A light-weight metal honeycomb panel

Abstract

The utility model provides a light metal honeycomb board, including upper metal skin, honeycomb core layer and lower metal skin, upper metal skin, honeycomb core layer and lower metal skin are sequentially laminated and set up, and upper metal skin and lower metal skin are engaged with honeycomb core layer through an interfacing layer respectively, and the interfacing layer includes: non - woven fabric layer, it sets up in the side to honeycomb core layer, and the end surface of non - woven fabric layer and honeycomb core layer is fused and is inlayed in the hot - pressing process, and adhesive layer is inseparablely combined in the side of non - woven fabric layer away from honeycomb core layer, to be suitable for bonding upper metal skin or lower metal skin, through the composite interfacing layer between metal skin and honeycomb core layer, the adhesive layer of interfacing layer and metal skin form firm bonding, effectively overcome the industry bottleneck that metal and polymer plastics are difficult to combine firmly because of the big difference in material.

Description

Technical Field

[0001] This utility model relates to the field of composite material technology, specifically to a lightweight metal honeycomb panel. Background Technology

[0002] With the booming development of the construction industry and the ever-increasing demands for material performance in the transportation manufacturing sector, the market demand for sheet materials that combine lightweight and high strength is becoming increasingly urgent. Lightweight sheet materials not only help reduce the overall load on building structures and decrease energy consumption, but also improve fuel efficiency or increase driving range in transportation manufacturing; while high strength ensures the reliability and safety of the sheet materials in complex operating environments, enabling them to withstand various external forces without damage.

[0003] Honeycomb panels, with their unique structural advantages, have demonstrated enormous application potential in numerous fields. Their typical structure consists of two layers of panels and a honeycomb core material, cleverly mimicking the efficient mechanical properties of honeycombs in nature. In the construction industry, honeycomb panels are widely used in building curtain walls. Their lightweight properties reduce the burden on the building structure, while their high strength ensures the stability of the curtain wall under external forces such as wind and earthquakes. In interior decoration, honeycomb panels not only provide an aesthetically pleasing appearance but also meet the requirements for sound insulation and heat insulation. The application of honeycomb panels in rail transit interiors is also becoming increasingly widespread, providing passengers with a comfortable and safe riding environment.

[0004] However, existing honeycomb panel technology still has many limitations. Currently, most common honeycomb panel structures use two layers of plastic panels as the face sheet, with a honeycomb core material in between, manufactured through heating, pressurizing, and cooling processes. While this structure achieves a certain degree of lightweighting and strength, the plastic face sheet has significant performance shortcomings. Plastic has relatively low strength and hardness, making it prone to deformation or even breakage under significant impact, which is insufficient for applications requiring high material strength.

[0005] Furthermore, there is room for improvement in the bonding process of existing honeycomb panels. The bonding strength and durability between the panel and the honeycomb core material directly affect the performance of the entire honeycomb panel. If the bonding is not strong, the panel and core material are prone to separation during use, leading to structural failure of the panel. However, existing bonding materials and processes cannot achieve a stable bond between the metal panel and the core material.

[0006] For example, Chinese invention patent CN118544642A provides a lightweight rigid honeycomb panel, including a first skin layer, a core layer, and a second skin layer. The first and second skin layers are connected to opposite first and second end faces of the core layer. Both the first and second skin layers include at least two layers of fiberglass tape. The core layer includes multiple tubular structures arranged in a honeycomb pattern. However, its first and second skin layers are composed of fiberglass, which has relatively limited structural strength. Under significant external forces, it is prone to breakage, making it difficult to meet the requirements of some applications with extremely high strength requirements.

[0007] In summary, existing honeycomb panel technologies have shortcomings in terms of panel material performance and bonding processes, making it difficult to fully meet the market's growing demand for lightweight, high-strength panels. Therefore, developing a lightweight metal honeycomb panel with superior performance is of significant practical importance. Utility Model Content

[0008] The present invention aims to provide a lightweight metal honeycomb panel to solve the problems of insufficient strength of panel materials and unstable bonding process in existing honeycomb panel technology, and to meet the market demand for lightweight and high-strength panels.

