JP2013220648A - Folding type honeycomb structure and method for producing folding type honeycomb structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a folding type honeycomb structure which can secure rigidity and strength applicable to a panel for vehicles and a method for producing the folding type honeycomb structure.SOLUTION: In a folding type honeycomb structure 10, a panel material is folded in a bellows-like shape, and a plurality of cells 13 which form a honeycomb core 12 by laying first cell half parts 16 one on top of the other and second cell half parts 17 one on top of the other are provided in the shape of a line. As for the folding type honeycomb structure 10, the first cell half part 16 and the second cell half part 17 are formed substantially a trapezoidal shape so that the cross section of the cell 13 is formed substantially in a hexagonal shape, the first cell top wall parts of the first cell half parts 16 are connected to each other, and the second cell top wall parts of the second cell half parts 17 are connected to each other.

Description

  The present invention relates to a foldable honeycomb structure in which a honeycomb core is formed by a plurality of cells by folding a panel material in a bellows shape, and a method for manufacturing the foldable honeycomb structure.

For example, a folding honeycomb structure in which a plurality of cells are provided in a row is known as a packing structure. This foldable honeycomb structure is formed by projecting a plurality of cell halves on one surface side of the panel material and projecting a plurality of cell halves on the other surface side and folding the panel material.
Specifically, the pair of cell halves are overlapped by folding the panel material, and a cell is formed by the pair of overlapped cell halves. The cells are formed in a row by folding the panel material, and a foldable honeycomb structure is formed by the cells in the row (see, for example, Patent Document 1).

Japanese Patent No. 4408331

When the foldable honeycomb structure of Patent Document 1 is used as a packaging panel, rigidity and strength are ensured.
However, since this foldable honeycomb structure is formed by folding the panel material and overlapping the cell halves, the overlapped cell halves are relatively easily separated.
For this reason, when the folding honeycomb structure is applied as a vehicle panel (for example, a dashboard panel, a floor panel, or a side panel), it is difficult to ensure the rigidity and strength of the folding honeycomb structure. There was room for improvement.

  The present invention provides a foldable honeycomb structure capable of ensuring rigidity and strength applicable to a vehicle panel (for example, a dashboard panel, a floor panel, and a side panel) and a method for manufacturing the foldable honeycomb structure. This is the issue.

  In the invention according to claim 1, a plurality of first cell half portions projecting to one surface side of the panel material and a plurality of second cell half portions projecting to the other surface side are alternately provided on the panel material, and the panel The material is folded in a saw blade shape by a guide means, the first cell halves are overlapped with each other by folding the folded panel material, and the second cell halves are overlapped with each other. Forming a plurality of cells in a row by bringing the cell wall portions into contact with each other, and forming the honeycomb core with the plurality of cells, wherein the honeycomb core is formed with the plurality of cells. Before performing, an adhesive is sprayed on the cell wall from the vicinity of the guide means.

  According to a second aspect of the present invention, the panel material is formed of a thermoplastic resin, and the adhesive is a thermoplastic resin that can contain reinforcing fibers.

  According to a third aspect of the present invention, the adhesive is sprayed onto the cell wall portion from both sides of the panel material.

  According to a fourth aspect of the present invention, the adhesive is sprayed in a heated state.

  Claim 5 includes a lamination step of covering the adhesive between the cell walls with the skin sheet by laminating a skin sheet on the lamination surface of the honeycomb core after forming the honeycomb core. In a pre-process of the process, a reinforcing material is sprayed on the laminated surface of the honeycomb core, and the sprayed reinforcing material is welded to the laminated surface and the skin sheet.

  According to a sixth aspect of the present invention, the first cell half projecting to one side of the panel material and the second cell half projecting to the other surface are alternately provided on the panel material, and the panel material is folded in a bellows shape. In the foldable honeycomb structure in which a plurality of cells forming a honeycomb core are formed in a row by overlapping the first cell halves and the second cell halves, By forming the first cell half and the second cell half in a substantially trapezoidal shape, the cell is formed in a substantially hexagonal cross section, and the cell walls that are the tops of the first cell half are joined together. At the same time, the cell walls that are the tops of the second cell half are joined together.

  According to a seventh aspect of the present invention, the panel material having the plurality of first cell halves and the second cell halves is formed of a thermoplastic resin, the cell walls of the first cell halves are joined to each other, and the first An adhesive made of a thermoplastic resin is used for joining the cell walls of two cell halves.

  According to an eighth aspect of the present invention, a connecting member is interposed between the core end portion of the honeycomb core and the vehicle body frame so that the core end portion is connected to the vehicle body frame by the connecting member.

  According to a ninth aspect of the present invention, when the panel material is folded in a bellows shape, a pair of folding portions are provided at the end portions of the cells so as to face each other with a gap therebetween, and formed between the pair of folding portions. The inside of the cell communicates with the outside through the gap.

  A tenth aspect of the present invention includes a skin sheet that covers a portion where the cell wall portions are bonded to each other by being laminated on the honeycomb core, and a reinforcing material that is laminated between the honeycomb core and the skin sheet. It is characterized by.

In the invention according to claim 1, before the honeycomb core is formed, the adhesive is applied to the cell wall by spraying the adhesive on the cell wall from the vicinity of the guide means.
Therefore, the cell wall portions can be joined with an adhesive by overlapping the first cell halves and contacting the cell wall portions by overlapping the second cell halves.
Thereby, the rigidity and strength of the honeycomb core can be increased, and the rigidity and strength applicable to a vehicle panel (for example, a dashboard panel, a floor panel, or a side panel) can be secured.

