JPH064306B2 - Honeycomb panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of use] The present invention relates to a honeycomb panel formed by fixing a honeycomb core and a face plate.

[Prior Art] Honeycomb panels are used in various fields such as transportation and construction in recent years because they are materials having excellent properties such as light weight, rigidity, heat insulation, sound insulation, and energy absorption. .

This type of honeycomb panel is formed by laminating a relatively soft metal, for example, a plate material made of aluminum or its alloy, or a metal foil such as aluminum foil or iron foil, or a laminating material made of a sheet of plastic such as polyethylene or polypropylene, and adhering them. A plate material or a material is fixed to each other at a constant interval by an agent or the like, and a honeycomb body having a honeycomb shape is formed by spreading the laminated body thus configured in the thickness direction. Both edges,
That is, the face plates are fixed to the front and back surfaces of the honeycomb core with an adhesive or the like.

By the way, as an improved version of such a honeycomb panel, a hollow part of a honeycomb core is filled with a synthetic resin foam to improve heat insulation, sound insulation, and vibration isolation of a core cell (Japanese Utility Model Publication No. 61-30844). "Sandwich panel"), which is fire-resistant by filling a honeycomb core with cement or the like ("fire-resistant honeycomb panel" in Japanese Patent Publication No. 61-5901), and a face plate fixed to the honeycomb core. A ceramic color layer transferred to the surface of a honeycomb panel to improve aesthetics, weather resistance, etc. (Japanese Patent Laid-Open No. 63-1)
No. 7,0027, “Aluminum honeycomb composite plate”) and the like have already been proposed.

[Problems to be Solved by the Invention] However, in these honeycomb panels, the face plate and the honeycomb core are made thin and the cell size of the honeycomb core is made large in order to enhance the lightness and rigidity, which are the greatest advantages. However, when a local load is applied to the face plate, the face plate is likely to be locally deformed (that is, the local load resistance is low). In addition, there is a problem that a dent is likely to remain when a foreign substance collides (that is, a problem that dent resistance is low).

Further, these honeycomb panels have a problem that the surface of the face plate is easily corroded when used in a corrosive atmosphere such as a factory zone or a coastal zone. Further, when used at a high temperature such as around the engine of a vehicle or around an exhaust gas pipe, the conventional one also has a problem of poor heat resistance.

As a means for solving such a problem, JP-A-63-17
The "aluminum honeycomb composite plate" of Japanese Patent Publication No. 0027 has been proposed, but this is heated to a temperature as high as or higher than the melting point (about 570 to 600 ° C.) of the brazing filler metal when baking or transferring the glaze. Since it is necessary, the brazing material may melt and drip during baking of the glaze or transfer, which may cause breakage of the brazing part. To avoid this, after transferring the glaze baking to the face plate or after transferring the ceramic color layer, if a method of brazing the face plate and the honeycomb core is adopted, for example, in the case of a thin aluminum plate suitable for the face plate of the honeycomb panel, the glaze baking or There was a problem of thermal deformation when transferring the ceramic color. Alternatively, if a thick plate that can withstand thermal deformation is used, there is a problem that the important advantage of the honeycomb panel is lost, that is, lightness.

The honeycomb core having a hollow resin filled with a rigid resinous foam is excellent in heat insulation and sound insulation,
In terms of heat resistance, local load resistance and dent resistance, it is no different from the one not filled with synthetic resin foam, and the one in which the honeycomb core is filled with cement etc. That is, there is a problem of impairing the lightness.

The present invention has been made in view of the above problems, it is possible to improve local load resistance and dent resistance, heat resistance, corrosion resistance without impairing the lightness and rigidity which are the original advantages of the honeycomb panel. An object is to provide a honeycomb panel that can be manufactured.

Structure of the Invention [Means for Solving the Problems] In order to achieve the above object, the present invention has the following structures as means for solving the above problems. That is, the honeycomb panel of the present invention is a honeycomb panel that is formed by brazing a metal honeycomb core and a face plate together, and after the brazing, a ceramic material is provided on the face opposite to the honeycomb core side of the face plate. The gist is that it is formed by welding.

