Panel structure and method for manufacturing panel structure

Abstract

To provide a panel structure which has high rigidity and a high degree of freedom of a design, and a method for manufacturing a panel structure.SOLUTION: A panel structure includes: two basic panels which have a base plate, and a pyramid-shaped plate where a plurality of pyramid-shaped parts have shapes as to be connected to each other in a plane direction and are joined to the base plate so that the pyramid-shaped parts project, so that the pyramid-shaped parts face each other; and a wavy member which has wavy parts along the pyramid-shaped parts and is sandwiched between the pyramid-shaped plates of the two basic panels.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a panel structure and a method for manufacturing the panel structure. [Background technology]

[0002] Highly rigid panel structures such as honeycomb panels are used in the bodies of automobiles, trains, aircraft, and other mobility products. Another known example is a panel structure in which a conical plate with square pyramidal portions arranged lengthwise and widthwise is joined to a flat member, with the conical portions facing each other (see, for example, Patent Document 1), but there are few examples of this being put to practical use. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Patent No. 4,495,237 Summary of the Invention [Problem to be solved by the invention]

[0004] In the panel structure as described in Patent Document 1, a configuration with high rigidity and a high degree of freedom in design is required.

[0005] The present disclosure has been made in view of the above, and aims to provide a panel structure that is highly rigid and has a high degree of freedom in design, and a method for manufacturing the panel structure. [Means for solving the problem]

[0006] The panel structure of the present disclosure comprises a base plate, a conical plate having a shape in which a plurality of conical portions are connected in a planar direction and joined to the base plate so that the conical portions protrude, two basic panels arranged with the conical portions facing each other, and a corrugated member having a corrugated portion along the conical portions and sandwiched between the conical plates of the two basic panels.

[0007] A method for manufacturing a panel structure according to the present disclosure includes the steps of: arranging two basic panels, each having a base plate and a conical plate having a shape in which a plurality of conical portions are connected in a planar direction and joined to the base plate so that the conical portions protrude, with the conical portions facing each other; arranging a corrugated member having corrugated portions that follow the conical portions between the two basic panels; and joining the corrugated member to the conical plates of each of the two basic panels so that the corrugated member is sandwiched between the conical plates of each of the two basic panels. [Effects of the Invention]

[0008] According to the present disclosure, it is possible to provide a panel structure having high rigidity and a high degree of freedom in design, and a method for manufacturing the panel structure. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an exploded perspective view showing an example of a panel structure according to the present embodiment. [Figure 2] FIG. 2 is a diagram showing an example of a corrugated member according to this embodiment. [Figure 3A] FIG. 3A is a diagram showing an example of a corrugated member according to this embodiment. [Figure 3B] FIG. 3B is an exploded perspective view showing an example of a corrugated member according to this embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing an example of a panel structure. [Figure 5A] FIG. 5A is an exploded perspective view showing an example of a panel structure. [Figure 5B] FIG. 5B is a cross-sectional view showing an example of a panel structure. [Figure 6A] FIG. 6A is an exploded perspective view showing an example of a panel structure. [Figure 6B] FIG. 6B is a cross-sectional view showing an example of a panel structure. [Figure 7A] FIG. 7A is an exploded perspective view showing an example of a panel structure. [Figure 7B]FIG. 7B is a cross-sectional view showing an example of a panel structure. [Figure 8A] FIG. 8A is an exploded perspective view showing an example of a panel structure. [Figure 8B] FIG. 8B is a cross-sectional view showing an example of a panel structure. [Figure 9] FIG. 9 is a cross-sectional view showing an example of a panel structure. [Figure 10] FIG. 10 is a cross-sectional view showing an example of a panel structure. [Figure 11] FIG. 11 is a cross-sectional view showing an example of a panel structure. [Figure 12] FIG. 12 is a cross-sectional view showing an example of a panel structure. [Figure 13] FIG. 13 is a cross-sectional view showing an example of a panel structure. [Figure 14] FIG. 14 is a cross-sectional view showing an example of a panel structure. [Figure 15] FIG. 15 is a cross-sectional view showing an example of a panel structure. [Figure 16] FIG. 16 is a cross-sectional view showing an example of a panel structure. [Figure 17] FIG. 17 is a cross-sectional view showing an example of a panel structure. [Figure 18] FIG. 18 is a cross-sectional view showing an example of a panel structure. [Figure 19] FIG. 19 is a cross-sectional view showing an example of a panel structure. [Figure 20] FIG. 20 is a cross-sectional view showing an example of a panel structure. [Figure 21] FIG. 21 is a cross-sectional view showing an example of a panel structure. [Figure 22] FIG. 22 is a cross-sectional view showing an example of a panel structure. [Figure 23] FIG. 23 is a cross-sectional view showing an example of a panel structure. [Figure 24] FIG. 24 is a cross-sectional view showing an example of a panel structure. [Figure 25] FIG. 25 is a flowchart showing an example of a method for manufacturing a panel structure. [Figure 26]FIG. 26 is a diagram schematically showing an example of a joining method. [Figure 27] FIG. 27 is a diagram schematically showing an example of a joining method. [Figure 28] FIG. 28 is a diagram schematically illustrating an example of a bonding method. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of a panel structure and a method for manufacturing a panel structure according to the present disclosure will be described with reference to the drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially identical.

[0011] Fig. 1 is an exploded perspective view showing an example of a panel structure 100 according to this embodiment. As shown in Fig. 1, the panel structure 100 includes a basic panel 10 and a corrugated member 20. In Fig. 1, the corrugated member 20 is shown as a corrugated sheet 21, which will be described later. The panel structure 100 has a laminated body 30 in which the corrugated member 20 is sandwiched between two basic panels 10.