In the invention which concerns on Claim 2, the panel material was formed with the thermoplastic resin and the adhesive agent was made into the thermoplastic resin. Thereby, it becomes possible to melt the honeycomb core and the adhesive formed from the panel material and return them to the raw material resin, thereby improving the recyclability.
Furthermore, the rigidity and strength of the honeycomb core can be further increased by containing reinforcing fibers in the adhesive.

  In the invention according to claim 3, the adhesive is sprayed onto the cell wall from both sides of the panel material. As a result, the adhesive can be applied simultaneously to the cell wall portion of the first cell half projecting to the one surface side and the cell wall portion of the second cell half projecting to the other surface side, thereby improving productivity. Can do.

In the invention which concerns on Claim 4, when the adhesive agent is sprayed in the heated state, when the adhesive agent is sprayed, the adhesive force at the initial stage of application can be maintained.
Thereby, for example, even when applied to the cell wall portion facing downward from the lower surface side of the panel material, it is possible to prevent the adhesive from dropping from the cell wall portion.

In the invention according to claim 5, the reinforcing material is sprayed on the laminated surface of the honeycomb core, and the sprayed reinforcing material is welded to the laminated surface and the skin sheet.
Thereby, since the joining strength of the adhesive between the cell walls can be supplemented by the welded reinforcing material, the rigidity and strength of the folding honeycomb structure can be increased.
Furthermore, since the reinforcing material can be welded using the skin sheet, there is no need to newly provide a sheet covering the reinforcing material. Thereby, an increase in cost and an increase in weight can be minimized.

In the invention which concerns on Claim 6, the 1st, 2nd cell half part was formed in the substantially trapezoid shape so that a cell may be formed in a cross-sectional substantially hexagonal shape. Furthermore, the cell walls that are the tops of the first cell half are joined together, and the cell walls that are the tops of the second cell half are joined together.
Thereby, the rigidity and strength of the honeycomb core can be increased, and the rigidity and strength applicable to a vehicle panel (for example, a dashboard panel, a floor panel, or a side panel) can be secured.

In the invention according to claim 7, the panel material is formed of a thermoplastic resin, and an adhesive made of a thermoplastic resin is used for joining the cell wall portions.
Thereby, it becomes possible to melt the honeycomb core and adhesive formed with the panel material and return them to the raw material resin, and to improve the recyclability of the panel material and adhesive.

In the invention according to claim 8, the folding honeycomb structure can be employed as a floor panel by securing the rigidity and strength of the folding honeycomb structure formed of a thermoplastic resin.
Thereby, since the steel floor panel conventionally employ | adopted can be made unnecessary, the weight reduction of a floor panel can be achieved.

In the invention according to claim 9, the panel material is folded in a bellows shape so that a pair of folded portions are provided at the end portions of the cells so as to face each other with a gap.
Therefore, the inside of the cell can be communicated with the outside through a gap formed between the pair of folding parts. Thus, by directing the gap formed between the pair of folding parts to the outside of the passenger compartment, road noise outside the passenger compartment can be resonated within the cell and reduced.
Further, by directing the gap formed between the pair of folding parts into the vehicle interior, noise in the vehicle interior (noise) can be resonated in the cell and reduced.

In the invention according to claim 10, the reinforcing material is laminated between the honeycomb core and the skin sheet.
Thereby, since the joint strength of the joined part between the cell walls can be supplemented by the laminated reinforcing material, the rigidity and strength of the folding honeycomb structure can be increased.
Furthermore, since a reinforcing material can be laminated | stacked using a skin sheet, it is not necessary to provide the sheet | seat which covers a reinforcing material newly. Thereby, an increase in cost and an increase in weight can be minimized.

1 is a perspective view showing a foldable honeycomb structure of Example 1 according to the present invention. FIG. FIG. 2 is a sectional view taken along line 2-2 of FIG. FIG. 3 is an exploded perspective view showing the foldable honeycomb structure of FIG. 2. (A) is the sectional view on the 4a-4a line of FIG. 1, (b) is the sectional view on the 4b-4b line of FIG. FIG. 3 is a side view showing a manufacturing apparatus that performs the method for manufacturing the folding honeycomb structure of Example 1. It is a side view which shows the principal part of the manufacturing apparatus of FIG. It is a figure explaining the example which forms the panel material of Example 1. FIG. It is a figure explaining the example which bends the panel material of Example 1. FIG. It is a figure explaining the example which apply | coats an adhesive agent to the panel material of Example 1. FIG. It is a figure explaining the example which folds the panel material of Example 1. FIG. (A) is a figure explaining the state which formed the cell in the 1st cell half part, (b) is a figure explaining the state fractured | ruptured by the 11b-11b line | wire of (a). (A) is the sectional view on the 12a-12a line of FIG. 10, (b) is the sectional view on the 12b-12b line of FIG. FIG. 13 is a sectional view taken along line 13-13 of FIG. It is a figure explaining the example which laminates | stacks a skin sheet on the honeycomb core of FIG. It is sectional drawing which shows the foldable honeycomb structure of Example 2 which concerns on this invention. It is sectional drawing which shows the foldable honeycomb structure of Example 3 which concerns on this invention. It is a side view which shows the manufacturing apparatus of the foldable honeycomb structure of FIG. It is sectional drawing which shows the foldable honeycomb structure of Example 4 which concerns on this invention.