[Operation] In the honeycomb panel of the present invention configured as described above,
After brazing the honeycomb core and the face plate, a ceramic material is welded to the face plate.

This is because when the ceramic material is welded to the face plate before brazing, the face plate is deformed by the heat at the time of welding, and it becomes difficult to form a panel thereafter. In addition, the use of both the metallic honeycomb core and the face plate,
This is because, for example, a honeycomb core made of synthetic resin or a face plate cannot withstand the heat at the time of welding. Similarly, the reason why the honeycomb core and the face plate are brazed is that the adhesive cannot withstand the heat at the time of welding. Moreover, since the honeycomb panel and the face plate are brazed, this has excellent rigidity and is not subjected to thermal deformation due to the welding of the ceramic material.

Further, by adopting such a procedure, only one step (welding) is added to the conventional brazing honeycomb panel manufacturing process, and the process is not complicated.

The ceramic material is, for example, alumina, titania, zirconia, or the like. The welding thickness of the ceramic material is 0.3μ
It is preferably m to 8 mm. This is because if the welding thickness of the ceramic material is less than 0.3 μm, the layers will not be uniform and many pores will be generated, and the corrosion resistance will decrease, and if it exceeds 8 mm, the weight will increase and the honeycomb This is because it is disadvantageous in weight reduction which is an advantage of the panel.

In this honeycomb panel, the ceramic material works so as to cover the surface of the face plate opposite to the honeycomb core side. Therefore, the honeycomb panel reflects the high heat resistance, high corrosion resistance, and high hardness of the ceramic material.

[Embodiment] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the drawings.

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

As shown in the figure, the honeycomb panel 1 of the present embodiment has a honeycomb core formed by using an aluminum plate (BA7PC) having a plate thickness of 0.14 mm and having a cell size of 3/4 inch and a height of 12.7 mm. 3 and a lower surface plate 7 made of an aluminum plate (BA7PC) having a plate thickness of 1.2 mm, which is fixed to the back surface in the thickness direction of the honeycomb core 3 through a brazing material layer 5 coated with a clad ratio of 10%, An upper surface plate 11 of the same shape and the same material as the lower surface plate 7 fixed to the surface in the thickness direction of the honeycomb core 3 via the brazing material layer 9 covered with a clad ratio of 10%, and a honeycomb of the upper surface plate 11 The ceramic layer 13 is welded to the surface opposite to the core 3 side.

Such a honeycomb panel 1 is manufactured by the procedure shown in FIG. 2. The manufacturing method will be described below. First,
Lower surface plate 7 and upper surface plate 11 are respectively arranged on the back surface and the front surface of honeycomb core 3 in the thickness direction, and brazing material layers 5 and 9 are arranged on these contact surfaces to melt and cool the brazing material layers 5 and 9. Then, the respective members are joined together to manufacture the honeycomb core 3 to which the lower plate 7 and the upper plate 11 are fixed (procedure 1). Then, the surface of the upper surface plate 11 opposite to the honeycomb core 3 side is ground and cleaned by a method such as shot blasting to obtain a surface roughness R.
A clean surface of about 100z is obtained at max 100s or Rz (procedure 2). This is because the surface of the top plate 11 (the surface opposite to the honeycomb core 3 side) is provided with irregularities,
It is intended to increase the adhesiveness of the ceramic layer to be welded in the subsequent procedure, and the roughness thereof is preferably the one described above, but is not limited thereto. Subsequently, fine powder of ceramics (for example, alumina) is sprayed on the surface of the upper surface plate 11 that has been cleaned by the plasma method (a method using a gas, a method applying a voltage, etc.) (step 3). ), The surface is covered with the ceramic layer 13 (procedure 4). The thickness of the sprayed ceramic layer 13 is
In this embodiment, it is 120 μm. Then, the surface of the ceramic layer 13 is polished and ground to be flattened (step 5). In this way, the honeycomb panel 1 is completed.