[0012] The basic panel 10 has a base plate 11 and a conical plate 12. The base plate 11 is flat. The conical plate 12 has a shape in which multiple conical portions 12a are connected in a planar direction. In this embodiment, the conical portions 12a are square pyramid-shaped. The conical portions 12a are configured with four slopes formed by a plate-shaped member, with chamfered ridges and a bottom surface, and the portion surrounded by these surfaces is hollow. The multiple conical portions 12a are configured with the bases of the quadrangular pyramids connected to each other. In other words, the conical plate 12 is configured with square pyramidal portions 12a connected vertically and horizontally. The multiple conical portions 12a protrude in the same direction.

[0013] The cone-shaped plate 12 is joined to the base plate 11 so that the plurality of cone-shaped portions 12a protrude from the first surface 11a of the base plate 11 in the normal direction of the first surface 11a. Therefore, the basic panel 10 is configured such that the cone-shaped plate 12 is joined to the base plate 11 so that the plurality of cone-shaped portions 12a protrude from the base plate 11. In this embodiment, the base plate 11 is joined to the mesh-like portions 12b (see FIG. 3B) along the boundaries between the plurality of cone-shaped portions 12a of the cone-shaped plate 12. This allows the base plate 11 and the cone-shaped plate 12 to be joined easily and firmly.

[0014] The two basic panels 10 are arranged in a state in which the conical portions 12a of the two basic panels 10 face each other at positions shifted by half a pitch in the first direction D1 and the second direction D2.

[0015] The corrugated member 20 has corrugated portions 20a along the conical portions 12a. Figures 2, 3A, and 3B are views showing an example of the corrugated member 20 according to this embodiment. In this embodiment, at least one of a corrugated plate 21 shown in Figure 2 and a double-sided conical member 22 shown in Figure 3 is used as the corrugated member 20. Note that Figure 3B is an exploded perspective view showing an example of the double-sided conical member 22 according to this embodiment.

[0016] As shown in FIG. 2, the corrugated sheet 21 is a plate-like member formed in a rectangular wave shape. In the corrugated sheet 21, protruding portions on the first surface 21a become recessed portions on the second surface 21b. In addition, in the corrugated sheet 21, recessed portions on the first surface 21a become protruding portions on the second surface 21b. In other words, the corrugated sheet 21 has a wave-like portion 20a formed on both the first surface 21a and the second surface 21b, in which rectangular wave-like recesses and protrusions are repeated in one direction (first direction D1). Note that a second direction D2, which is perpendicular to the first direction D1 in the planar direction, is the direction in which the recesses and protrusions extend.

[0017] As shown in Figures 3A and 3B, the double-sided conical member 22 has a shape in which two conical plates 12 are joined together so that the conical portions 12a protrude in opposite directions. The double-sided conical member 22 is configured by joining two conical plates 12 together so that the bases of the conical portions 12a overlap. In this case, the mesh portions 12b of each conical plate 12 are joined together. The double-sided conical member 22 is configured so that the slopes of the conical portions 12a are arranged in a wavy pattern in the first direction D1 and the second direction D2. Therefore, the double-sided conical member 22 is configured so that wavy portions 20a that follow the conical portions 12a of the conical plates 12 are formed on both sides.

[0018] Examples of the panel structure will be described below. Figures 4 to 23 are diagrams showing examples of the panel structure. Each figure shows a schematic cross section of each component of the panel structure.

[0019] FIG. 4 is a cross-sectional view showing an example of a panel structure 101. The panel structure 101 shown in FIG. 4 has the same configuration as the panel structure 100 described above (see FIG. 1 for an exploded perspective view). The panel structure 101 shown in FIG. 4 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. The corrugated portions 20a on both sides of the corrugated sheet 21 are shaped to conform to the conical portions 12a of the basic panels 10, respectively, and are arranged so that the conical portions 12a are in close contact with the corrugated portions 20a of the corrugated sheets 21 on both sides. By arranging the corrugated sheet 21 in this manner, strength can be increased in the direction in which the recesses or protrusions of the corrugated portions 20a extend, i.e., in the direction perpendicular to the direction in which the recesses and protrusions of the corrugated portions 20a are repeatedly formed. Furthermore, by arranging the corrugated sheet 21, the two basic panels 10 can be easily and accurately positioned relative to each other.

[0020] FIG. 5A is an exploded perspective view showing an example of a panel structure. FIG. 5B is a cross-sectional view showing an example of a panel structure. The panel structure 102 shown in FIGS. 5A and 5B has a configuration in which a double-sided conical member 22 is sandwiched between two basic panels 10. In the panel structure 102, the two basic panels 10 and the double-sided conical member 22 are positioned so that the chamfered portions on the ridge lines of the conical portions 12a on the two basic panels 10 contact the chamfered portions on the ridge lines of the conical portions 12a on the double-sided conical member 22. By arranging the double-sided conical member 22 in this manner, the distance between the two basic panels 10 can be increased compared to the corrugated sheet 21. This allows the panel thickness of the panel structure 102 to be increased.

[0021] FIG. 6A is an exploded perspective view showing an example of a panel structure. FIG. 6B is a cross-sectional view showing an example of a panel structure. The panel structure 103 shown in FIGS. 6A and 6B is configured by sandwiching a plurality of double-sided conical members 22 stacked between two basic panels 10. The two basic panels 10 and the plurality of double-sided conical members 22 are positioned so that the chamfered portions on the ridges of the conical portions 12a are in contact with each other. By stacking a plurality of double-sided conical members 22 in this way, the panel thickness of the panel structure 102 can be increased.