  The best mode for carrying out the present invention will be described below with reference to the accompanying drawings.

A method for manufacturing the foldable honeycomb structure 10 and the foldable honeycomb structure 10 according to the first embodiment will be described.
As shown in FIG. 1, a foldable honeycomb structure 10 includes a honeycomb core 12 in which a plurality of cells 13 are arranged in a row, and an upper skin layered on an upper laminated surface (laminated surface) 12a of the honeycomb core 12. A sheet (skin sheet) 23 and a lower skin sheet (skin sheet) 24 laminated on the lower laminated surface (laminated surface) 12b of the honeycomb core 12 are provided.

As shown in FIG. 2 and FIG. 3, the honeycomb core 12 has a panel material 15 made of a thermoplastic resin (see FIG. 7A) folded in a bellows shape (accordion shape) and joined with an adhesive 21. It is formed by.
That is, when the panel material 15 is folded in a bellows shape (see FIGS. 4 and 10), the first cell halves 16 are overlapped and the second cell halves 17 are overlapped.

In this state, the first cell top wall portions (cell wall portions) 16 a of the first cell half portion 16 are joined to each other with the adhesive 21. Similarly, the second cell top wall portions (cell wall portions) 17 a of the second cell half portion 17 are joined together with an adhesive 21.
The first cell top wall portions 16a are joined to each other, and the second cell top wall portions 17a are joined to each other, whereby the plurality of cells 13 are provided in a row and the honeycomb core 12 is formed.

The first cell half 16 is formed in a substantially trapezoidal shape with a pair of inclined walls 15c and a first cell top wall 16a (see also FIG. 7B). The second cell half portion 17 is formed in a substantially trapezoidal shape with a pair of inclined walls 15c and a second cell top wall portion 17a (see also FIG. 7B).
Further, the plurality of cells 13 are formed in a substantially hexagonal cross section.

The panel material 15 is formed of a thermoplastic resin and has a plurality of first cell half portions 16 and second cell half portions 17.
The adhesive 21 is formed of a thermoplastic resin in the same manner as the panel material 15 made of thermoplastic resin.
This adhesive 21 is an adhesive that can contain a reinforcing material (a reinforcing material in which a reinforcing fiber is contained in a thermoplastic resin binder, or a reinforcing material only of a reinforcing material).
As the reinforcing fibers, for example, discontinuous fibers such as glass fibers and carbon fibers are used.

According to the foldable honeycomb structure 10 of Example 1, the first and second cell halves 16 and 17 were formed in a substantially trapezoidal shape so that the plurality of cells 13 were formed in a substantially hexagonal cross section. Further, the first cell top wall portions 16 a of the first cell half portion 16 were joined together, and the second cell top wall portions 17 a of the second cell half portion 17 were joined together.
Thereby, the rigidity and strength of the honeycomb core 12 can be increased, and the rigidity and strength applicable to a vehicle panel (for example, a dashboard panel, a floor panel, or a side panel) can be ensured.

Further, the panel material 15 (that is, the honeycomb core 12) was formed of a thermoplastic resin, and the adhesive 21 was a thermoplastic resin.
Thereby, the honeycomb core 12 and the adhesive 21 can be melted and returned to the raw material resin, and the recyclability can be improved.
Furthermore, the rigidity and strength of the honeycomb core 12 can be further increased by containing reinforcing fibers in the adhesive 21.

As shown in FIG. 4, the upper skin sheet 23 is laminated on the upper laminated surface 12 a of the honeycomb core 12.
Therefore, the upper part of the part 12c where the first cell top wall parts 16a, 16a and the second cell top wall parts 17a, 17a are joined by the adhesive 21 is covered with the upper skin sheet 23.
Thereby, the upper part 21a of the adhesive 21 between the first cell top wall parts 16a, 16a and the upper part 21a of the adhesive 21 between the second cell top wall parts 17a, 17a are covered with the upper skin sheet 23. .

The lower skin sheet 24 is laminated on the lower laminated surface 12 b of the honeycomb core 12.
Therefore, the lower part of the part 12d where the first cell top wall parts 16a, 16a and the second cell top wall parts 17a, 17a are joined by the adhesive 21 is covered with the lower skin sheet 24.
As a result, the lower portion 21b of the adhesive 21 between the first cell top wall portions 16a and 16a and the lower portion 21b of the adhesive 21 between the second cell top wall portions 17a and 17a are covered with the lower skin sheet 24. .

Next, a foldable honeycomb structure manufacturing apparatus 40 for manufacturing the foldable honeycomb structure 10 will be described with reference to FIGS. 5 and 6.
As shown in FIG. 5, the manufacturing apparatus 40 includes upper and lower supply rollers 41 that guide the panel material 15, upper and lower guide portions (guide means) 42 and 43 that bend the panel material 15, and an adhesive 21 on the panel material 15. An adhesive application means 45 for applying (see FIG. 3), upper and lower opposing rollers 54 for folding the panel material 15, brake means 55 capable of temporarily stopping the panel material 15, and upper and lower skin sheets 23, 24 And upper and lower laminating rollers 58 for laminating.

As shown in FIG. 6, the adhesive application means 45 includes an adhesive supply unit 46 that supplies adhesive to the melting furnace 48, a reinforcing material supply unit 47 that supplies reinforcing material to the melting furnace 48, and supplied adhesive And a melting furnace 48 containing a reinforcing material by melting the agent.
As the reinforcing material, a reinforcing material in which a reinforcing fiber is contained in a thermoplastic resin binder or a reinforcing material only of the reinforcing material is used.
As the reinforcing fibers, for example, discontinuous fibers such as glass fibers and carbon fibers are used.