As described above in detail, the honeycomb panel 1 of the first embodiment
Then, the ceramic layer 13 is the honeycomb core 3 of the top plate 11.
It is welded to cover the side opposite to the side. Therefore, the honeycomb panel is excellent in local load resistance, dent resistance, heat resistance, and corrosion resistance without impairing the lightness and rigidity which are the original advantages of the honeycomb panel.

How the ceramic panel 1 of this example is excellent in local load resistance, dent resistance, and corrosion resistance will be described below together with the test results.

First, a local load test for testing local load resistance was performed.
In this test, as shown in FIG. 3, a round bar 21 having a diameter (for example, 4 mm) smaller than the cell size of the honeycomb core 3 is used.
The test results are shown in Table 1 by using the above method to examine the deformation and breakage by gradually applying a large load to the cell center portion of the honeycomb core 3 through the upper surface plate 11. Note that the ceramic layer 1 is compared with a conventional honeycomb panel.
Honeycomb panel not covering 3 (double-sided plates 7, 11,
The honeycomb core 3 has the same shape and the same material as those in this embodiment. Hereinafter, this is referred to as a conventional honeycomb panel A. The test results of () are also shown in Table 1. In addition, after applying glaze for glaze on the surface of the honeycomb panel and baking the glaze at 580 ° C., the transfer sheet (PbO 45 to 55, SiO ₂ 40 to 40
30, B ₂ O ₃ 3.5, TiO ₂ 4.0 to 2.0, Al
Frit 85 composed of ₂ O ₃ 6.0 to 4.0 (% by weight)
˜90 parts by weight of inorganic pigment 15 to 10 parts by weight, oil 20
-25 parts by weight are kneaded to prepare a ceramic color composition, which is printed on a backing paper, and a heat-sensitive adhesive layer is applied thereon to form a transfer sheet. JP-A-63-170
No. 027, the same as the transfer sheet described in the upper right column on page 2, is transferred, heated to 580 ° C. to decompose and vaporize organic substances, and baked on the lower glaze layer to make a ceramic color layer (thickness 0.12).
Table 1 also shows the test results of a conventional honeycomb panel (hereinafter referred to as a conventional honeycomb panel B) having a thickness of mm.

As is clear from Table 1, the honeycomb panel 1 of this example is extremely excellent in local load resistance.
Incidentally, the conventional honeycomb panel B to which the ceramic coating by transfer is applied is extremely inferior in local load resistance to the conventional honeycomb panel A which is not applied with the ceramic coating. It shows a drawback.

In addition, a micro Vickers test for testing dent resistance was performed. The size and material of the honeycomb panel 1 used in this test are as follows.

Double-sided plates 7 and 11: Aluminum plate with a thickness of 1 mm (BA2
3PC) Honeycomb core 3: 0.2 mm thick aluminum plate (B
A23PC), cell size 3/4 inch, height 12.7
mm Ceramic layer 13 (Example A): Titania / zirconia mixed material having a thickness of 80 μm (Example B): Alumina having a thickness of 5 mm Sample C of the conventional example is one in which the ceramic layer 13 is not coated, Same size and same material as the one. Further, in the sample D of the conventional example, a ceramic color layer having a thickness of 0.12 mm was transferred and formed on the surface of a honeycomb panel made of the same size and the same material as the above, similarly to the conventional honeycomb panel B. It is a thing. The results of these tests are shown in Table 2.

As is apparent from Table 2 above, the honeycomb panels of Examples A and B according to this example are extremely excellent in dent resistance. It should be noted that the conventional honeycomb panel D on which the ceramic coating by transfer is applied is extremely inferior in dent resistance, which shows a drawback of the ceramic coating method by transfer.