[0022] FIG. 7A is an exploded perspective view showing an example of a panel structure. FIG. 7B is a cross-sectional view showing an example of a panel structure. The panel structure 104 shown in FIGS. 7A and 7B is configured by sandwiching a corrugated sheet 21 and a double-sided conical member 22 between two stacked basic panels 10. The corrugated sheet 21 is disposed between the conical portion 12a of the opposing basic panel 10 and the conical portion 12a of the double-sided conical member 22, and between the conical portions 12a of the opposing double-sided conical members 22. By disposing the corrugated sheet 21 in this manner, the strength can be increased in the direction in which the concave or convex portion of the corrugated portion 20a extends. Furthermore, by disposing the double-sided conical member 22, the panel thickness of the panel structure 102 can be increased. The number of corrugated sheets 21 and the double-sided conical members 22 may be one each, or at least one of them may be two or more.

[0023] FIG. 8A is an exploded perspective view showing an example of a panel structure. FIG. 8B is a cross-sectional view showing an example of a panel structure. The panel structure 105 shown in FIGS. 8A and 8B is configured such that a corrugated sheet 21 and a double-sided conical member 22 are sandwiched between two basic panels 10. In this panel structure 105, a double-sided corrugated member 23, which is formed by joining two corrugated sheets 21, is sandwiched between the opposing conical portions 12a. The double-sided corrugated member 23 is configured such that the convex portions are joined together. By arranging the double-sided corrugated member 23, it is possible to further increase the strength in the direction in which the concave or convex portions extend.

[0024] The panel structure 106 shown in Fig. 9 is configured such that a corrugated sheet 21 and a double-sided conical member 22 are sandwiched between two basic panels 10. In this panel structure 106, the protruding height of the conical portion 12a of the double-sided conical member 22 gradually increases in one direction. With this configuration, the panel thickness of the panel structure 106 can be changed in one direction.

[0025] The panel structure 107 shown in FIG. 10 is configured by sandwiching a corrugated plate 21 and a double-sided conical member 22 between two stacked basic panels 10. In each basic panel 10, the base plate 11 has a curved shape. The base plate 11 may be curved so that the panel thickness is constant (panel structure 107A) or curved so that the panel thickness varies (panel structure 107B). The panel structure 107 may also be configured to have a ring shape in cross section (panel structure 107C). ​​The conical plate 12, the corrugated plate 21, and the double-sided conical member 22 have shapes that conform to the base plate 11. That is, the conical portions 12a of the conical plate 12 and the double-sided conical member 22 are arranged so as to conform to the curved base plate 11. The corrugated plate 21 has wave portions 20a that correspond to the conical portions 12a of the conical plate 12 and the double-sided conical member 22. This configuration allows the panel structure 107 to be used for various purposes depending on its shape.

[0026] The panel structure 108 shown in FIG. 11 is configured such that a corrugated sheet 21 and a double-sided conical member 22 are sandwiched between two basic panels 10. In each basic panel 10, the conical sheet 12, the corrugated sheet 21, and the double-sided conical member 22 have a thickness-changing portion 24 where the thickness varies. For example, in portion A of the panel structure 108, the thickness-changing portion 24 is formed so that the thickness of the conical member 12a of the double-sided conical member 22 gradually increases toward the tip in the protruding direction. In this configuration, the thickness of the conical member 12a is increased toward the bottom, thereby enhancing rigidity. In addition, in portion B of the panel structure 108, the thickness-changing portion 24 is formed so that the thickness of the conical member 12a of the conical sheet 12 gradually decreases toward the tip in the protruding direction. In this configuration, the thickness is increased toward the tip in the protruding direction, thereby enhancing rigidity. Furthermore, the corrugated sheet 21 of the panel structure 108 may have a thickness-varying portion 24 formed so that the thickness of one portion is greater than the other portion in one direction. With this configuration, the rigidity can be appropriately increased in one direction as needed.

[0027] The panel structure 109 shown in Fig. 12 has a configuration in which resin or foamed resin 25 is sandwiched between two basic panels 10. When foamed resin 25 is used, it is possible to reduce weight and improve heat insulation, sound insulation, and shock absorption.

[0028] The panel structure 110 shown in FIG. 13 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 110, the corrugated sheet 21 is formed using an adhesive that can be bonded to the basic panels 10. This configuration significantly simplifies the work of applying the adhesive. Furthermore, by using the corrugated sheet 21 as an adhesive as well, the number of parts can be reduced.

[0029] The panel structure 111 shown in Fig. 14 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 111, an adhesive 25 that can adhere to the basic panel 10 is applied to the surface of the corrugated sheet 21. Specifically, the adhesive 25 is applied to the surface of the corrugated sheet 21 that faces the basic panel 10. With this configuration, there is no need to apply an adhesive separately to the location where the corrugated sheet 21 will be placed between the two basic panels 10.

[0030] The panel structure 112 shown in FIG. 15 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 112, the conical sheet 12 and the corrugated sheet 21 are formed using a composite material 50 in which thermoplastic resin fibers 51 having a lower melting point or glass transition temperature than the base sheet 11 are woven. With this configuration, when joining using the thermoplastic resin fibers 51, a higher temperature is required compared to adhesives such as resin. If, for example, a material with a melting point or glass transition temperature similar to that of the base sheet 11 is used as the thermoplastic resin fibers 51, when the thermoplastic resin fibers 51 are heated to soften, the base sheet 11 also softens and loses its shape. In contrast, in this embodiment, the conical sheet 12 and the corrugated sheet 21 are formed using a composite material 50 in which thermoplastic resin fibers 51 having a lower melting point or glass transition temperature than the base sheet 11 are woven, thereby suppressing softening of the base sheet 11 when the thermoplastic resin fibers 51 are heated.