Further, the adhesive application means 45 includes a supply pump 49 that guides the adhesive (referred to as melt adhesive) 22 containing a reinforcing material to the upper and lower nozzles 51 and 52, and the melt adhesive 22 guided from the supply pump 49. The upper nozzle 51 that can be blown toward one surface (one surface of both surfaces) 15a of the panel material 15 and the molten adhesive 22 guided from the supply pump 49 are connected to the other surface (the other surface of both surfaces) 15b. And a lower nozzle 52 that can be blown toward the bottom.
Here, as the reinforcing fibers of the melt adhesive 22, for example, discontinuous fibers such as glass fibers and carbon fibers are used. Therefore, the molten adhesive 22 can be blown out from the upper and lower nozzles 51 and 52.

The upper nozzle 51 is provided in the vicinity of the upper guide portion 42 by being embedded in the upper guide portion 42. The outlet 51 a of the upper nozzle 51 is opened to the back surface 42 a of the upper guide portion 42, so that it faces the one surface 15 a of the panel material 15.
The lower nozzle 52 is provided in the vicinity of the lower guide portion 43 by being embedded in the lower guide portion 43. The outlet 52 a of the lower nozzle 52 is opened to the back surface 43 a of the lower guide portion 43 so as to face the other surface 15 b of the panel material 15.

Next, a manufacturing method for manufacturing the foldable honeycomb structure 10 using the foldable honeycomb structure manufacturing apparatus 40 shown in FIG. 5 will be described with reference to FIGS.
As shown in FIG. 6, the adhesive is supplied from the adhesive supply unit 46 of the adhesive application unit 45 to the melting furnace 48, and the reinforcing material is supplied from the reinforcing material supply unit 47 to the melting furnace 48.
The supplied adhesive is heated and melted in the melting furnace 48 to contain the reinforcing material in the melted adhesive to produce the molten adhesive 22.
The molten adhesive 22 generated in the melting furnace 48 is guided from the melting furnace 48 to the supply pump 49.

  As shown in FIGS. 7A and 7B, the panel material 15 is formed in a cross-sectional wave shape. Specifically, the panel material 15 is provided with first cell half portions 16 protruding to the one surface 15a side and second cell half portions 17 protruding to the other surface 15b side alternately.

The first cell half portion 16 is formed in a substantially trapezoidal shape with a pair of inclined walls 15 c that are inclined walls of the first cell half portion 16 and a first cell top wall portion 16 a that is the top portion of the first cell half portion 16. Has been.
The second cell half 17 has a pair of inclined walls 15 c that are inclined walls of the second cell half 17 and a second cell top wall 17 a that is the top of the second cell half 17. (Inverted trapezoidal shape).
That is, the pair of inclined walls 15 c serves as both the inclined wall of the first cell half 16 and the inclined wall of the second cell half 17.

As shown in FIG. 6, the upper and lower supply rollers 41 are rotated as indicated by an arrow A to guide the panel material 15 at a conveying speed V1 as indicated by an arrow B (see also FIG. 5).
Here, the panel material 15 is heated so as to be plastically deformed so as to be bent.
By guiding the guided panel material 15 to the upper and lower guide portions 42 and 43, the panel material 15 is bent from the folding line portion 31 (see FIG. 7A) by the upper and lower guide portions 42 and 43 in the bending process.

  As shown in FIG. 8, the panel material 15 is bent from the fold line portion 31 so that the first cell half portions 16 face each other and the second cell half portions 17 face each other (see also FIG. 5). .

As shown in FIG. 6, the panel material 15 is bent in a saw blade shape by continuously bending the panel material 15 with the upper and lower guide portions 42 and 43 (see also FIG. 5).
By driving the supply pump 49 of the adhesive application means 45, in the adhesive application process, the molten adhesive 22 is sprayed from the outlet 51a of the upper nozzle 51 onto the one surface 15a of the panel material 15 in a heated state as indicated by the arrow C. . The sprayed molten adhesive 22 is applied to the first cell top wall portion 16a of the first cell half 16 (portion protruding to the one surface 15a side).

Similarly, the molten adhesive 22 is sprayed from the outlet 52a of the lower nozzle 52 to the other surface 15b of the panel material 15 in a heated state as indicated by an arrow D.
The sprayed molten adhesive 22 is applied to the second cell top wall portion 17a of the second cell half portion 17 (portion protruding to the other surface 15b side).

That is, in the adhesive application step, the molten adhesive 22 is heated from both sides 15a and 15b of the panel material 15 and sprayed to the first cell top wall portion 16a and the second cell top wall portion 17a, and the first cell top wall The molten adhesive 22 in a heated state is applied to the part 16a and the second cell top wall part 17a.
As shown in FIG. 9, the melt adhesive 22 is applied to the first cell top wall portion 16 a of the first cell half 16, and the melt adhesive is applied to the second cell top wall portion 17 a of the second cell half 17. 22 is applied.

In this way, the molten adhesive 22 was sprayed from the both surfaces 15a, 15b side of the panel material 15 to the first cell top wall portion 16a and the second cell top wall portion 17a.
As a result, the melt adhesive 22 can be simultaneously applied to the first cell top wall portion 16a and the second cell top wall portion 17a, so that productivity can be improved.

