores 16a and 16b are arranged so that the waveform forming directions are orthogonal to each other. It will be manufactured by the same method as the sandwich panel 10 shown in the first embodiment.
[0075]
Even in such an embodiment, the corrugated aluminum alloy upper and lower corrugated cores 16a, 16b are sandwiched between upper and lower plates 12, 14 made of the same kind of aluminum alloy, In addition, they are integrally brazed with a special Al—Si brazing alloy having a low Si content and not containing Mg to form the sandwich panel 10. Such excellent characteristics can be effectively exhibited.
[0076]
In the present embodiment, since the upper and lower corrugated cores 16a and 16b are laminated between the upper and lower plates 12 and 14 so that the corrugated shapes are formed in a direction perpendicular to each other, the sandwich panel 10 The anisotropy of the bending rigidity and bending strength of the intermediate plate 34 can be effectively eliminated, and the intermediate plate 34 sandwiched between the upper and lower corrugated cores 16a and 16b functions as a reinforcing member, thereby In the sandwich panel 10, better bending strength and compressive strength can be advantageously exhibited.
[0077]
Furthermore, in the present embodiment, the upper and lower corrugated cores 16a and 16b that are laminated so that the waveform forming directions are orthogonal to each other are integrally brazed via the intermediate plate 34. Therefore, both the upper corrugated core 16a and the lower corrugated core 16b to be laminated are brought into contact with the intermediate plate 34 by line contact, and thereby the corrugated shape forming directions are orthogonal to each other. As compared with the case where the upper and lower corrugated cores 16a and 16b are laminated directly, the bonding strength of the upper and lower corrugated cores 16a and 16b can be effectively increased. It becomes.
[0078]
Furthermore, in the present embodiment, the intermediate plate 34 that exhibits the above-described excellent characteristics is similar to the upper and lower surface plates 12 and 14 and the upper and lower corrugated cores 16a and 16b. The above-mentioned obtained by using the upper and lower plate 12, 14 and the upper and lower corrugated cores 16a, 16b made of such an aluminum alloy from the Mg-Si based 6000 series aluminum alloy. It can be advantageously avoided that such advantages are impaired by the arrangement of the intermediate plate 34.
[0079]
Further, in FIG. 9, a so-called curved panel having a predetermined curved surface shape protruding upward is formed as a whole, and the upper and lower plates 12 and 14 stacked between the upper and lower plates 12 and 14 are formed. An example of a structure in which an intermediate plate 34 is disposed between two corrugated cores 16a and 16b is shown. There, the upper and lower corrugated cores 16a, 16b are overlapped with each other via the intermediate plate 34 so that the corrugated shapes are formed in the same direction. It is sandwiched and positioned between an upper surface plate 12 having a convex curved surface shape and a lower surface plate 14 having a concave curved surface shape.
[0080]
In such an arrangement state, the upper corrugated core 16a and the lower corrugated core 16b are integrally brazed to each other via the intermediate plate 34, and the upper corrugated core 16a has an upper end portion thereof. The lower corrugated core 16b is integrally brazed to the upper surface of the lower surface plate 14 at the lower end thereof.
[0081]
  In this case as well, the brazing alloy for brazing the upper and lower corrugated cores 16a and 16b to each other via the intermediate plate 34, and the upper and lower corrugated cores 16a and 16b to the upper and lower corrugated plates 12 and 14 are used. All brazing alloys for brazing are made of Si.6.0-9.0It is contained in a relatively low proportion such as% by weight and the balance is made of Al and inevitable impurities.MIt is comprised by the special Al-Si type brazing alloy which does not contain g.
[0082]
Thus, in the sandwich panel 10 having such a structure, for example, first, the upper and lower corrugated cores 16a and 16b and the intermediate plate 34 are disposed between the upper surface plate 12 and the lower surface plate 14 from the lower side. The assembly 16 is formed by stacking the core 16b, the intermediate plate 34, and the upper corrugated core 16a in this order, and arranging the upper and lower corrugated cores 16a and 16b so that the forming directions of the corrugated shapes coincide with each other. . The upper and lower plates 12 and 14 and the intermediate plate 34 for providing the assembly 17 are flat plates, and the upper and lower corrugated cores 16a and 16b are curved as a whole. What is not used is used. That is, here, the assembly 17 is formed to have a flat plate shape as a whole.