[0031] The panel structure 113 shown in FIG. 16 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 113, the corrugated sheet 21 is formed using a conductive material. In this configuration, the basic panel 10 and the corrugated sheet 21 are joined together by an adhesive 25 that softens when heated by passing an electric current through the corrugated sheet 21. If heat is applied to the outer surface of the basic panel 10 to soften the adhesive 25, the basic panel 10 also softens and is no longer able to maintain its shape. In this embodiment, by passing an electric current through the corrugated sheet 21 to generate heat, the adhesive 25 can be heated from the inside of the portion sandwiched between the basic panels 10. This makes it possible to prevent the basic panel 10 from softening.

[0032] The panel structure 114 shown in FIG. 17 is configured by connecting a stack 30, each of which sandwiches a corrugated sheet 21 or a corrugated member 20 made of a double-sided conical member 22, between two basic panels 10 in the planar direction D. In this panel structure 114, the stacks 30 are joined at their connecting portions 31 via a splice plate 52. The panel structure 114A is configured such that two basic panels 10 protrude from each other in the connecting direction D, and the stacks 30 are connected by facing the protruding portions. The panel structure 114B is configured such that the panel structures 114A are stacked in the stacking direction, so that the opposing connecting portions 31 of the panel structures 114A are closed. By connecting the stacks 30 in the planar direction D in this way, a large panel structure 114 can be obtained.

[0033] The panel structure 115 shown in FIG. 18 is a laminated body 30 in which a corrugated plate 21 or a corrugated member 20 made of a double-sided conical member 22 is sandwiched between two basic panels 10. The panel structure 115 is in a state in which an end 32 in the planar direction D of the laminated body 30 is deformed so that the inside is closed off from the outside of the laminated body 30. The panel structure 115A is configured by bonding the base plates 11 of two basic panels 10 together at the end 32. The panel structure 115B is configured by bonding the base plates 11 of two basic panels 10 together at the end 32 and then folding them. The panel structure 115C is configured by bonding the base plates 11 of two basic panels 10 together at the end 32 and then folding them back. The panel structure 115D is configured by blocking the end 32 with a blocking member 33. The blocking member 33 may be used in the panel structures 115A, 115B, and 115C. By closing the end 32 of the panel structure 115, it is possible to prevent foreign matter from entering the interior.

[0034] The panel structure 116 (116A, 116B) shown in FIG. 19 is a laminated body 30 in which two basic panels 10 sandwich a corrugated sheet 21 or a corrugated member 20 made of a double-sided conical member 22. In the panel structure 116A shown in FIG. 19, a filler 34 is filled between the two basic panels 10. The panel structure 116A (laminate 30) has a through-hole 35 formed in the stacking direction in the portion filled with the filler 34. By forming the through-hole 35 in the panel structure 116A, the panel structure 116A can be used for a wider range of applications, such as for mounting. Furthermore, since the strength of the hole-formed portion is reduced, reinforcement can be achieved by partially increasing the thickness of the basic panel 10. The panel structure 116B shown in FIG. 19 is configured such that the thickness of the basic panel 10 (e.g., the base plate 11) at predetermined portions 11f and 11g where the through-hole 35 is located is increased compared to other portions. 19B shows a configuration in which the thickness of the base plate 11 is thicker on the inside at a predetermined portion 11f, and a configuration in which the thickness of the base plate 11 is thicker on the outside at a predetermined portion 11g. Note that the thickness of the base plate 11 may be thicker on both the inside and outside. This configuration can reinforce the strength around the through-hole 35.

[0035] The panel structure 117 shown in Fig. 20 is configured as a laminate 30 in which a corrugated member 20 made of a corrugated sheet 21 or a double-sided conical member 22 is sandwiched between two basic panels 10. The panel structure 117 has an insert member 36 disposed at an end in the planar direction D, which is inserted between the two basic panels 10 and covers the end 32. A through hole 37 penetrating the panel structure 117 in the stacking direction may be provided in the portion where the insert member 36 is disposed. With this configuration, the end 32 of the panel structure 117 can be closed and protected by covering the end 32.

[0036] The panel structure 118 shown in FIG. 21 is a laminated body 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided conical member 22 is sandwiched between two basic panels 10. The panel structure 118 has an interface member 38 connected to the end of the laminated body 30 in the planar direction D. The interface member 38 is inserted between the two basic panels 10. In the panel structure 118A, the interface member 38A has through-holes 39 that penetrate the panel in a direction perpendicular to the paper surface in a cross-sectional view, and any number of through-holes may be provided in any direction. By inserting a rod-shaped member or fastener (not shown) into the through-holes 39, the panel structure 118A can be fixed to other members or rotated or turned. In the panel structure 118B, the interface member 38B connects the laminated bodies 30 together in the planar direction D. The interface member 38B has through-holes 40 that run along the planar direction D, and any number of through-holes may be provided in any direction. Panel structure 118B can be fixed to another member or can be rotated or turned by inserting a rod-shaped member or fastening member (not shown) into through-hole 40. In this way, by providing interface member 38, the range of uses of panel structure 118 can be expanded.

[0037] The panel structure 119 shown in Figure 22 is a laminated body 30 configured with two basic panels 10 sandwiching a double-sided conical member 22. In the panel structure 119, an interface member 41 is connected to the end of the laminated body 30 in the planar direction D. The interface member 41 is inserted and joined so as to partially replace the double-sided conical member. This configuration allows the interface member 41 to be firmly attached. The interface member 41 may be provided with a through hole 41a similar to the through hole 39 described above.