Furthermore, when the molten adhesive 22 is sprayed in a heated state, the adhesive force at the initial stage of application can be maintained when the molten adhesive 22 is sprayed.
Thereby, for example, even when applied to the second cell top wall portion 17a facing downward from the other surface 15b (that is, the lower surface) side of the panel material 15, the molten adhesive 22 falls from the second cell top wall portion 17a. Can be prevented.

As shown in FIG. 6, after the molten adhesive 22 is applied to the first cell top wall portion 16a and the second cell top wall portion 17a, the panel material 15 to which the molten adhesive 22 has been applied is moved to the upper and lower opposing rollers 54. Be guided to.
Here, the panel material 15 is continuously heated so as to be plastically deformable so as to be folded.

As shown in FIG. 5, the upper and lower opposing rollers 54 are rotated as indicated by an arrow E. By rotating the upper and lower opposing rollers 54 as indicated by an arrow E, the panel material 15 is guided at a conveying speed V2 as indicated by an arrow F.
The conveyance speed V2 is a speed slower than the conveyance speed V1.
Therefore, in the conveyance path of the manufacturing apparatus 40, the panel material 15 folded between the upper and lower guide portions 42 and 43 and the upper and lower opposing rollers 54 can be folded into a bellows shape (accordion shape).

The folded panel material 15 is guided to the brake means 55 by the upper and lower opposing rollers 54.
The brake means 55 has upper and lower flaps 56 for stoppers arranged at a stop position (indicated by imaginary lines).
Therefore, the folded panel material 15 is temporarily stopped by the upper and lower flaps 56.

As shown in FIGS. 10 and 11, when the panel material 15 is folded in a bellows shape in the folding step, the first cell halves 16 are overlapped and the second cell halves 17 are overlapped.
As shown in FIGS. 12 and 13, the first cell top wall portions 16 a of the first cell half portion 16 are brought into contact with each other to be joined by the molten adhesive 22. Further, the second cell top wall portions 17 a of the second cell half 17 are brought into contact with each other to be joined by the molten adhesive 22.

Here, the molten adhesive 22 in a heated state is sprayed onto the first cell top wall portion 16a and the second cell top wall portion 17a.
Accordingly, the first cell half portions 16 are overlapped with each other, and the second cell half portions 17 are overlapped with each other, whereby the molten adhesive 22 spreads over the entire area of the first and second cell half portions 16 and 17.

When the molten adhesive 22 spreads, the first cell halves 16 are favorably bonded (bonded), and the second cell halves 17 are favorably bonded (bonded).
Thereby, the plurality of cells 13 are formed in a row by the plurality of first cell halves 16 and the plurality of second cell halves 17, and the honeycomb core 12 is formed by the plurality of cells 13.
The plurality of cells 13 are formed in a substantially hexagonal cross section.

As shown in FIG. 5, the honeycomb core 12 (see also FIG. 1) is formed by the plurality of cells 13 by completing the entire folding of the panel material 15 in the folding step.
By forming the honeycomb core 12, the conveying force of the panel material 15 by the upper and lower opposing rollers 54 is increased. When the conveying force of the panel material 15 increases, the upper and lower flaps 56 are opened to the open position by the panel material 15.

Therefore, the honeycomb core 12 formed in the folding process is guided as indicated by the arrow G toward the upper and lower stacking rollers 58 in the stacking process.
The upper and lower lamination rollers 58 are rotated as indicated by an arrow H. Further, the upper skin sheet 23 is disposed along the upper lamination roller 58, and the lower skin sheet 24 is disposed along the lower lamination roller 58.

  Therefore, in the laminating step, the upper skin sheet 23 is laminated on the upper laminated surface 12a (see FIG. 12) of the honeycomb core 12 by welding (thermal welding) by guiding the honeycomb core 12 to the upper and lower laminating rollers 58. At the same time, the lower skin sheet 24 is laminated on the lower lamination surface 12b (see FIG. 12) of the honeycomb core 12 by welding (thermal welding).

As shown in FIG. 14, the upper part of the part 12 c where the first cell top wall parts 16 a and 16 a are joined together by the molten adhesive 22 is covered with the upper skin sheet 23. Further, the upper portion of the portion 12 d where the second cell top wall portions 17 a and 17 a are joined together by the molten adhesive 22 is covered with the upper skin sheet 23.
Thus, the upper skin sheet 23 covers the upper portion 22a of the melt adhesive 22 between the first cell top wall portions 16a and 16a and the upper portion 22a of the melt adhesive 22 between the second cell top wall portions 17a and 17a. .

Similarly, the lower part of the part 12 c where the first cell top wall parts 16 a and 16 a are joined together by the molten adhesive 22 is covered with the lower skin sheet 24. Furthermore, the lower part of the part 12 d where the second cell top wall parts 17 a and 17 a are joined together by the melt adhesive 22 is covered with the lower skin sheet 24.
Thus, the lower skin sheet 24 covers the lower portion 22b of the melt adhesive 22 between the first cell top wall portions 16a and 16a and the lower portion 22b of the melt adhesive 22 between the second cell top wall portions 17a and 17a. .

After the upper skin sheet 23 is laminated on the upper laminated surface 12a of the honeycomb core 12 and the lower skin sheet 24 is laminated on the lower laminated surface 12b of the honeycomb core 12, the molten adhesive 22 is solidified by cooling to form the adhesive 21 and To do.
Thereby, the honeycomb core 12 is fixed (bonded) to obtain the foldable honeycomb structure 10 (see FIG. 1).