[0083]
Next, the flat plate-like assembly 17 thus obtained is brazed and joined, for example, in accordance with the method of manufacturing a curved panel described in Japanese Patent Application Laid-Open No. 8-174111. The objective sandwich panel 10 having a convex curved surface shape is obtained. In adopting such a brazing method, the curved surface shapes of the convex pressing surface of the upper molding jig (upper pressing jig) and the concave pressing surface of the lower molding jig (lower pressing jig) are If a molding apparatus having a composite curved surface shape with a gradually changing curvature radius is used, the target sandwich panel 10 can be easily obtained as a composite curved panel having a composite curved surface shape.
[0084]
According to such an embodiment, corrugated aluminum alloy upper and lower corrugated cores 16a, 16b are sandwiched between upper and lower plates 12, 14 of the same type of aluminum alloy, and These are integrally brazed with a special Al—Si brazing alloy having a low Si content and no Mg, thereby forming a sandwich panel 10 having a curved surface as a whole. Therefore, the same effect as that of the first embodiment relating to the sandwich panel formed as a flat panel is effective in the sandwich panel 10 formed as a so-called curved panel having a curved surface shape as a whole. It can be enjoyed.
[0085]
Moreover, in this embodiment, since the upper corrugated core 16a and the lower corrugated core 16b are laminated | stacked so that the formation direction of a corrugated shape may correspond, the process of curving the assembly | attachment body 17 which exhibits a flat plate shape is smooth. There is an advantage that it can be implemented.
[0086]
Furthermore, in the present embodiment, when the assembly 17 is formed from where the intermediate plate 34 is disposed between the upper corrugated core 16a and the lower corrugated core 16b, Unlike the case in which the upper and lower corrugated cores 16a and 16b are directly laminated, the troublesome work to make the apex portion of the concave portion of the upper corrugated core 16a and the apex portion of the convex portion of the lower corrugated core 16b contact each other. Thus, there is no need to perform proper positioning, and the operation of forming the assembly 17 can be performed more easily and quickly.
[0087]
In FIG. 10, the corrugated core 16 and a plurality of (here, seven) frame members 36 positioned so as to surround the corrugated core 16 are disposed between the upper surface plate 12 and the lower surface plate 14. An example structure is shown.
[0088]
In this case, the plurality of frame members 36 are made of an Al-Mg-Si-based 6000-series aluminum alloy having excellent strength, and are each formed of an extruded profile having a square-shaped hollow cross section. Then, the frame members 36 as a whole have a substantially “day” shape and are assembled so as to have substantially the same size as the upper and lower surface plates 12 and 14, thereby providing two rectangular window portions. A frame 40 having 38 and 38 is formed. Further, the corrugated cores 16 and 16 having the same thickness as that of the frame body 36 are accommodated and positioned in the two rectangular windows 38 and 38 of the frame body 40, respectively. ing. Accordingly, a plurality of frame members 36 are arranged around the two corrugated cores 16 and 16 so as to surround the corrugated cores 16 and 16. The plurality of frame members 36 and the two corrugated cores 16 and 16 are disposed between the upper surface plate 12 and the lower surface plate 14 in the height direction of the corrugated shape of the corrugated cores 16 and 16. Also, under such an arrangement, the two corrugated cores 16 and 16 and the plurality of frame members 36 are integrally brazed to the upper and lower surface plates 12 and 14.
[0089]
  Also here, the brazing alloy for brazing the two corrugated cores 16 and 16 and the plurality of frame members 36 to the upper and lower plates 12 and 14 is Si.6.0-9.0It is contained in a relatively low proportion such as% by weight and the balance is made of Al and inevitable impurities.MIt is made of a special Al—Si brazing alloy not containing g. In the present embodiment, the frame member 36 surrounding the corrugated core 16 is made of an aluminum alloy extruded shape having a hollow hollow cross section. However, the frame member 36 has an appropriate thickness, for example. There is no problem even if it is constituted by a flat plate.