Next, a dry-wet alternating immersion test for testing corrosion resistance and CA
An SS test was conducted. Dry and wet alternating immersion test is 3% N
Immerse in aCl (PH3) at 40 ° C for 30 minutes, and
It is to be exposed to hot air of 0 ° C. for 30 minutes, and the surface change with the lapse of time thereafter is examined. What is the CASS test?
4% NaCl + in the test specified by JIS 8681
50 in 0.26 g / CuCl ₂ .2H ₂ O (PH3)
Continuous spraying is carried out at a temperature of ℃, and the surface change with the lapse of time thereafter is examined. The size and material of the honeycomb panel 1 used in these tests are as follows.

Double-sided plates 7, 11: Aluminum plate with a plate thickness of 1.2 mm (B
A7PC) Honeycomb core 3: 0.14 mm thick aluminum plate (BA7PC), cell size 3/4 inch, height 12.
7 mm Ceramic layer 13: Alumina having a thickness of 0.5 μm Further, the sample E of the conventional example is not coated with the ceramic layer 13 and has the same size and the same material as those described above. In the sample F of the conventional example, a ceramic color layer having a thickness of 0.12 mm was transferred and formed on the surface of a honeycomb panel manufactured with the same size and the same material as the above, similarly to the above-mentioned conventional honeycomb panel B. . The results of these tests are shown in Table 3.

As is apparent from Table 3, the honeycomb panel 1 of this example
Is superior in corrosion resistance to the conventional examples E and F.

Also from the above test results, the honeycomb panel 1 of the present example
However, it is found that the electrode has excellent load resistance, dent resistance and corrosion resistance. On the other hand, when the ceramic coating by transfer is applied, although the corrosion resistance of Conventional Example F in Table 3 is slightly improved as compared with Conventional Example E, as shown in Tables 1 and 2, the local load resistance is It can be seen that the durability and the dent resistance are extremely lowered, and the practicality is poor.

In the embodiment, the ceramic layer 13 is used for the upper surface plate 11
Although the surface opposite to the honeycomb core side is covered, the surface of the lower surface plate 7 opposite to the honeycomb core side may be covered with the ceramic layer in some cases.

Further, the thickness of the upper surface plate 11 to which the ceramic layer 13 is welded needs to be preferably 30 μm or more when it is made of aluminum. Because the face plate 11 is 30μ
This is because when the thickness is smaller than m, the face plate 11 is melted by the heat of the thermal spraying when the ceramic is sprayed and coated, and the ceramic layer 13 is difficult to be formed.

In this embodiment, the honeycomb core 3 and the upper surface plate 11 are fixed to each other by the brazing material. However, this is because the fixing performance is deteriorated by the thermal spraying heat generated when the ceramic layer 13 is formed. This is to prevent it. This is because when the honeycomb core 3 and the upper surface plate 11 are adhered by a resin adhesive material, the adhesive portion may be melted by the thermal spraying heat and the adhesive performance may be deteriorated. The two are joined together by.

Next, a second embodiment of the present invention will be described.

FIG. 4 is a front view of the honeycomb panel of the second embodiment. The difference between the honeycomb panel of the present embodiment and the first embodiment is that the surface of the ceramic layer 13 coated on the upper surface plate 11 is further treated with Teflon (fluorine resin manufactured by Du Pont), and the honeycomb core 3. The lower plate 7 is the same as that of the first embodiment. That is, the honeycomb panel 31 of the present embodiment is
Similar to the first embodiment, the lower surface plate 7 and the upper surface plate 11 are fixed to both surfaces in the thickness direction of the honeycomb core 3 through the brazing material layers 5 and 9, and the upper surface plate 11 is opposite to the honeycomb core side. Is covered with a ceramic layer 13, and
The surface of the ceramic layer 13 is covered with the Teflon layer 33. In this embodiment, the shapes and materials of the honeycomb core 3, the lower surface plate 7, the upper surface plate 11 and the ceramic layer 13 are the same as those in the first embodiment, and the Teflon layer 33 has a thickness of 4 mm.
It is 0 μm.