As described above, according to the method for manufacturing the foldable honeycomb structure of Example 1, before the honeycomb core 12 is formed by the plurality of cells 13, the first cell top wall portion 16a and the second cell top wall are formed. The molten adhesive 22 was applied to the part 17a.
Therefore, by overlapping the first cell half portions 16 and contacting the second cell half portions 17 with each other, the first cell top wall portions 16a and the second cell top wall portions 17a are bonded to each other by the adhesive 21. Can be joined.
Thereby, the rigidity and strength of the honeycomb core 12 can be increased, and the rigidity and strength applicable to a vehicle panel (for example, a dashboard panel, a floor panel, or a side panel) can be ensured.

  Next, the foldable honeycomb structures of Examples 2 to 4 will be described with reference to FIGS. 15 to 18. In addition, in the foldable honeycomb structure of Examples 2 to 4, the same members as those of the foldable honeycomb structure 10 of Example 1 are denoted by the same reference numerals and description thereof is omitted.

The folding honeycomb structure 70 according to the second embodiment will be described.
As shown in FIG. 15, in the foldable honeycomb structure 70, the lower skin sheet 24 is removed from the lower laminated surface 12b of the honeycomb core 72, and the lower folded portion (folded portion) of the adjacent first cell half portion 16 is removed. ) 16b is provided with a gap 73, and the other configuration is the same as that of the foldable honeycomb structure 10 of the first embodiment.

The honeycomb core 72 is formed by folding the panel material 15 (see FIG. 7) into a bellows shape (accordion shape), similarly to the honeycomb core 12 of the first embodiment.
A pair of lower folded portions 16b are provided on the honeycomb core 72 and the lower end portion (cell end portion) 13a of the cell 13 so as to face each other with a gap 73 therebetween.
Specifically, the first cell half 16 has a lower folding part 16b, and a pair of adjacent lower folding parts 16b are provided so as to face each other with a gap 73 therebetween.
Therefore, the inside 14 of the cell 13 communicates with the outside 74 through a gap 73 formed between the pair of lower folding portions 16b.

  The honeycomb core 72 has rigidity and strength secured in the same manner as the honeycomb core 12 of the first embodiment. By securing the rigidity and strength of the honeycomb core 72, the honeycomb core 72 can be employed as a vehicle floor panel.

Specifically, a connecting member 76 is interposed between the end portion 70a of the foldable honeycomb structure 70 (the core end portion 72a of the honeycomb core 72) and the vehicle body frame 75, and the core end portion 72a is connected to the vehicle body by the connecting member 76. It is connected to the frame 75.
A side sill or the like corresponds to the body frame 75.
The connecting member 76 is formed by extrusion using an aluminum alloy as a material, and has a flange portion 76a and a fitting portion 76b having a substantially U-shaped cross section. The connecting member 76 has a flange portion 76 a attached to a bottom portion 75 a of the vehicle body frame 75 with bolts 77 and nuts 78.

The end portion 70a of the foldable honeycomb structure 70 is fitted to the fitting portion 76b, and the end portion 70a is bonded to the fitting portion 76b with an adhesive 81.
By joining the end portion 70a to the fitting portion 76b, the end portion 70a of the foldable honeycomb structure 70 (the core end portion 72a of the honeycomb core 72) is coupled to the fitting portion 76b.
Therefore, the foldable honeycomb structure 70 can be employed as a vehicle panel (specifically, a floor panel). Thereby, since the steel floor panel conventionally employ | adopted can be made unnecessary, the weight reduction of a floor panel can be achieved.

By adopting the foldable honeycomb structure 70 as a floor panel, the gap 73 formed between the pair of lower foldable portions 16b can be directed to the outside 74 of the passenger compartment 83.
In this way, by directing the gap 73 toward the outside 74 of the passenger compartment 83, road noise and the like of the outside 74 can be resonated within the cell 13 and reduced.
On the other hand, when the gap 73 formed between the pair of lower folding parts 16b is directed into the passenger compartment 83, noise in the passenger compartment 83 can be resonated in the cell 13 and reduced.

  Furthermore, according to the foldable honeycomb structure 70 according to the second embodiment, the same effect as that of the foldable honeycomb structure 10 can be obtained.

  When the foldable honeycomb structure 70 is employed as a floor panel, a floor carpet can be integrated with the upper skin sheet 23 laminated on the honeycomb core 12 (upper laminated surface 12a).

In the second embodiment, the example in which the end portion 70a of the foldable honeycomb structure 70 is joined to the fitting portion 76b of the connecting member 76 with the adhesive 81 has been described. It is also possible to use a member.
It is also possible to use only a fastening member such as a rivet without using the adhesive 81.

  Furthermore, in the second embodiment, the example in which the foldable honeycomb structure 70 is applied to the floor panel has been described. However, the present invention is not limited to this, and the foldable honeycomb structure 70 is not limited to the dashboard panel or the side panel. It can also be applied to a vehicle panel.

Next, the folding honeycomb structure 90 according to the third embodiment will be described.
As shown in FIG. 16, the foldable honeycomb structure 90 includes an upper reinforcing material (reinforcing material) 91 interposed (laminated) between the honeycomb core 12 and the upper skin sheet 23, and the honeycomb core 12 and the lower skin sheet 24. A lower reinforcing material (reinforcing material) 92 is interposed (laminated) therebetween, and the other configuration is the same as that of the folding honeycomb structure 10 of the first embodiment.