[0038] The panel structure 120 shown in FIG. 23 is a laminated body 30 in which a corrugated sheet 21 or a corrugated member 20 (double-sided conical member 22) is sandwiched between two basic panels 10. The panel structure 120 has a communication portion 42 that communicates the space sandwiched between the base plates 11 in the planar direction. In the panel structure 120A, the communication portion 42A is formed by removing a portion of the double-sided conical member in the communication direction. In the panel structure 120B, the communication portion 42B is formed by disposing a tubular portion 43 in the communication portion 42A of the panel structure 120A. In a plan view, the communication portion 42 and the tubular portion 43 may be arranged in a linear direction or in a curved or bent direction. The communication portion 42 and the tubular portion 43 allow piping, wiring, liquids, and gases to pass through the interior of the panel structure 120. This broadens the range of uses of the panel structure 120.

[0039] The panel structure 121 shown in FIG. 24 is configured as a laminated body 30 in which a corrugated plate 21 or a corrugated member 20 made of a double-sided conical member 22 is sandwiched between two basic panels 10. The panel structure 121 has a communication portion 44 that connects the inside and outside of the laminated body 30. The communication portion 44 is provided, for example, by penetrating a part of the base plate 11 or a part of the conical plate 12, and also connects with an internal communication portion. The provision of the communication portion 44 makes it possible to pass piping, wiring, liquids, and gases between the inside and outside of the panel structure 121. This allows the panel structure 121 to have a wider range of uses.

[0040] Next, a method for manufacturing the panel structure 100 configured as described above will be described. Fig. 25 is a flowchart showing an example of a method for manufacturing the panel structure 100. As shown in Fig. 25, the method for manufacturing the panel structure 100 includes a basic panel arrangement step S10, a corrugated member arrangement step S20, and a joining step S30.

[0041] In the basic panel arrangement step S10, two basic panels 10 are arranged with the conical portions 12a facing each other.

[0042] In the wave-shaped member arrangement step S20, a double-sided conical member 22 is arranged between two base panels 10.

[0043] In the joining step S30, the double-sided conical member 22 is joined to the conical plates 12 of the two basic panels 10 so that the double-sided conical member 22 is sandwiched between the conical plates 12 of the two basic panels 10.

[0044] Fig. 26 is a diagram schematically illustrating an example of the bonding process. As shown in Fig. 26, in the bonding process S30, vibrations are generated between the two basic panels 10 by a vibration generator 60, thereby generating heat at the bonding surface. The base material is softened by the heat, and the two basic panels 10 can be bonded by applying pressure to them in the softened state. This process makes it possible to selectively heat the interiors of the two basic panels 10, thereby suppressing softening of the basic panels 10. The vibrations include ultrasonic vibrations.

[0045] In the bonding step S30, the two basic panels 10 may be heated by a separate heat source so as not to reach their melting points or glass transition temperatures, and vibrations may be generated between the two basic panels 10 by the vibration generator 60. By heating the two basic panels 10 so as not to reach their melting points or glass transition temperatures, softening of the basic panels 10 can be suppressed, and the amount of heat generated by the vibration generator 60 can also be reduced.

[0046] Fig. 27 is a diagram schematically illustrating an example of the joining step. As shown in Fig. 27, in the joining step S30, two basic panels 10 are heated by a high-frequency induction heating device 70. The base material is softened by the heating, and the two basic panels 10 can be joined by applying pressure to them in the softened state.

[0047] In the bonding step S30, the two basic panels 10 may be heated in a state where they are heated so as not to reach their melting points or glass transition temperatures, and then the two basic panels 10 may be heated by the high-frequency induction heating device 70. By heating the two basic panels 10 so as not to reach their melting points or glass transition temperatures, softening of the basic panels can be suppressed and the amount of heat applied by the high-frequency induction heating device 70 can also be reduced.

[0048] FIG. 28 is a diagram schematically illustrating an example of the bonding process. As shown in FIG. 28, in the bonding process S30, the bonding surfaces are heated by a heating device 80 having a heating surface 81 corresponding to the shape of the bonding surfaces of the basic panel 10 and the corrugated member 20. The heat from the heating softens the base material, and in the softened state, the heating device is removed. The two basic panels 10 are pressed together, thereby bonding the corrugated member 20 and the two basic panels 10. Since the bonding surfaces have unevenness, the shape of the heating device 80 can be adapted to the bonding surfaces to enable efficient and uniform heating. Various devices can be used as the heating device 80, such as a hot plate, an infrared irradiation device, a far-infrared irradiation device, or a laser irradiation device.

[0049] As described above, according to the first aspect of the present disclosure, a panel structure is provided which comprises a base plate 11, a conical plate 12 having a shape in which a plurality of conical portions 12a are connected in a planar direction D and joined to the base plate 11 so that the conical portions 12a protrude, two basic panels 10 arranged with the conical portions 12a facing each other, and a corrugated member 20 having a corrugated portion 20a along the conical portions 12a and sandwiched between the conical plates 12 of the two basic panels 10.

[0050] With this configuration, the corrugated member 20 is sandwiched between the conical plates 12 of the two basic panels 10, ensuring rigidity with the corrugated member 20 and allowing the thickness of the panel structure to be freely set. This makes it possible to provide a panel structure that is highly rigid and offers a high degree of freedom in design.

[0051] According to the second aspect of the present disclosure, in the panel structure relating to the first aspect, the corrugated member 20 is at least one of a corrugated plate 21 having a corrugated portion 20a, and a double-sided conical member 22 having a shape in which two conical plates 12 are joined so that the conical portions 12a protrude in opposite directions.

[0052] According to this configuration, by providing the corrugated plate 21 as the corrugated member 20, it is possible to ensure rigidity in the direction perpendicular to the direction in which the corrugated portion 20a is formed, i.e., in the direction in which the recesses and protrusions that make up the corrugated portion 20a extend. In addition, by providing the double-sided conical member 22 as the corrugated member 20, it is possible to widen the gap between the two basic panels 10.