[0009] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A lightweight metal honeycomb panel includes an upper metal skin, a honeycomb core layer, and a lower metal skin. The upper metal skin, honeycomb core layer, and lower metal skin are sequentially stacked and bonded together by hot pressing. The honeycomb core layer is formed by multiple plastic tubes arranged axially parallel to the thickness direction of the honeycomb core layer and fused together. The upper metal skin and lower metal skin are respectively bonded to the honeycomb core layer through a connecting layer, the connecting layer comprising: A nonwoven fabric layer is disposed on the side facing the honeycomb core layer, and the end faces of the nonwoven fabric layer and the honeycomb core layer are fused together during hot pressing; and An adhesive layer is inseparably bonded to the side of the nonwoven layer opposite to the honeycomb core layer to be suitable for bonding the upper metal skin or the lower metal skin. The nonwoven fabric layer is configured to improve the bonding strength between the metal skin and the honeycomb core layer by increasing the interfacial bonding performance between the honeycomb core layer and the adhesive layer.

[0010] Furthermore, the nonwoven fabric layer has a porous structure with a porosity between 30% and 80%.

[0011] Furthermore, the nonwoven fabric layer is physically integrated with the end face of the honeycomb core layer during the hot pressing process.

[0012] Furthermore, the overall thickness of the connecting layer is 0.1mm to 1.0mm.

[0013] Furthermore, the adhesive layer is attached to the nonwoven fabric to form a coated nonwoven fabric.

[0014] Furthermore, the plastic tube in the honeycomb core layer is a round tube, an elliptical tube, a polygonal tube, or a tube with an irregular cross-section.

[0015] Furthermore, the plastic tube includes a PP inner tube and a POE outer tube. The POE outer tube melts during the hot pressing process, bonding and fixing adjacent plastic tubes to form a honeycomb core layer.

[0016] Furthermore, the wall thickness of the POE outer tube is less than 15% of the wall thickness of the plastic tube.

[0017] Furthermore, the thickness of both the upper and lower metal skins is 0.2–1.0 mm.

[0018] Furthermore, the density of the honeycomb core layer does not exceed 120 kg / m³.

[0019] By adopting the above technical solution, this utility model has the following beneficial effects: This invention establishes a highly efficient composite bonding mechanism by introducing a unique "non-woven fabric layer + adhesive layer" composite bonding layer between the metal outer skin and the honeycomb core layer. The non-woven fabric layer fuses and integrates with the end face of the plastic tube during hot pressing, significantly increasing the bonding performance at the interface; simultaneously, the adhesive layer forms a stable bond with the metal outer skin. This effectively overcomes the industry bottleneck of difficulty in firmly bonding metal and polymer plastics due to significant material differences, ensuring that the panel and core layer maintain extremely high bonding strength and durability even under harsh environments such as high and low temperatures and humid conditions, eliminating the risk of delamination.

[0020] Replacing traditional plastic panels with a metal cladding (0.2–1.0 mm thick) provides higher strength and hardness, while the honeycomb core layer is composed of low-density plastic tubing (density not exceeding 120 kg / m³) bonded together via hot pressing. This allows the panel to maintain its lightweight properties while possessing excellent load-bearing capacity and impact resistance. This lightweight and high-strength characteristic makes it suitable for applications with high material performance requirements, such as building curtain walls and vehicle interiors.

[0021] The nonwoven fabric layer has a porous structure (porosity 30%–80%), which physically interlocks with the honeycomb core layer during hot pressing, forming a strong mechanical interlock. Simultaneously, the adhesive layer is tightly bonded to the nonwoven fabric layer, ensuring stable adhesion of the metal skin. This interlayer design overcomes the defects of weak adhesion in existing technologies, improves the peel resistance and durability of the board in complex environments, and guarantees long-term reliability. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings of the embodiments will be briefly introduced below. Obviously, the drawings described below only involve some embodiments of this utility model, and are not intended to limit this utility model.

