Round honeycomb core structure and manufacturing method thereof

Abstract

The invention provides a circular honeycomb core structure and a manufacturing method thereof, and relates to the technical field of honeycomb cores, the manufacturing method comprises the following operation steps: S1, providing a plurality of circular metal tubes, and forming a groove in the same position of the peripheral wall of each metal tube; s2, arranging a plurality of metal tube arrays into a honeycomb shape; s3, metal fibers are wound in the grooves to connect the multiple metal pipes together, and a preformed product is formed; and S4, sintering the preformed product, so that the joints of the metal pipes are fixed together through sintering to obtain the circular honeycomb core structure. Through the metal fiber winding and sintering mode, the limitation of a corundum crucible is eliminated, circular honeycomb cores of different sizes can be manufactured, the production flexibility is improved, material waste and resource consumption are reduced, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of honeycomb core technology, and in particular to a circular honeycomb core structure and a manufacturing method thereof. Background Art

[0002] Honeycomb core is a structural material with light weight and high strength, which is widely used in aerospace, construction, transportation and other fields. Traditional honeycomb cores mostly adopt hexagonal cell structure, because the hexagonal structure has a good comprehensive performance in terms of material utilization and mechanical properties. However, with the development of technology and the diversification of application needs, circular honeycomb cores have gradually attracted attention.

[0003] The circular honeycomb core is a honeycomb structure material composed of several parallel and evenly distributed circular cells. Each circular cell is made of a metal round tube. This structure has unique advantages in certain specific applications. For example, the circular honeycomb aluminum core has a smaller initial peak stress than the hexagonal honeycomb when it is impacted. It can ensure the safety of the protected object while absorbing the impact energy. In terms of absorbing impact energy, the circular honeycomb core can provide better performance and is suitable for occasions that require high energy absorption, such as anti-collision structures and protective equipment. The design and manufacturing of the circular honeycomb core is relatively flexible, and the diameter and density of the cells can be adjusted according to specific needs to achieve different performance indicators.

[0004] Although circular honeycomb cores have shown unique advantages in certain applications, there are some challenges in the manufacturing process of circular honeycomb cores, mainly reflected in the connection process of metal round tubes. Currently, the main connection methods of circular honeycomb cores include bonding, brazing and sintering.

[0005] Among them, the gluing method has significant advantages such as simple operation and low cost. However, at the same time, the gluing method uses a gluing process to connect round tubes and fix the positions between round tubes. The bonding strength of the adhesive is limited and may lose viscosity in high temperature or high humidity environments, resulting in structural failure.

[0006] Brazing is a process that melts the brazing material by heating it and makes it wet and spread in the gap between the infusible base materials, and then cools and solidifies to form a bond with the base materials. However, gravity hinders the formation of the transverse weld, resulting in differences in the size of the transverse weld and the longitudinal weld, which leads to the anisotropy of the overall performance of the circular honeycomb.

[0007] The sintering method is to heat the circular honeycomb core preform to a certain temperature and keep it for a period of time to fix it together. However, the production of preforms has certain limitations. Laboratories generally use corundum crucibles to make preforms. The circular aluminum tubes are placed in the corundum crucible according to a certain pattern, and corundum sheets are inserted around the preform and between the corundum crucible to pre-tighten it. This means that the production of circular honeycomb core preforms of different sizes requires different corundum crucibles, which will cause unnecessary waste. At the same time, the corundum crucibles required for large circular honeycomb preforms are more expensive to make and the waste is more serious. Summary of the invention

[0008] In view of this, the present invention proposes a circular honeycomb core structure and a method for manufacturing the same, aiming to solve the problem that when a circular honeycomb core is manufactured by a traditional sintering method, circular honeycomb core preforms of different sizes require a corundum crucible of a specific size to be manufactured, resulting in limitations and waste of resources in the manufacture of the circular honeycomb core.