The honeycomb panel 31 of the second embodiment thus constituted
Is excellent in local load resistance and dent resistance without impairing lightness and rigidity, as in the first embodiment, and
Since the surface of the ceramic layer 13 is covered with the Teflon layer 33, the corrosion resistance, the durability, the heat resistance, the weather resistance, and the decorativeness (aesthetics) are better than those of the first embodiment as well as the conventional ones.
Is better in terms of.

Here, also with respect to the honeycomb panel 31 of the present embodiment, the dry-wet alternate immersion test for testing the corrosion resistance and the CA described above are performed.
An SS test was conducted. The test results are shown in Table 4. As comparative examples, the test results of the conventional honeycomb panel E and the conventional honeycomb panel F shown in Table 3 are also shown.

As is clear from Table 4, the honeycomb panel 31 of the present embodiment, in which the upper layer obtained by welding the ceramic material is coated with Teflon.
Has excellent corrosion resistance.

Conventionally, there is a technique for coating an aluminum plate with Teflon, but in such a technique, it is necessary to bond the two via an adhesive primer, whereas in the present embodiment, the upper plate 11 (aluminum plate) is used. As shown in FIG. 5, the surface of the ceramic layer 13 that has been sprayed and deposited on) has appropriate irregularities 13a and holes 13b. Therefore, Teflon is applied to these protrusions 13a and holes 13b. It enters and becomes an anchor effect (spike effect), and the Teflon layer 33 is securely fixed without the need for an adhesive primer.

In the second embodiment, the surface of the ceramic layer 13 is configured to be coated with Teflon. However, the same effect as in the second embodiment can be obtained by coating the surface of the ceramic layer 13 with an inorganic material instead of Teflon. At this time, the inorganic material is directly applied to the aluminum upper surface plate 11 by the ceramic layer 13.
Since it does not come into contact with aluminum, aluminum is not eroded by the alkaline inorganic material.

Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments and can be carried out in various modes without departing from the scope of the present invention. Of course.

EFFECTS OF THE INVENTION As described in detail above, the honeycomb panel of the present invention is excellent in local load resistance, dent resistance, heat resistance, and corrosion resistance without impairing the lightness and rigidity which are the original advantages of the honeycomb panel. . Moreover, it is only necessary to add a welding process to the conventional brazing honeycomb panel manufacturing process, and the manufacturing process is not complicated.

Further, since the ceramic material is welded, only the surface portion of the face plate is heated during the welding, and the entire face plate or the entire honeycomb panel is not heated. The amount of heat provided to the face plate or the honeycomb panel by welding is small, and the brazing material inside the honeycomb panel is not melted. Therefore, the honeycomb panel is free from breakage of the brazed portion and thermal deformation of the face plate due to high temperature heating, and the quality of the ceramic-coated honeycomb panel is extremely good.

[Brief description of drawings]

FIG. 1 is a broken perspective view of a honeycomb panel of a first embodiment of the present invention, FIG. 2 is an explanatory view showing a manufacturing procedure of the honeycomb panel, and FIG. 3 is a local load for testing local load resistance of the honeycomb panel. FIG. 4 is a front perspective view of the honeycomb panel according to the second embodiment of the present invention, and FIG. 5 is an explanatory view for explaining the fixing condition of the Teflon layer of the honeycomb panel. 1, 31 ... Honeycomb panel 3 ... Honeycomb core 5, 9 ... Brazing material layer 7 ... Lower surface plate 11 ... Upper surface plate 13 ... Ceramic layer 33 ... Teflon layer

Continuation of the front page (56) Reference JP 62-240543 (JP, A) JP 56-1009095 (JP, A) JP 63-170027 (JP, A)

Claims (1)

[Claims] 1. A honeycomb panel formed by brazing a honeycomb core and a face plate, both of which are made of metal, and after the brazing, a ceramic material is welded to the face plate opposite to the honeycomb core side. Honeycomb panel characterized by being.