[0023] Figure 1 This is a schematic diagram of the overall structure of the solid metal honeycomb panel of this utility model; Figure 2 This is an exploded view of the metal honeycomb panel of this utility model; Figure 3 This is an exploded view of the metal honeycomb panel of this utility model from another perspective; Figure 4 for Figure 3 Enlarged view of point A in the middle; Figure 5 This is a schematic diagram of the honeycomb core structure of this utility model; Figure 6 This is a cross-sectional view of the honeycomb core of this utility model.

[0024] Explanation of reference numerals in the attached figures: 1-Upper metal outer skin; 2-Lower metal outer skin; 3-Honeycomb core layer; 31-Plastic tube; 311-PP inner tube; 312-POE outer tube; 4-Connecting layer; 41-Non-woven fabric layer; 42-Adhesive layer. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the utility model will be further described in detail below with reference to the accompanying drawings. The components of the embodiments of this utility model described and shown in the accompanying drawings can be arranged and designed in various different configurations. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0026] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0027] Unless otherwise defined, the technical or scientific terms used in this patent document shall have the ordinary meaning understood by one of ordinary skill in the art to which this utility model pertains. The terms "first," "second," and similar terms used in this utility model patent specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms "an," "a," or "the" do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising" or "including" indicate that the element or object preceding "comprising" encompasses the element or object listed following "comprising" or its equivalents, and do not exclude other elements or objects. Terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" are used only to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0028] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the utility model will be further described in detail below with reference to the accompanying drawings. The components of the embodiments of this utility model described and shown in the accompanying drawings can be arranged and designed in various different configurations. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0030] Example 1: Please see Figures 1 to 6 This embodiment provides a lightweight metal honeycomb panel, the core of which is to solve the industry technical problem of the metal skin and the honeycomb core layer 3 being difficult to bond stably and firmly due to the large material difference through a connecting layer structure.

[0031] The lightweight metal honeycomb panel includes an upper metal skin 1, a honeycomb core layer 3, and a lower metal skin 2. The upper metal skin 1, the honeycomb core layer 3, and the lower metal skin 2 are stacked sequentially from top to bottom and are composited into a robust and lightweight integral structure through a hot-pressing process.

[0032] The upper metal skin 1 and lower metal skin 2 are the main load-bearing surfaces of the sheet metal. Their materials can be selected from common thin metal sheets such as aluminum alloy, galvanized steel sheet, and stainless steel. In this embodiment, aluminum alloy is chosen based on its excellent strength-to-weight ratio, good corrosion resistance, and processability. Preferably, the thickness of both the upper metal skin 1 and lower metal skin 2 is 0.2 mm to 1.0 mm. If the thickness is less than 0.2 mm, the rigidity and strength of the metal skin may be insufficient, easily leading to localized indentations under stress; if the thickness is greater than 1.0 mm, it will significantly increase the overall weight of the sheet metal, deviating from the lightweight design intention. In a preferred embodiment, both the upper and lower metal skins are made of 0.5 mm thick aluminum alloy sheet. This alloy has good corrosion resistance, formability, and strength, making it very suitable for use in building curtain walls and vehicle interiors. In this embodiment, the first metal skin 1 and the second metal skin 2 are coated with a protective coating to prevent aging and fading. Specifically, the protective coating is configured as an ice-crack fluorocarbon paint or polyester paint coating, and the thickness of the protective coating is configured to be 30-40 μm.

[0033] Please refer to Figures 5 to 6 The honeycomb core layer 3 is the core supporting unit of the entire structure, and its function is to minimize weight while ensuring high strength. The honeycomb core layer 3 is composed of a large number of plastic tubes 31 arranged closely along their axial direction (i.e., the length direction of the tubes) parallel to the thickness direction of the honeycomb core layer 3, and the walls of adjacent plastic tubes 31 are fused together through a hot-pressing process to form a stable honeycomb structure. The cross-sectional shape of the plastic tubes 31 can be circular, elliptical, hexagonal, rectangular, or other irregular cross-sections. In this embodiment, circular cross-section plastic tubes 31 are preferred, as they are easy to manufacture and assemble.