[0009] The technical solution of the present invention is achieved in this way:

[0010] In a first aspect, the present invention provides a method for manufacturing a circular honeycomb core structure, comprising the following steps:

[0011] S1. Provide a plurality of circular metal tubes, and provide a groove at the same position on the outer peripheral wall of each metal tube;

[0012] S2, arranging a plurality of metal tube arrays into a honeycomb shape;

[0013] S3, connecting a plurality of metal tubes to each other by winding metal fibers in the grooves to form a preform;

[0014] S4, sintering the preformed product, so that the joints of the metal tubes are fixed together by sintering to obtain a circular honeycomb core structure.

[0015] As some implementation methods, the groove is opened at a middle position of the outer peripheral wall of the metal tube.

[0016] As some other embodiments, the grooves are provided at both ends of the outer peripheral wall of the metal tube.

[0017] As some other embodiments, the grooves are provided at the middle and both ends of the outer peripheral wall of the metal tube.

[0018] On the basis of the above technical solution, preferably, the depth of the groove is greater than or equal to the diameter of the metal fiber, and the width of the groove is greater than twice the diameter of the metal fiber.

[0019] On the basis of the above technical solution, preferably, step S3 further includes the following steps:

[0020] S31, arranging a plurality of metal tubes into a single-row metal tube structure;

[0021] S32, winding metal fibers into the grooves of each metal tube, so that the metal tubes are tightly fixed into a single-row metal tube structure;

[0022] S33, arranging and combining a plurality of wound and fixed single-row metal tube structures into a multi-row metal tube structure;

[0023] S34. Metal fibers are respectively wound around the head end and the tail end of the multi-row metal tube structure to fasten the multi-row metal tube structure together as a whole to form a preform.

[0024] Based on the above technical solution, preferably, in step S32, the metal fiber is spirally wound in the groove of each metal tube starting from one end of the single-row metal tube structure until it is wound to the other end of the single-row metal tube structure.

[0025] Based on the above technical solution, preferably, step S34 also includes: at the head end of the multi-row metal tube structure, starting from one end of the first row of metal tubes, the metal fiber is spirally wound in the groove of each metal tube, and all the metal tubes of the entire head end are wound in turn; and then, at the tail end of the multi-row metal tube structure, starting from one end of the tail row of metal tubes, the metal fiber is wound in the same manner to ensure that the multi-row metal tube structure is fastened together as a whole.

[0026] Based on the above technical solution, preferably, the metal tube and the metal fiber are made of the same material, including one or more of aluminum, magnesium, iron, titanium, copper, nickel, manganese, molybdenum, tungsten, zirconium, tantalum, tin, cobalt, chromium, niobium, vanadium and zinc.

[0027] In a second aspect, the present invention further provides a circular honeycomb core structure, which is manufactured using the circular honeycomb core structure manufacturing method described in the first aspect.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] (1) The present invention gets rid of the limitation of the corundum crucible by winding and sintering metal fibers, and can produce circular honeycomb cores of different sizes, thereby improving production flexibility, reducing material waste and resource consumption, and reducing manufacturing costs.

[0030] (2) Since the metal fiber itself has certain plasticity and strength, it is tightly wound around the bottom of the groove using a tool so that the metal tubes are tightly connected together to form a preform. The preform is then sintered. Since the metal fiber is in close contact with the bottom of the groove on the outer wall of the metal tube, a sintering neck will be formed at the contact point between the metal fiber and the bottom of the groove on the outer wall of the metal tube after sintering, which will also play a role in strengthening the connection. At the same time, the metal fiber is wound around the metal tube to connect the tubes together. When subjected to impact compression, the metal fiber also has a certain strength, which makes the tubes tightly combined together to reduce the possibility of collapse.

[0031] (3) By making the depth of the groove greater than or equal to the diameter of the metal fiber, it is ensured that the metal fiber can be firmly embedded in the groove to avoid the fiber loosening or falling off during use. The appropriate depth of the groove ensures that the metal tubes can be in close contact with each other, and there will be no contact gap between the metal tubes due to the leakage of the metal fiber outside the groove, which will affect the formation of metallurgical bonding of the tube wall during subsequent sintering.