[0090]
Thus, in the sandwich panel 10 having such a structure, the corrugated cores 16 and 16 are accommodated one by one in the two rectangular window portions 38 and 38 of the frame body 40 composed of a plurality of frame members 36. In the first embodiment, the plurality of frame members 36 and the two corrugated cores 16 are sandwiched between the upper surface plate 12 and the lower surface plate 14 to form the assembly 17. It is manufactured by the same method as the sandwich panel 10 to be manufactured. When forming the assembly 17, a plurality of frame members 36 are welded in advance to form the frame body 40 in a shape-fixed state, and in this state, the plurality of frame members 36 are attached to the upper and lower surface plates. The frame body 40 may be formed by simply assembling the plurality of frame members 36 without being joined to each other, and in this state, the plurality of frame members 36 may be arranged between the frame members 36. May be arranged between the upper and lower plates 12, 14.
[0091]
Also in such an embodiment, the corrugated core 16 is sandwiched between upper and lower plates 12, 14 made of the same type of aluminum alloy, and they have a special low Si content and no Mg. Since the sandwich panel 10 is constituted by brazing integrally with an Al—Si brazing alloy, the same effects as those of the first embodiment can be enjoyed effectively.
[0092]
Further, in the present embodiment, a plurality of frame members 36 made of extruded aluminum alloy are disposed between the upper and lower plates 12 and 14 so as to surround the corrugated cores 16 and 16. Therefore, the anisotropy of the bending rigidity and bending strength in the sandwich panel 10 can be advantageously eliminated or alleviated, and further, the outer surface of the frame member 36 exposed to the outside at the outer peripheral portion of the sandwich panel 10 is removed. It can be used as a joining surface for welding or the like, whereby independent sandwich panels 10 can be welded together. As a result, a large-sized panel or the like having a large area can be easily manufactured.
[0093]
Furthermore, in the present embodiment, since each of the frame members 36 has a hollow shape having a square hollow cross section, the inside of the hollow portions of the frame members 36 is, for example, a refrigerant flow path or There is also an advantage that it can be used as a wiring route for electrical wiring.
[0094]
Incidentally, the sandwich panel 10 having the structure as shown in FIG. 10 or FIG. 1 is actually manufactured by the following specific steps according to the method of the present invention, and the obtained sandwich panel is evaluated with respect to the above-described excellent features. Went.
[0095]
That is, first, a large number of 6951 alloy plates having a thickness of 0.2 mm were used, and they were press-molded so that the uneven portions having a height of 2.6 mm were continuously formed in one direction at a pitch of 3.0 mm. A large number of rectangular corrugated sheets having a length and a width of 500 mm were formed. A large number of corrugated plates thus obtained were used as corrugated cores. Separately, a large number of rectangular 6951 alloy plates having a length of 500 mm, a width of 500 mm, and a thickness of 0.8 mm were used, and for each side of each of these many alloy plates, the following Table 1 and As shown in Table 2, Si is contained in any proportion of 4% by weight, 6% by weight, 9% by weight, and 11% by weight, and Mg is not contained or 0.6% by weight, . Any one of 12 types of Al-Si brazing alloys comprising any proportion of 2% by weight is clad at a cladding rate of 5%, and the brazing alloys are different from each other. A plurality of 12 types of brazing sheets were obtained. These brazing sheets were used as upper and lower plates, respectively. Further, a number of elongated rectangular 6063 alloy plates having a length of 500 mm, a width of 2.6 mm, and a thickness of 7 mm were prepared and used as frame members.
[0096]
Next, the corrugated core and the frame member are sandwiched between the upper surface plate and the lower surface plate made of any one of the 12 types of brazing sheets obtained as described above in the state shown in FIG. To obtain an assembly. Similarly, the corrugated core and the frame material are disposed between the upper surface plate and the lower surface plate made of each of the other 11 types of brazing sheets to form the assembly, thereby forming the corrugated core. Twelve types of assemblies with different brazing alloys for brazing the frame and the frame material to the upper and lower plates were obtained. And here, ten of each of these 12 types of assemblies were formed. In addition, the thickness of those assembly bodies is all 4.2mmMet.