[0034] To further optimize performance and cost, the plastic tube 31 adopts a double-layer composite structure. Specifically, it includes a PP (polypropylene) inner tube 311 and a POE (polyolefin elastomer) outer tube 312. The PP inner tube 311, as the main structure, provides the main rigidity and shape retention of the plastic tube, while PP material itself has low density and high cost-effectiveness. The POE outer tube 312 covers the outer periphery of the PP inner tube 311, and its wall thickness is strictly controlled to be less than 15% of the total wall thickness of the plastic tube 31. Specifically, the wall thickness of the POE outer tube 312 accounts for 10% of the total wall thickness of the plastic tube 31. Specifically, the inner diameter of the plastic tube 31 is 8mm, the total wall thickness is 3mm, and the wall thickness of its POE outer tube 312 is 0.3mm. POE material has excellent low-temperature toughness and hot-melt bonding performance. During the hot pressing process, when the temperature rises above the melting point of the POE outer tube 312, the POE outer tube 312 melts, but the PP inner tube 311, due to its higher melting point, essentially maintains its shape. The molten POE material overflows from the contact interface of adjacent plastic tubes 31 under pressure, forming a weld point. After cooling and solidification, all plastic tubes 31 are firmly bonded together to form a single honeycomb core layer 3. This design ensures dimensional stability during the core layer molding process while achieving reliable internal connections. By controlling the wall thickness, diameter, and arrangement density of the plastic tubes 31, the density of the honeycomb core layer 3 in this embodiment is successfully controlled to no more than 120 kg / m³, specifically, the density of the honeycomb core layer 3 is successfully controlled to 70 kg / m³, achieving extreme lightweighting.

[0035] Please refer to Figures 3 to 4 The most critical improvement of this invention lies in the connecting layer 4. The upper metal skin 1 and the lower metal skin 2 are respectively bonded to the upper and lower end faces of the honeycomb core layer 3 through an independent connecting layer 4. The connecting layer 4 is a composite structure, which includes a non-woven fabric layer 41 near the honeycomb core layer 3 and an adhesive layer 42 near the metal skin.

[0036] The nonwoven fabric layer 41 is the core component for improving interfacial bonding performance. It is made of high-molecular polymer fibers (such as polyester fibers or polypropylene fibers), forming a porous structure. In this embodiment, the porosity of the nonwoven fabric layer 41 is set between 30% and 80%. Preferably, a polyester nonwoven fabric with a porosity of approximately 60% is used. During the hot-pressing composite process, the plastic tube 31 at the top of the honeycomb core layer 3 (especially its POE outer tube 312) softens or even melts under heat. At this time, the molten or softened polymer material flows under pressure and embeds itself into the abundant pores and fiber gaps of the nonwoven fabric layer 41. After cooling and solidification, the fibers of the nonwoven fabric layer 41 and the end face of the plastic tube 31 form a strong "physical interlocking" structure. This bonding method is far superior to simple planar bonding, greatly increasing the contact area and bonding force between the two.

[0037] The adhesive layer 42 is inseparably bonded to the side of the nonwoven fabric layer 41 facing away from the honeycomb core layer 3. Its function is to provide strong adhesion to the metal outer skin. The adhesive layer 42 is a polymer hot melt adhesive that allows for a stable transition between metal and plastic; this hot melt adhesive can be purchased commercially or prepared in-house. The overall thickness of the connecting layer 4 (i.e., the combined thickness of the nonwoven fabric layer 41 and the adhesive layer 42) is controlled between 0.1 mm and 1.0 mm. This thickness range ensures sufficient adhesive for a strong bond while avoiding excessive thickness that could reduce the cohesive strength of the adhesive layer or add unnecessary weight. In a preferred embodiment, the total thickness of the connecting layer 4 is 0.5 mm, with the nonwoven fabric layer approximately 0.3 mm thick and the adhesive layer approximately 0.2 mm thick.