[0032] (4) By making the width of the groove greater than 2 times the diameter of the metal fiber, sufficient space is provided for the winding of the metal fiber, avoiding the cross-overlapping and unevenness that may occur during the winding process. In addition, the wider groove can increase the number of turns of the metal fiber winding, enhance the fixing effect of the metal fiber on the metal tube, and improve the stability and durability of the entire structure.

[0033] (5) By first arranging the metal tubes into a single row and tightly winding and fixing them, and then modularly combining them into a multi-row structure, and further winding and fixing them at the head and tail ends, the operation process is simplified, the production efficiency is improved, the overall strength and stability of the structure are enhanced, the tightness and consistency of the multi-row structure are ensured, and finally a durable and stable preform is formed.

[0034] (6) The spiral winding method ensures that the metal fibers are evenly distributed in each metal tube groove, so that the fixing force on each metal tube is evenly distributed, improving the overall uniformity of the force on the structure. The spiral winding method can fix the metal tube more firmly, because this winding method can increase the contact area with the metal tube surface, thereby enhancing the fixing effect and improving the stability of the single-row metal tube structure. The spiral winding increases the friction between the metal fiber and the groove, preventing the fiber from falling off or loosening during use, and further ensuring the stability of the single-row metal tube structure.

[0035] (7) By performing spiral winding at the head and tail ends, the entire multi-row metal tube structure can be fully fixed at both ends to avoid local looseness and enhance the overall tightness and stability. The spiral winding method makes the metal fiber more evenly distributed in each metal tube groove, so that the force of the entire multi-row metal tube structure is more uniform, improving the overall mechanical properties and stability of the structure.

[0036] (8) Metal tubes and metal fibers made of the same material are used. Through the sintering process, the metal fibers melt in the grooves and form a metallurgical bond with the metal tube, which significantly increases the bonding strength of the joint. This bond is not only mechanical, but also metallurgically strong, allowing the joint to withstand greater loads and stresses. The uniform metal structure formed by the metallurgical bond can effectively disperse stress and avoid stress concentration, thereby improving the stability and fatigue resistance of the circular honeycomb core structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0038] Figure 1 It is a flow chart of the method for manufacturing a circular honeycomb core structure disclosed in the present invention;

[0039] Figure 2 It is a schematic diagram of the structure of the metal tube disclosed in the present invention;

[0040] Figure 3 It is a schematic diagram of the three-dimensional structure of a single-row metal tube structure disclosed in the present invention;

[0041] Figure 4 It is a schematic diagram of the three-dimensional structure after the multiple rows of metal tube structures disclosed in the present invention are fixedly connected;

[0042] Figure 5 It is a schematic diagram of the planar structure of the multiple rows of metal tube structures disclosed in the present invention after being fixedly connected;

[0043] Reference numerals:

[0044] 1. Metal tube; 11. Groove; 2. Metal fiber; 3. Single-row metal tube structure. DETAILED DESCRIPTION

[0045] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0046] like Figure 1 As shown, combined Figure 2-5 The embodiment of the present invention discloses a method for manufacturing a circular honeycomb core structure, comprising the following steps:

[0047] S1. Provide a plurality of circular metal tubes, and open a groove at the same position on the outer wall of each metal tube. The setting of the groove provides a fixing point for the subsequent winding of the metal fiber, ensuring that the metal fiber can be firmly connected to each metal tube.

[0048] S2. Arrange multiple metal tube arrays into a honeycomb shape. In this embodiment, the array arrangement can be an equidistant array, an equidistant array, a gradient array, or other regular or irregular arrays. The arrangement of these metal tube arrays depends on the shape requirements of the circular honeycomb core.