[0097]
After that, among the 12 types of assembled bodies thus formed, 10 of any one type of assembled bodies are stacked in a vertical direction and set in a predetermined molding apparatus, and then vacuumed. After being housed in the heating furnace, the inside of the vacuum heating furnace was heated while pressurizing 10 assembled bodies at a pressure of 1 kPa under a vacuum state. Of the 10 assembled assemblies, the assembly is located at the top (first from the top), the bottom (from the top 10) and the center (from the top 6). When the temperature measured by the thermocouples attached to the center and corners of each of the above materials exceeds 580 ° C., which is substantially the same as the melting point of the brazing alloy, the heating is terminated, and then immediately in the vacuum heating furnace. After introducing nitrogen gas into the furnace and returning the pressure inside the heating furnace, 10 assembled bodies were taken out of the heating furnace and cooled. As a result, the brazed joint of each assembly is completed, and the corrugated core and the frame material are integrally brazed to the upper and lower plates with the same type of brazing alloy. Ten sandwich panels were obtained. Apart from that, the same operations were performed on the remaining 11 types of assemblies, so that the corrugated core and the frame material were attached to the upper and lower plates as shown in Tables 1 and 2 below. Thus, 10 types of 12 types of sandwich panels (panel Nos. 1 to 12) each obtained by brazing with different types of brazing alloys (brazing alloys having different contents of Si and Mg) were obtained.
[0098]
Table 1

[0099]
Table 2

[0100]
After that, in each type of 12 types of sandwich panels (panel Nos. 1 to 12), each of which is 10 types, in the vacuum heating furnace, the top level (first level from the top) and Three sandwich panels obtained from the assembly located at the bottom (10th from the top) and the middle (6th from the top) are cut in two at appropriate positions, and The panel thickness of each one at the cutting site is measured at the site where it is maximized and the region where it is minimized to determine the range of panel thickness variation in each sandwich panel, The brazing state of the brazed joint portion between the corrugated core and the face plate at the cutting site was examined visually. The results are shown in Tables 3 to 5 below.
In addition, in the evaluation of the brazing state in Table 3 to Table 5, for those in which the occurrence of bonding failure was confirmed, insufficient melting of the brazing alloy was recognized, and for those in which the core collapse was confirmed, Significant erosion was observed.
[0101]
Table 3

[0102]
Table 4

[0103]
Table 5

[0104]
As is apparent from the results of Tables 3 to 5, the difference in heating temperature (brazing temperature) of each assembly due to the difference in the stacking position in the vacuum heating furnace of the assembly providing each sandwich panel. The sandwich according to the present invention, in which the corrugated core and the face plate are integrally brazed with an Al—Si brazing alloy containing 6 wt% or 9 wt% of Si and not containing Mg. Panels (Panel No. 4 and Panel No. 7) have not only extremely small variations in panel thickness of 0.1 mm or 0.2 mm, but also an assembly before brazing and joining. The amount of decrease in thickness with respect to is extremely small, and the brazed state between the corrugated core and the face plate is good.
[0105]
On the other hand, a sandwich panel in which the corrugated core and the face plate are integrally brazed with a brazing alloy different from the Al—Si brazing alloy specified in the present invention, that is, the Si content is 6 Sandwich panels (panel Nos. 5, 6, 8, and 9) brazed with a brazing alloy containing 0.6% by weight or 1.2% by weight of Mg although the weight is 9% by weight or 9% by weight , A sandwich panel (panel No. 1 and 10) brazed with a brazing alloy that does not contain Mg but has a Si content of 4% by weight or 11% by weight, and a Si content of 4% by weight or In a sandwich panel (panel No. 2, 3, 11, 12) brazed with a brazing alloy having a content of 11% by weight and a Mg content of 0.6% by weight or 1.2% by weight The pole Most of them, except for some, have a large variation in panel thickness and a large reduction in thickness relative to the assembly before brazing, and there is a difference between the corrugated core and face plate. In the joint, there is a joint failure due to insufficient melting of the brazing alloy, or deformation or collapse of the corrugated core due to the occurrence of erosion, and the brazed state between the corrugated core and the face plate is defective.