[0053] According to a third aspect of the present disclosure, in the panel structure according to the second aspect, a plurality of corrugated members 20 are arranged in a stacked state.

[0054] According to this configuration, the distance between the two basic panels 10 can be set with a high degree of freedom.

[0055] According to a fourth aspect of the present disclosure, in the panel structure according to the second aspect, the double-sided conical member 22 is formed so that the protruding height of the conical portion 12a gradually increases in one direction.

[0056] This configuration makes it possible to form a panel structure in which the panel thickness gradually increases in one direction.

[0057] According to the fifth aspect of the present disclosure, in a panel structure relating to any of the first to third aspects, each base plate 11 has a curved shape, and the conical plate 12 and the corrugated member 20 have a shape that follows the base plate 11.

[0058] According to this configuration, a curved panel structure can be formed, which widens the range of uses for the panel structure.

[0059] According to a sixth aspect of the present disclosure, in the panel structure according to any one of the first to fifth aspects, the conical plate 12 and the corrugated member 20 have a thickness varying portion 24 where the plate thickness varies.

[0060] According to this configuration, the provision of the thickness-changing portion 24 can increase the strength of a portion of the interior of the panel structure.

[0061] According to the seventh aspect of the present disclosure, in a panel structure relating to any of the first to sixth aspects, the base plate 11 is joined to a mesh-like portion along the boundary between multiple conical portions 12a of the conical plate 12.

[0062] According to this configuration, the base plate 11 and the conical plate 12 can be firmly joined together.

[0063] According to the eighth aspect of the present disclosure, in the panel structure according to the second aspect, the double-sided conical member 22 is formed by joining mesh-like portions along the boundaries between the plurality of conical portions 12a of the conical plate 12 together.

[0064] This configuration makes it possible to obtain a double-sided conical member 22 having high strength.

[0065] According to a ninth aspect of the present disclosure, in the panel structure according to any one of the first to eighth aspects, a resin or a foamed resin is filled between the basic panel 10 and the corrugated member 20.

[0066] This configuration allows the base panel 10 and the corrugated member 20 to be firmly joined together.

[0067] According to a tenth aspect of the present disclosure, in the panel structure according to any one of the first to ninth aspects, the corrugated member 20 is formed using an adhesive 25 that can be bonded to the basic panel 10 .

[0068] According to this configuration, the corrugated member 20 itself is made of the adhesive material 25, so that the number of parts can be reduced.

[0069] According to an eleventh aspect of the present disclosure, in the panel structure according to any one of the first to tenth aspects, the corrugated member 20 has an adhesive 25 applied to the surface facing the base panel 10.

[0070] According to this configuration, there is no need to separately apply adhesive 25, and therefore the number of manufacturing steps for the panel structure can be reduced.

[0071] According to the twelfth aspect of the present disclosure, in a panel structure relating to any of the first to eleventh aspects, at least one of the conical plate 12 and the corrugated member 20 is formed using a composite material 50 woven with thermoplastic resin fibers 51 having a melting point or glass transition temperature lower than that of the base plate 11.

[0072] According to this configuration, there is no need to separately apply adhesive 25, and therefore the number of manufacturing steps for the panel structure can be reduced.

[0073] According to the thirteenth aspect of the present disclosure, in a panel structure relating to any of the first to twelfth aspects, the corrugated member 20 is formed using a conductive material, and when an electric current is passed through the corrugated member 20, the heat generated softens the resin of the base material, thereby joining the basic panel 10 and the corrugated member 20.

[0074] According to this configuration, the base material between the basic panels 10 can be heated from the inside, so there is no need to heat the basic panels 10 from the outer surface, and thermal deformation of the basic panels 10 can be prevented.

[0075] According to the 14th aspect of the present disclosure, in a panel structure relating to any of the 1st to 13th aspects, a laminate 30 having a corrugated member 20 sandwiched between two basic panels 10 is connected in the planar direction D, and the connecting portion of the laminate 30 is joined via a splice plate 52.

[0076] According to this configuration, by connecting the laminates 30 together in the planar direction, the dimension of the panel structure in the planar direction D can be increased.

[0077] According to the 15th aspect of the present disclosure, in a panel structure relating to any of the 1st to 14th aspects, the end 32 in the planar direction D of the laminate 30, in which the corrugated member 20 is sandwiched between two basic panels 10, is deformed so that the inside is closed off from the outside of the laminate 30.

[0078] According to this configuration, by closing the end portion of the laminate 30 in the planar direction D, it is possible to prevent foreign matter from entering through the end portion 32.

[0079] According to the 16th aspect of the present disclosure, in a panel structure relating to any of the 1st to 15th aspects, in a laminate 30 in which two basic panels 10 sandwich a corrugated member 20, a filler 34 is filled between the two basic panels 10, and a through hole 35 penetrating the laminate 30 in the stacking direction is formed in the portion filled with the filler 34.

[0080] According to this configuration, by forming through holes 35 in the portion of panel structure 116 filled with filler 34, the range of uses such as mounting of panel structure 116 is expanded.

[0081] According to the 17th aspect of the present disclosure, in a panel structure relating to any of the first to sixteenth aspects, in a laminate 30 in which two basic panels 10 sandwich a corrugated member 20, an insertion member 36 is arranged at the end in the planar direction D, inserted between the two basic panels 10 and covering the end.

[0082] According to this configuration, the end portion 32 of the panel structure 117 can be closed, and the end portion 32 can be protected by being covered.

[0083] According to the 18th aspect of the present disclosure, in a panel structure relating to any of the 1st to 17th aspects, an interface member 38 is connected to the end in the planar direction D of the laminate 30, which has a corrugated member 20 sandwiched between two basic panels 10.