[0049] S3, use metal fiber winding in the groove to connect multiple metal tubes to each other to form a preform. The winding of metal fiber not only provides initial mechanical fixation, but also provides support for the subsequent sintering process, ensuring that the structure does not fall apart before sintering.

[0050] S4, sintering the preformed product, so that the joints of the metal tubes are fixed together by sintering to obtain a circular honeycomb core structure.

[0051] In this embodiment, the preform is placed in a sintering furnace for sintering, and the high temperature causes solid diffusion or fusion of the metal tubes at the joints, thereby achieving a strong bond. The sintering process forms a strong metallurgical bond at the joints of the metal tubes, ensuring that the final circular honeycomb core structure has high strength and stability.

[0052] The traditional method requires a corundum crucible of a specific size to make circular honeycomb cores of different sizes, which limits the flexibility of manufacturing and increases the cost. The present application gets rid of the limitation of the corundum crucible by winding and sintering metal fibers, and can make circular honeycomb cores of different sizes, which improves the flexibility of production, reduces material waste and resource consumption, and reduces manufacturing costs.

[0053] As some embodiments, the groove is opened in the middle of the outer peripheral wall of the metal tube. The groove in the middle can evenly distribute the stress of the wound metal fibers, so that each metal tube remains balanced during the forming process, thereby increasing the overall stability of the structure.

[0054] As other embodiments, grooves are provided at both ends of the outer peripheral wall of the metal tube. Providing grooves at both ends and winding metal fibers can enhance the connection strength between the metal tubes, especially for longer metal tubes, and can effectively prevent the connection from loosening and falling off.

[0055] As other embodiments, grooves are provided in the middle and at both ends of the outer peripheral wall of the metal tube. At the same time, grooves are provided in the middle and at both ends and metal fibers are wound around the grooves, which can maximize the connection strength between the metal tubes and the stability of the overall structure.

[0056] It is worth noting that the technical effects of the above-mentioned embodiments are gradually improved.

[0057] As some preferred embodiments, the depth of the groove is greater than or equal to the diameter of the metal fiber, thereby ensuring that the metal fiber can be firmly embedded in the groove to avoid loosening or falling off of the fiber during use. The appropriate depth of the groove ensures that the metal tubes can be in close contact with each other, and there will be no contact gap between the metal tubes due to the leakage of the metal fiber outside the groove, which will affect the metallurgical bonding of the tube wall during subsequent sintering.

[0058] In this embodiment, the width of the groove is greater than 2 times the diameter of the metal fiber, which provides sufficient space for the winding of the metal fiber and avoids the cross-overlapping and unevenness that may occur during the winding process. In addition, the wider groove can increase the number of turns of the metal fiber winding, enhance the fixing effect of the metal fiber on the metal tube, and improve the stability and durability of the entire structure.

[0059] It is worth noting that, since the metal fiber itself has certain plasticity and strength, it is tightly wound around the bottom of the groove using a tool so that the metal tubes are tightly connected together to form a preform. The preform is then sintered. Since the metal fiber is in close contact with the bottom of the groove on the outer wall of the metal tube, a sintering neck will be formed at the contact point between the metal fiber and the bottom of the groove on the outer wall of the metal tube after sintering, which will also play a role in strengthening the connection. At the same time, the metal fiber is wound around the metal tube to connect the tubes together. When subjected to impact compression, the metal fiber also has a certain strength, which makes the tubes tightly combined together to reduce the possibility of collapse.

[0060] The operation method of step S3 is disclosed as follows.

[0061] Step S3 includes the following steps:

[0062] S31. Arrange a plurality of metal tubes into a single-row metal tube structure.

[0063] Arranging the metal tubes in a single row first facilitates the subsequent winding operation and simplifies the initial arrangement steps. The single-row arrangement structure is easy to mechanize and improves production efficiency.

[0064] S32, winding metal fibers in the grooves of each metal tube, so that the metal tubes are tightly fixed into a single-row metal tube structure. By winding the metal fibers in the grooves, the winding process makes the connection between the metal tubes tighter, fixes the multiple metal tubes into a whole, ensures the stability of the single-row metal tube structure, and enhances the overall strength of the single-row metal tube structure.