[0106]
From this, according to the present invention, the thin assembly can be brazed and joined in a healthy brazing state by the vacuum brazing method, so that the thin sandwich panel has a desired thickness. It can be clearly recognized that it can be easily manufactured with high surface accuracy.
[0116]
The specific configuration of the present invention has been described in detail above. However, this is merely an example, and the present invention is not limited by the above description, and is based on the knowledge of those skilled in the art. The present invention can be implemented in a mode in which various changes, modifications, improvements and the like are added. And it is needless to say that such embodiments are all included in the scope of the present invention without departing from the gist of the present invention.
[0117]
【The invention's effect】
  As is clear from the above description, according to the method for manufacturing a sandwich panel according to the present invention, the core thickness is reduced, and the overall thickness of the panel is also reduced, thereby reducing the weight effectively. The resulting sandwich panel can be advantageously produced industrially without any loss of productivity and economy. And the two face plates and the corrugated core that constitute the thin sandwich panel thus obtainedButEasily and reliably with a sound brazed state with no defects, core deformation, collapse or crushingvacuumIt can be brazed, whereby excellent quality and high surface accuracy can be very effectively ensured in a thin sandwich panel.
[0118]
Moreover, in the sandwich panel according to the present invention, the overall thickness of the panel can be easily reduced without causing deterioration in quality and surface accuracy, and further weight reduction can be effectively achieved. As a result, it has been difficult to apply to conventional sandwich panels such as honeycomb panels such as top plates of doors, face plates of doors, shelves, or side plates and bottom plates of packing materials made of a predetermined casing. It can be sufficiently applied to light and light plate materials and the like, and its application range can be effectively expanded.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view showing an example of a sandwich panel according to the present invention.
2 is an explanatory view of a longitudinal section of the sandwich panel shown in FIG. 1. FIG.
FIG. 3 is a view corresponding to FIG. 2 showing another example of a sandwich panel according to the present invention.
FIG. 4 is an explanatory view showing an example of a process for manufacturing a sandwich panel according to the method of the present invention, and shows a state in which a plurality of assemblies are set in a molding apparatus.
FIG. 5 is a view corresponding to FIG. 1 showing still another example of a sandwich panel according to the present invention.
6 is a longitudinal sectional view of the sandwich panel shown in FIG. 5. FIG.
FIG. 7 is a view corresponding to FIG. 1 showing another example of a brazed sandwich panel according to the present invention.
8 is an explanatory view of a longitudinal section of the sandwich panel shown in FIG.
FIG. 9 is a longitudinal sectional view showing still another example of a sandwich panel according to the present invention.
FIG. 10 is a partially exploded perspective view showing another example of a sandwich panel according to the present invention.