[0084] According to this configuration, by providing the interface member 38, the range of uses of the panel structure 118 can be expanded.

[0085] According to the 19th aspect of the present disclosure, in a panel structure relating to any of the 1st to 18th aspects, the interface member 38 is inserted and joined between the conical portions 12a of the opposing conical plates 12 so as to partially replace the double-sided conical member.

[0086] According to this configuration, the interface member 41 can be attached firmly.

[0087] According to the 20th aspect of the present disclosure, in a panel structure relating to any of the first to 19th aspects, a laminate 30 in which a corrugated member 20 is sandwiched between two basic panels 10 has a communication portion 42 that connects the space sandwiched between the base plates 11 in the planar direction D.

[0088] This configuration allows piping, wiring, liquids, and gases to pass through the interior of panel structure 120. This allows panel structure 120 to be used in a wider range of applications.

[0089] According to the 21st aspect of the present disclosure, in a panel structure relating to any of the 1st to 20th aspects, a laminate 30 having a corrugated member 20 sandwiched between two basic panels 10 has a communication portion 44 that connects the inside and outside of the laminate 30.

[0090] This configuration allows piping, wiring, liquids, and gases to pass between the inside and outside of panel structure 121. This allows panel structure 121 to be used in a wider range of applications.

[0091] According to a 22nd aspect of the present disclosure, there is provided a method for manufacturing a panel structure, including the steps of: arranging two basic panels 10, each having a base plate 11 and a conical plate 12 having a shape in which a plurality of conical portions 12a are connected in a planar direction D and joined to the base plate 11 so that the conical portions 12a protrude, with the conical portions 12a facing each other; arranging a corrugated member 20 having corrugated portions 20a along the conical portions 12a between the two basic panels 10; and joining the corrugated member 20 to each of the conical plates 12 of the two basic panels 10 so that the corrugated member 20 is sandwiched between the conical plates 12 of each of the two basic panels 10.

[0092] This configuration allows efficient manufacturing of a panel structure that is highly rigid and has a high degree of freedom in design.

[0093] According to the 23rd aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 22nd aspect, vibrations are generated between two basic panels 10 by a vibration generating device 60, thereby generating heat at the joining surface, which softens the base material, and the two basic panels 10 are joined by applying pressure to them in the softened state.

[0094] According to this configuration, the insides of the two basic panels 10 can be selectively heated, and therefore softening of the basic panels 10 can be suppressed.

[0095] According to the 24th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 23rd aspect, vibrations are generated between the two basic panels 10 by a vibration generating device 60 while the two basic panels 10 are heated so that the base material does not reach its melting point or glass transition temperature.

[0096] According to this configuration, by heating the two basic panels 10 so that they do not reach their melting point or glass transition temperature, softening of the basic panels 10 can be suppressed and at the same time the amount of heat generated by the vibration generating device 60 can be suppressed.

[0097] According to the 25th aspect of the present disclosure, in the manufacturing method of the panel structure related to the 22nd aspect, the base material is softened by heating using a high-frequency induction heating device 70, and in the softened state, two basic panels 10 are joined by applying pressure.

[0098] According to this configuration, the insides of the two basic panels 10 can be selectively heated, and therefore softening of the basic panels 10 can be suppressed.

[0099] According to the 26th aspect of the present disclosure, in the manufacturing method of the panel structure related to the 25th aspect, the two basic panels 10 are heated in a state where the base material does not reach its melting point or glass transition temperature, and then heated using a high-frequency induction heating device 70.

[0100] According to this configuration, by heating the two basic panels 10 so that they do not reach their melting point or glass transition temperature, softening of the basic panels 10 can be suppressed and the amount of heat applied by the high-frequency induction heating device 70 can be reduced.

[0101] According to the 27th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 22nd aspect, the joining surface is heated by a heating device 80 having a heating surface 81 corresponding to the shape of the joining surface between the basic panel 10 and the corrugated member 20, the heat from the heating softens the base material, and the two basic panels 10 are joined by applying pressure to the softened base material.

[0102] According to this configuration, the shape of the heating device 80 is adapted to the joining surface having the uneven portions, so that heating can be performed efficiently and uniformly.

[0103] The technical scope of the present invention is not limited to the above-described embodiment, and appropriate modifications can be made without departing from the spirit of the present invention. For example, in the above-described embodiment, the base plate 11, the conical plate 12, and the corrugated member 20 can be formed using various materials such as thermoplastic resin, thermosetting resin, metal, and composite material.

[0104] In the above embodiment, the base plate 11, the conical plate 12, and the corrugated member 20 can be joined together by adhesion, welding, or the like.

[0105] In the above embodiment, the thickness of the base plate 11 can be set appropriately depending on the application, location, and the like.

[0106] In the above embodiment, the conical plate 12 or the double-sided conical member 22 may have a flat portion between adjacent conical portions 12a. Similarly, the corrugated plate 21 may have a flat portion between adjacent concave-convex portions.

[0107] In the above embodiment, the tip of the conical plate 12 or the double-sided conical member 22 in the protruding direction or the ridge of the conical portion 12a may be chamfered. Similarly, the tip of the corrugated plate 21 in the protruding direction may be chamfered.