[0065] S33, arranging and combining a plurality of wound and fixed single-row metal tube structures into a multi-row metal tube structure. Modularizing the single-row metal tube structure and combining a plurality of single-rows into a multi-row structure simplifies the assembly process of the complex structure.

[0066] S34. Metal fibers are wound around the head and tail ends of the multi-row metal tube structure to fasten the multi-row metal tube structure together as a whole to form a preform. Winding and fixing at the head and tail ends ensures the overall fastness of the multi-row structure to form a stable preform. Winding and fixing at the head and tail ends ensures the uniform distribution of force on the multi-row structure and improves the consistency and durability of the structure.

[0067] As some preferred implementation methods, in step S32, the metal fiber is wound in the groove of each metal tube in a spiral manner starting from one end of the single-row metal tube structure until it is wound to the other end of the single-row metal tube structure. With the above technical solution, the spiral winding method ensures that the metal fiber is evenly distributed in the groove of each metal tube, so that the fixing force on each metal tube is evenly distributed, thereby improving the overall uniform force of the structure. The spiral winding method can fix the metal tube more firmly, because this winding method can increase the contact area with the surface of the metal tube, thereby enhancing the fixing effect and improving the stability of the single-row metal tube structure. The spiral winding increases the friction between the metal fiber and the groove, preventing the fiber from falling off or loosening during use, and further ensuring the stability of the single-row metal tube structure.

[0068] In the above embodiment, after the single-row metal tube structure is fixed by winding the metal fibers, it is necessary to arrange and combine multiple single-row metal tube structures to form a multi-row metal tube structure, and ensure that the multi-row metal tube structures form a whole to form a preformed product, so that in the subsequent sintering process of the preformed product, the metal tubes can be tightly connected to each other, thereby achieving metallurgical bonding at the connection point, and then completing the production of the circular honeycomb core.

[0069] A specific solution is provided as follows. Specifically, at the head end of the multi-row metal tube structure, starting from one end of the first row of metal tubes, the metal fiber is spirally wound in the groove of each metal tube, and all the metal tubes of the entire head end are wound in turn. Then, at the tail end of the multi-row metal tube structure, starting from one end of the tail row of metal tubes, the fibers are wound in the same manner to ensure that the multi-row metal tube structure is fastened together as a whole.

[0070] By performing spiral winding at the head and tail ends, the entire multi-row metal tube structure can be fully fixed at both ends to avoid local looseness and enhance the overall tightness and stability. The spiral winding method makes the metal fiber more evenly distributed in each metal tube groove, so that the stress of the entire multi-row metal tube structure is more uniform, improving the overall mechanical properties and stability of the circular honeycomb core structure.

[0071] In this embodiment, the metal tube and the metal fiber are made of the same material, including one or more of aluminum, magnesium, iron, titanium, copper, nickel, manganese, molybdenum, tungsten, zirconium, tantalum, tin, cobalt, chromium, niobium, vanadium, and zinc.

[0072] Use metal tubes and metal fibers made of the same material, whose melting points are the same or very close. During the sintering process, this ensures that both can reach the optimal sintering temperature at the same time, promoting effective metallurgical bonding. The same material has the same physical and chemical properties, such as the same thermal expansion coefficient, thermal conductivity and electrochemical properties. This reduces stress concentration and interface instability caused by differences in the properties of different materials during sintering and use.

[0073] Better compatibility between the same materials can form a more uniform metallurgical bonding interface. Different materials may be incompatible with each other, resulting in microstructural defects at the interface, which will weaken the mechanical properties and durability of the overall structure.

[0074] Through the sintering process, the metal fibers melt in the grooves and form a metallurgical bond with the metal tube, which significantly increases the bonding strength of the joint. This bond is not only mechanical, but also metallurgically strong, allowing the joint to withstand greater loads and stresses. The uniform metal structure formed by the metallurgical bond can effectively disperse stress and avoid stress concentration, thereby improving the stability and fatigue resistance of the circular honeycomb core structure.