As the upper reinforcing material 91, a reinforcing material in which a reinforcing fiber is contained in a thermoplastic resin binder or a reinforcing material containing only a reinforcing material is used.
The lower reinforcing material 92 has the same mechanism as that of the upper reinforcing material 91, and a reinforcing material in which reinforcing fibers are contained in a thermoplastic resin binder or a reinforcing material only of the reinforcing material is used.
As the reinforcing fibers, for example, discontinuous fibers such as glass fibers and carbon fibers are used.

As shown in FIG. 17, the folding honeycomb structure manufacturing apparatus 100 includes a reinforcing material applying unit 101, and other configurations are the same as those of the manufacturing apparatus 40 of the first embodiment.
The reinforcing material applying means 101 includes reinforcing material supplying means 102 for supplying upper and lower reinforcing materials 91 and 92 and upper and lower nozzles 103 and 104 communicating with the reinforcing material supplying means 102.

The reinforcing material supply means 102 is a means for supplying the molten reinforcing material to the upper and lower nozzles 103, 104.
This reinforcing material is blown out from the upper and lower nozzles 103 and 104 in a molten state and solidified, whereby the reinforcing material becomes the upper and lower reinforcing materials 91 and 92.

The upper nozzle 103 is provided in the vicinity of the upper lamination roller 58, and an outlet is opened toward the upper lamination surface 12 a of the honeycomb core 12.
Further, the lower nozzle 104 is provided in the vicinity of the lower lamination roller 58, and an air outlet is opened toward the lower lamination surface 12b of the honeycomb core 12.
Here, for example, discontinuous fibers such as glass fibers and carbon fibers are used as the reinforcing fibers of the upper and lower reinforcing materials 91 and 92. Therefore, the upper reinforcing material 91 can be blown out from the upper nozzle 103 and the lower reinforcing material 92 can be blown out from the lower nozzle 104.

The upper reinforcing material 91 is sprayed and applied from the outlet of the upper nozzle 103 to the upper laminated surface 12a as shown by the arrow I. At the same time, the lower reinforcing material 92 is sprayed and applied to the lower laminated surface 12b from the outlet of the lower nozzle 104 as shown by an arrow J.
Therefore, in the reinforcing material application step, the upper reinforcing material 91 is applied to the upper laminated surface 12a, and the lower reinforcing material 92 is applied to the lower laminated surface 12b.

The honeycomb core 12 coated with the upper and lower reinforcing materials 91 and 92 is guided to the upper and lower laminating rollers 58 as indicated by arrows G in the laminating step.
The upper and lower lamination rollers 58 are rotated as indicated by an arrow H. Further, the upper skin sheet 23 is disposed along the upper lamination roller 58, and the lower skin sheet 24 is disposed along the lower lamination roller 58.

Therefore, in the lamination step, the upper skin sheet 23 is laminated on the upper reinforcing material 91 of the upper lamination surface 12 a by guiding the honeycomb core 12 to the upper and lower lamination rollers 58. At the same time, the lower skin sheet 24 is laminated on the lower reinforcing material 92 of the lower laminated surface 12b.
As shown in FIG. 16, the upper reinforcing material 91 is laminated between the upper laminated surface 12a and the upper skin sheet 23 by welding (thermal welding).
Similarly, the lower reinforcing material 92 is laminated between the lower laminated surface 12b and the lower skin sheet 24 by welding (thermal welding).

Thus, the laminated upper and lower reinforcing materials 91 and 92 supplement the bonding strength of the adhesive 21 between the first cell top wall portions 16a, and the adhesion between the second cell top wall portions 17a (see FIG. 4A). The bonding strength of the agent 21 can be supplemented.
Thereby, the rigidity and intensity | strength of the folding-type honeycomb structure 90 can be improved with the laminated | stacked upper and lower reinforcement materials 91 and 92. FIG.

  Furthermore, since the upper reinforcing material 91 can be laminated (welded) using the upper skin sheet 23 and the lower reinforcing material 92 can be laminated (welded) using the lower skin sheet 24, the upper and lower reinforcing materials 91, 92 can be attached. There is no need to provide a new covering sheet. Thereby, an increase in cost and an increase in weight can be minimized.

  Furthermore, according to the foldable honeycomb structure 90 according to the third embodiment, the same effect as that of the foldable honeycomb structure 10 can be obtained.

  In Example 3, the example in which the upper reinforcing material 91 is laminated between the honeycomb core 12 and the upper skin sheet 23 and the lower reinforcing material 92 is laminated between the honeycomb core 12 and the lower skin sheet 24 has been described. However, the present invention is not limited to this, and one of the upper and lower reinforcing materials 91 and 92 can be laminated.

Next, the folding honeycomb structure 110 according to the fourth embodiment will be described.
As shown in FIG. 18, the foldable honeycomb structure 110 removes the upper and lower skin sheets 23 and 24 from the foldable honeycomb structure 10 and welds the upper and lower butted portions 16c and 16d of the honeycomb core 12 (for example, The other configuration is the same as that of the folding honeycomb structure 10 of the first embodiment.

  Specifically, the upper abutting portion 16c and the lower abutting portion 16d of the first cell top wall portions (cell wall portions) 16a of the first cell half portion 16 are welded. Similarly, the upper part and the lower part of 2nd cell top wall part (cell wall part) 17a (refer Fig.4 (a)) of the 2nd cell half part 17 are welded.