[0108] In the above embodiment, the pyramidal portion 12a is not limited to a quadrangular pyramid, but may be any other polygonal pyramid. The pyramidal portion 12a may also be frustum-shaped. [Explanation of symbols]

[0109] 10 Basic Panel 11 Base plate 11a,21a 1st page 12 conical plate 12a Cone 20 Corrugated member 20a wavy part 21 Corrugated sheet 21b 2nd side 22 Conical member 23 Surface corrugated plate member 24 Plate thickness change area 25 Adhesive 30 laminate 31 Connecting part 32 End 33 Closure member 34 Filling material 35, 37, 39, 40, 41a Through holes 36 Insertion member 38, 38A, 38B, 41 Interface member 42,42A,42B,44 Communication part 43 Tubular part 50 Composites 51 Thermoplastic resin fibers 52 Splice Plate 60 Vibration Generator 70 High frequency induction heating device 80 Heating device 81 Heating surface 100,101,102,103,104,105,106,107,108,109,110,111,112,113,114,114A,114B,115,115A,115B,115C,115D,116,117,118,118A,118B,119,120,120A,120B,121 Panel structure D Plane direction, connection direction S10 Basic panel placement process S20 Wave-shaped member placement process S30 Joining process

Claims

1. two basic panels each having a base plate and a conical plate having a shape in which a plurality of conical portions are connected in a planar direction and joined to the base plate so that the conical portions protrude, the two basic panels being arranged with the conical portions facing each other; a corrugated member having a corrugated portion along the conical portion and sandwiched between the conical plates of the two basic panels; A panel structure comprising:

2. The corrugated member is at least one of a corrugated plate having the corrugated portions and a double-sided conical member formed by joining two conical plates so that the conical portions protrude in opposite directions. The panel structure according to claim 1 .

3. The corrugated members are arranged in a stacked state. The panel structure according to claim 2 .

4. The double-sided conical member is formed so that the protruding height of the conical portion gradually increases in one direction. The panel structure according to claim 2 .

5. Each of the base plates has a curved shape; The conical plate and the corrugated member have shapes that conform to the base plate. The panel structure according to claim 1 .

6. The tapered plate and the corrugated member have a thickness varying portion where the plate thickness varies. The panel structure according to claim 1 .

7. The base plate is joined to a mesh portion of the cone-shaped plate along the boundary between the plurality of cone-shaped portions. The panel structure according to claim 1 .

8. The double-sided conical member is formed by joining mesh-like portions along the boundaries between the plurality of conical portions of the conical plate. The panel structure according to claim 2 .

9. Between the basic panel and the corrugated member, a resin or foam resin is formed. The panel structure according to claim 1 .

10. The corrugated member is formed using an adhesive that can be bonded to the basic panel. The panel structure according to claim 1 .

11. The corrugated member has an adhesive applied to the surface facing the base panel. The panel structure according to claim 1 .

12. At least one of the conical plate and the corrugated member is formed using a composite material in which thermoplastic resin fibers having a melting point or glass transition temperature lower than that of the base plate are woven. The panel structure according to claim 1 .

13. the corrugated member is formed using a conductive material, When an electric current is passed through the corrugated member, the base material is softened by heat generated, thereby bonding the basic panel and the corrugated member together. The panel structure according to claim 1 .

14. a laminate in which the corrugated member is sandwiched between two of the basic panels is connected in a planar direction; The connecting portions of the laminate are joined via a splice plate. The panel structure according to claim 1 .

15. The planar end of the laminate in which the corrugated member is sandwiched between the two basic panels is deformed so that the inside of the laminate is closed off from the outside. The panel structure according to claim 1 .

16. In a laminate in which the corrugated member is sandwiched between two of the basic panels, a filler is filled between the two basic panels, The laminate has a through hole formed in the portion filled with the filler, the through hole penetrating the laminate in the stacking direction. The panel structure according to claim 1 .

17. In a laminate in which the corrugated member is sandwiched between two of the basic panels, an insert member is disposed at an end in a planar direction, the insert member being inserted between the two basic panels to cover the end. The panel structure according to claim 1 .

18. An interface member is connected to the end of the laminate in the planar direction, in which the corrugated member is sandwiched between the two basic panels. The panel structure according to claim 1 .

19. The interface member is inserted between the cone-shaped portions of the opposing cone-shaped plates and joined so as to partially replace the double-sided cone-shaped member.

20. The panel structure of claim 18.

20. The laminated body in which the corrugated member is sandwiched between the two basic panels has a communication portion that communicates the space sandwiched between the base plates in the planar direction. The panel structure according to claim 1 .

21. The laminated body, in which the corrugated member is sandwiched between the two basic panels, has a communication portion that communicates the inside and outside of the laminated body. The panel structure according to claim 1 .

22. a step of arranging two basic panels each having a base plate and a cone-shaped plate having a shape in which a plurality of cone-shaped portions are connected in a planar direction and joined to the base plate so that the cone-shaped portions protrude, with the cone-shaped portions facing each other; disposing a corrugated member having a corrugated portion along the cone-shaped portion between two of the basic panels; a step of joining the corrugated member and the conical plates of the two basic panels so that the corrugated member is sandwiched between the conical plates of the two basic panels; A method for manufacturing a panel structure comprising:

23. Heat is generated by generating vibrations between the two basic panels using a vibration generator, which softens the base material, and the two basic panels are joined by applying pressure to the softened base material. A method for manufacturing the panel structure according to claim 22.

24. The vibration is generated between the two basic panels by a vibration generator while the two basic panels are heated so that the base material does not reach the melting point or glass transition temperature. A method for manufacturing the panel structure according to claim 23.

25. The base material is softened by heating it with a high-frequency induction heating device, and in the softened state, the two basic panels are pressed together to be joined. A method for manufacturing the panel structure according to claim 22.

26. The two basic panels are heated in a state where the base material does not reach its melting point or glass transition temperature, and are then heated using a high-frequency induction heating device. A method for manufacturing the panel structure according to claim 25.

27. The joining surfaces are heated by a heating device having a heating surface corresponding to the shape of the joining surfaces of the basic panel and the corrugated member, the base material is softened by the heat generated by the heating, and the two basic panels are joined by applying pressure to the softened base material. A method for manufacturing the panel structure according to claim 22.

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