[Explanation of symbols]
10 Sandwich panel 12, 14 face plate
16 Corrugated core 18 Molding device
22 Upper molding jig 26 Lower molding jig
34 Intermediate plate 36 Frame material

Claims (10)

The two face plates of 6000 series aluminum alloy material of Al-Mg-Si-based, at least, be vacuum brazed assembled body formed by sandwiching Al-Mg-Si based 6000-based core of the aluminum alloy material of the Thus, when manufacturing a sandwich panel in which at least these two face plates and the core are integrally vacuum brazed,
A corrugated core having a corrugated shape in which the corrugated shape is continuously formed in one direction is used as the core, and the corrugated core is sandwiched between the two face plates in the height direction of the corrugated shape. in, after forming the assembled body, silicon and (Si) comprises in a proportion of 6.0 to 9.0 wt%, and the balance ing of aluminum (Al) and inevitable impurities, magnesium (Mg) A method for producing a sandwich panel, characterized in that the assembly is vacuum brazed and bonded using an Al-Si brazing alloy not containing any of the above. The face plate is composed of an aluminum molded body formed by using a brazing sheet in which the Al—Si brazing alloy is clad on one or both sides of a plate material made of an Al—Mg—Si based 6000 series aluminum alloy. The method for producing a sandwich panel according to claim 1. The corrugated core is composed of an aluminum molded body formed by using a brazing sheet in which the Al—Si brazing alloy is clad on one or both sides of a plate made of an Al—Mg—Si based 6000 series aluminum alloy. The manufacturing method of the sandwich panel of Claim 1 or Claim 2 currently performed. A brazing sheet in which the Al-Si brazing alloy is clad on one side or both sides of a plate made of aluminum or an alloy thereof between at least one of the two face plates and the corrugated core, Or the sheet | seat or board | plate material which consists of the said Al-Si type brazing alloy is further pinched | interposed, and the said assembly is formed, The manufacturing method of the sandwich panel of Claim 1 characterized by the above-mentioned.   A plurality of the corrugated cores are used, the plurality of corrugated cores are stacked in the height direction of the corrugated shape in each of the corrugated cores, and the adjacent ones are arranged so that the corrugated shape forming directions are orthogonal to each other. 5. The assembly is formed by sandwiching the plurality of corrugated cores to be stacked between the two face plates in the stacking direction. 6. Manufacturing method for sandwich panels.   A plurality of the corrugated cores and at least one intermediate plate made of an aluminum material are used, and the plurality of corrugated cores are laminated in the height direction of the corrugated shape in each of the corrugated cores. The plurality of corrugated cores sandwiched between the two face plates in the laminating direction are positioned between the corrugated cores to be stacked, and further sandwiched between the two face plates in the stacking direction. After forming the brazed body, the two face plates, the plurality of corrugated cores, and the at least one intermediate plate are integrally brazed to each other by brazing and joining the assembled bodies. A method for producing a sandwich panel according to any one of claims 1 to 5.   Using a plurality of the corrugated cores and at least one aluminum-made intermediate plate, laminating the plurality of corrugated cores in the height direction of the corrugated shape in each of the corrugated cores, The at least one intermediate plate is positioned so as to be sandwiched between the plurality of corrugated cores that are stacked, and the plurality of the stacks that are stacked with the intermediate plate interposed therebetween. The corrugated core is sandwiched between the two face plates in the stacking direction to form the assembly, and then a pair of forming jigs having a pressing surface having a predetermined curved surface shape is used. The formed assembly is sandwiched between the forming jigs, and the face plate, the plurality of corrugated cores, and the at least With one intermediate plate Mutually with brazed integrally method of the sandwich panel according to any one of claims 1 to 4 them, characterized in that molded into a curved surface shape corresponding to the pressing surface.   The said intermediate | middle board is comprised with the aluminum molded object shape | molded using the brazing sheet by which the said Al-Si type brazing alloy was clad | crushed on the single side | surface or both surfaces of the board | plate material which consists of aluminum or its alloy. The manufacturing method of the sandwich panel of Claim 7.   Using a frame material made of aluminum, the frame material is arranged around the corrugated core so as to surround it, and the frame material and the corrugated core are arranged in the height direction of the corrugated shape of the corrugated core, After forming the assembly by sandwiching it between the two face plates, the face plate, the corrugated core and the frame material are brazed integrally with each other by brazing and joining the assembly. A method for manufacturing a sandwich panel according to any one of claims 1 to 8, wherein: A sandwich panel obtained by the manufacturing method according to claim 1, wherein at least Al—Mg— is provided between two face plates made of an Al—Mg—Si based 6000 series aluminum alloy. In a structure in which a core of Si-based 6000 series aluminum alloy material is sandwiched and at least the two face plates and the core are integrally vacuum brazed,
The core is composed of a corrugated core having a corrugated shape in which the corrugated shape is continuously formed in one direction, and the corrugated core is the two face plates in the height direction of the corrugated shape. under sandwiched state between, comprise silicon and (Si) in a proportion of 6.0 to 9.0 wt%, and the balance ing of aluminum (Al) and inevitable impurities, free of magnesium (Mg) A sandwich panel characterized in that the two face plates are integrally vacuum brazed with a non-Al-Si brazing alloy.

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