Thereby, the rigidity and strength of the foldable honeycomb structure 110 according to the fourth embodiment can be ensured similarly to the foldable honeycomb structure 10 of the first embodiment.
Furthermore, since the upper and lower skin sheets 23 and 24 can be removed, the cost of the folding honeycomb structure 110 can be reduced.

  Furthermore, according to the foldable honeycomb structure 110 according to the fourth embodiment, the same effect as that of the foldable honeycomb structure 10 can be obtained.

The foldable honeycomb structure and the method for manufacturing the foldable honeycomb structure according to the present invention are not limited to the above-described embodiments, and can be appropriately changed and improved.
For example, the shapes and configurations of the folding honeycomb structure, the honeycomb core, the cell, the panel material, the vehicle body frame, the connecting member, and the like shown in the above embodiment are not limited to those illustrated, and can be changed as appropriate.

  INDUSTRIAL APPLICATION This invention manufactures a foldable honeycomb structure with the manufacturing method which folds a panel material in the shape of a bellows, and it is suitable for the application to a motor vehicle by using a foldable honeycomb structure as a vehicle panel.

  10, 70, 90, 110: foldable honeycomb structure, 12, 72: honeycomb core, 12a: upper laminated surface (laminated surface) of honeycomb core, 12b: lower laminated surface (laminated surface) of honeycomb core, 12c, 12d: a portion where the cell wall portions are joined, 13 ... a cell, 13a ... a lower end portion (cell end portion) of the cell, 14 ... an inside of the cell, 15 ... a panel material, 15a ... one surface of the panel material (one of both surfaces) ), 15b ... the other side of the panel material (the other side of both sides), 16 ... the first cell half, 16a ... the first cell top wall (cell wall), 16b ... the lower folding part (folding) Part), 17 ... second cell half part, 17a ... second cell top wall part (cell wall part), 21 ... adhesive, 22 ... molten adhesive, 23 ... upper skin sheet (skin sheet), 24 ... lower skin Sheet (skin sheet), 42, 43 ... Upper and lower guide portions (guide means), 72a ... Core end , 73 ... gap, 74 ... external, 75 ... body frame, 76 ... coupling member, 91 ... upper reinforcement (reinforcement), 92 ... lower reinforcement (reinforcement).

Claims (10)

A plurality of first cell halves protruding to one surface side of the panel material and a plurality of second cell halves protruding to the other surface side are alternately provided on the panel material, and the panel material is saw-toothed by a guide means The first cell halves are overlapped with each other by folding the folded panel material, and the second cell halves are overlapped to bring the cell walls that are the tops of the cell halves into contact with each other. In the method for manufacturing a foldable honeycomb structure in which a plurality of cells are formed in a row and a honeycomb core is formed by the plurality of cells.
Before forming a honeycomb core with the plurality of cells, a method for manufacturing a foldable honeycomb structure is characterized in that an adhesive is applied to the cell wall from the vicinity of the guide means. The panel material is formed of a thermoplastic resin,
The method for manufacturing a foldable honeycomb structure according to claim 1, wherein the adhesive is a thermoplastic resin that can contain reinforcing fibers.   The method for manufacturing a foldable honeycomb structure according to claim 1 or 2, wherein the adhesive is sprayed onto the cell wall from both sides of the panel material.   The method for manufacturing a foldable honeycomb structure according to any one of claims 1 to 3, wherein the adhesive is sprayed in a heated state. After forming the honeycomb core, by laminating a skin sheet on the lamination surface of the honeycomb core, comprising a laminating step of covering the adhesive between the cell walls with the skin sheet,
The pre-process of this lamination process WHEREIN: A reinforcing material is sprayed on the lamination surface of the said honeycomb core, and the sprayed reinforcement is welded to the said lamination surface and the said skin sheet, The any one of Claims 1-4 characterized by the above-mentioned. The manufacturing method of the foldable honeycomb structure as described. A first cell half projecting to one side of the panel material and a second cell half projecting to the other side are alternately provided on the panel material, the panel material is folded in a bellows shape, and the first cell In the foldable honeycomb structure in which a plurality of cells forming a honeycomb core is formed in a row by overlapping the second cell halves and the second cell halves,
By forming the first cell half and the second cell half in a substantially trapezoidal shape, the cell is formed in a substantially hexagonal cross section,
A foldable honeycomb structure characterized in that cell walls that are the top of the first cell half are joined together, and cell walls that are the top of the second cell half are joined. The panel material having the plurality of first cell halves and the second cell halves is formed of a thermoplastic resin,
7. The folding according to claim 6, wherein an adhesive made of a thermoplastic resin is used for joining the cell walls of the first cell half and joining the cell walls of the second cell half. Tatami honeycomb structure.   The said core end part was connected with the vehicle body frame by the said connection member by interposing a connection member between the core edge part of the said honeycomb core and a vehicle body frame, The Claim 6 or Claim 7 characterized by the above-mentioned. Foldable honeycomb structure. When the panel material is folded in a bellows shape, a pair of folded portions are provided at the end portions of the cells so as to face each other with a gap between them,
The foldable honeycomb structure according to any one of claims 6 to 8, wherein the inside of the cell communicates with the outside through the gap formed between the pair of foldable portions. A skin sheet covering the portion where the cell wall portions are joined together by being laminated on the honeycomb core;
A reinforcing material laminated between the honeycomb core and the skin sheet;
The foldable honeycomb structure according to any one of claims 6 to 9, comprising:

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