[0038] Please refer to Figures 1 to 6 To manufacture this metal honeycomb panel, the metal outer skin is first cut; the plastic tubes 31 are extruded according to the designed cross-sectional shape and cut to the required length; a non-woven fabric roll with an adhesive layer 42 is prepared as the connecting layer 4. Then, the lower connecting layer 4 (adhesive layer 42 facing down in contact with the metal outer skin), the honeycomb core layer 3 (plastic tubes 31 arranged vertically), the upper connecting layer 4 (non-woven fabric layer 41 facing down in contact with the core layer), and the upper metal outer skin 1 are sequentially laid on the lower metal outer skin 2. Finally, the entire laid structure is sent into a hot press. It is held at the set temperature and pressure for a certain period of time. During this period, the POE outer tubes 312 melt to bond the core layer internally, while the polymer at the end face of the core layer fuses and embeds with the non-woven fabric layer 41, and the adhesive layer 42 also melts and firmly bonds the non-woven fabric layer 41 to the metal outer skin. After holding the pressure and cooling to room temperature, the formed lightweight metal honeycomb panel is removed from the mold.

[0039] The honeycomb panel provided in this embodiment successfully solves the problem of firmly bonding the metal and plastic core layers through a unique connecting layer design, and the product combines the high strength of metal with the lightweight of honeycomb structure.

[0040] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A lightweight metal honeycomb panel, comprising an upper metal skin, a honeycomb core layer, and a lower metal skin, wherein the upper metal skin, the honeycomb core layer, and the lower metal skin are sequentially stacked and bonded together by hot pressing, wherein the honeycomb core layer is formed by assembling and fusing together multiple plastic tubes arranged axially parallel to the thickness direction of the honeycomb core layer; characterized in that, The upper metal skin and the lower metal skin are respectively bonded to the honeycomb core layer through a connecting layer, the connecting layer comprising: A nonwoven fabric layer is disposed on the side facing the honeycomb core layer, and the end faces of the nonwoven fabric layer and the honeycomb core layer are fused together during hot pressing; and An adhesive layer is inseparably bonded to the side of the nonwoven layer opposite to the honeycomb core layer to be suitable for bonding the upper metal skin or the lower metal skin. The nonwoven fabric layer is configured to improve the bonding strength between the metal skin and the honeycomb core layer by increasing the interfacial bonding performance between the honeycomb core layer and the adhesive layer.

2. The metal honeycomb panel according to claim 1, characterized in that, The nonwoven fabric layer has a porous structure with a porosity between 30% and 80%.

3. The metal honeycomb panel according to claim 1 or 2, characterized in that, The nonwoven fabric layer is physically integrated with the end face of the honeycomb core layer during the hot pressing process.

4. The metal honeycomb panel according to claim 1 or 2, characterized in that, The overall thickness of the connecting layer is 0.1mm to 1.0mm.

5. The metal honeycomb panel according to claim 1, characterized in that, The adhesive layer is attached to the nonwoven fabric to form a coated nonwoven fabric.

6. The metal honeycomb panel according to claim 1, characterized in that, The plastic tubes in the honeycomb core layer are round tubes, elliptical tubes, polygonal tubes, or tubes with irregular cross-sections.

7. The metal honeycomb panel according to claim 1 or 6, characterized in that, The plastic tube includes a PP inner tube and a POE outer tube. The POE outer tube melts during the hot pressing process, bonding and fixing adjacent plastic tubes to form a honeycomb core layer.

8. The metal honeycomb panel according to claim 7, characterized in that, The wall thickness of the POE outer tube is less than 15% of the wall thickness of the plastic tube.

9. The metal honeycomb panel according to claim 1, characterized in that, The thickness of both the upper and lower metal skins is 0.2–1.0 mm.

10. The metal honeycomb panel according to claim 1, characterized in that, The density of the honeycomb core layer does not exceed 120 kg / m³.

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