[0075] The present invention also discloses a circular honeycomb core structure, which is manufactured by adopting the circular honeycomb core structure manufacturing method described in the first aspect.

[0076] Through the above-mentioned production method, the circular honeycomb core structure gets rid of the limitation of the corundum crucible during the production process, and circular honeycomb cores of different sizes can be produced, which improves the production flexibility, reduces material waste and resource consumption, and reduces manufacturing costs.

[0077] In addition, especially the use of sintering technology and metal fibers, the circular honeycomb core structure can obtain a uniform metallurgical bonding interface, which enhances the overall strength and stability of the structure. At the same time, the metal fibers melt in the grooves, further improving the bonding strength and fatigue resistance of the joints.

[0078] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for manufacturing a circular honeycomb core structure, characterized in that: The steps are as follows: S1. Provide a plurality of circular metal tubes, and provide a groove at the same position on the outer wall of each metal tube; S2, arranging a plurality of metal tube arrays into a honeycomb shape; S3, connecting a plurality of metal tubes to each other by winding metal fibers in the grooves to form a preform; S4, sintering the preformed product, so that the joints of the metal tubes are fixed together by sintering to obtain a circular honeycomb core structure.

2. The method for manufacturing a circular honeycomb core structure according to claim 1, characterized in that: The groove is arranged at the middle position of the outer peripheral wall of the metal tube.

3. The method for manufacturing a circular honeycomb core structure according to claim 1, characterized in that: The grooves are arranged at two ends of the outer peripheral wall of the metal tube.

4. The method for manufacturing a circular honeycomb core structure according to claim 1, characterized in that: The grooves are arranged at the middle position and two end positions of the outer peripheral wall of the metal tube.

5. The method for manufacturing a circular honeycomb core structure according to any one of claims 2 to 4, characterized in that: The depth of the groove is greater than or equal to the diameter of the metal fiber, and the width of the groove is greater than twice the diameter of the metal fiber.

6. The method for manufacturing a circular honeycomb core structure according to claim 5, characterized in that: Step S3 also includes the following steps: S31, arranging a plurality of metal tubes into a single-row metal tube structure; S32, winding metal fibers into the grooves of each metal tube, so that the metal tubes are tightly fixed into a single-row metal tube structure; S33, arranging and combining a plurality of wound and fixed single-row metal tube structures into a multi-row metal tube structure; S34. Metal fibers are respectively wound around the head end and the tail end of the multi-row metal tube structure to fasten the multi-row metal tube structure together as a whole to form a preform.

7. The method for manufacturing a circular honeycomb core structure according to claim 6, characterized in that: In step S32, the metal fiber is spirally wound in the groove of each metal tube starting from one end of the single-row metal tube structure until it is wound to the other end of the single-row metal tube structure.

8. The method for manufacturing a circular honeycomb core structure according to claim 5, characterized in that: Step S34 also includes: at the head end of the multi-row metal tube structure, starting from one end of the first row of metal tubes, the metal fiber is spirally wound in the groove of each metal tube, and all the metal tubes of the entire head end are wound in turn, and then, at the tail end of the multi-row metal tube structure, starting from one end of the tail row of metal tubes, the metal fiber is wound in the same way to ensure that the multi-row metal tube structure is fastened together as a whole.

9. The method for manufacturing a circular honeycomb core structure according to claim 1, characterized in that: The metal tube and the metal fiber are made of the same material, including one or more of aluminum, magnesium, iron, titanium, copper, nickel, manganese, molybdenum, tungsten, zirconium, tantalum, tin, cobalt, chromium, niobium, vanadium and zinc.

10. A circular honeycomb core structure, characterized in that: The circular honeycomb core structure is manufactured by the manufacturing method of any one of claims 1 to 9.

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