Method for manufacturing hexagonal tube continuous body

Abstract

To provide a method for manufacturing a hexagonal tube continuous body capable of contributing to simplification of processing work.SOLUTION: A method for manufacturing a hexagonal tube continuous body comprises defining in a sheet material: a valley region sandwiched between a pair of first fold lines 52, and a peak region disposed between the valley regions and sandwiched between a pair of second fold lines 54; a first notches extending from the valley region to the adjacent valley region while maintaining a peak fold hinge 56 in the valley region; and a second notches alternately positioned with the first notches in a direction of a line of action of the force and extending from the peak region to the adjacent peak region while maintaining a valley fold hinge 58 in the peak region. A distance between the first notch and the second notch is set to be larger than a distance between the valley region and the peak region at a ratio set according to the rigidity of the valley fold hinge 58 and the peak fold hinge 56. Applying a pulling force to the sheet material 51 causes mountain folds at the mountain fold hinges 56 and valley folds at the valley fold hinge 58.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a continuous hexagonal tube. [Background technology]

[0002] Patent Document 1 discloses a method for manufacturing a honeycomb structure (a continuous hexagonal cylinder). In this manufacturing method, a sheet material is formed with valley regions defined by folding along a pair of parallel valley fold lines, and with peak regions defined by folding along a pair of mountain fold lines parallel to the valley fold lines, disposed between the valley regions. The sheet material is processed into a corrugated shape according to the folding along the mountain fold lines and valley fold lines. The corrugated sheet material is alternately arranged at equal intervals with first incisions extending from a valley region to an adjacent valley region in a direction perpendicular to the valley fold lines while maintaining mountain fold hinges in the valley regions, and second incisions extending from a peak region to an adjacent peak region in a direction perpendicular to the mountain fold lines while maintaining valley fold hinges in the peak regions.

[0003] In the processed corrugated sheet material, the mountain fold hinges are folded in mountain folds. The mountain regions are separated at the first cut. The valley fold hinges are folded in valley folds. The valley regions are separated at the second cut. As the mountain fold hinges are folded, the valley regions overlap. Individual hexagonal tubes are formed. As the valley fold hinges are folded, the mountain regions overlap. The hexagonal tubes form a continuous body. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 56-150534 [Patent Document 2] Patent No. 6548074 Summary of the Invention [Problem to be solved by the invention]

[0005] When establishing the waveform, the valley and peak regions are pressed against a mold. High precision positioning is required when pressing. When creating the peak folds of a mountain fold hinge or the valley folds of a valley fold hinge, the valley and peak regions are pressed against a mold. Again, high precision positioning is required when pressing. Establishing the waveform and the peak and valley folds requires complex work. Different molds and processing machines are required for each specification.

[0006] An object of the present invention is to provide a method for manufacturing a continuous hexagonal tube that can contribute to simplifying the processing work. [Means for solving the problem]

[0007] A method for manufacturing a continuous hexagonal tube according to one embodiment of the present invention includes forming, on a sheet material, valley regions sandwiched between a pair of first fold lines parallel to a line of action of a force, peak regions disposed between the valley regions and sandwiched between a pair of second fold lines parallel to the line of action, first notches extending from the valley regions to the adjacent valley regions in a direction transverse to the line of action while maintaining a peak fold hinge in the valley region, and first notches alternately set with the first notches in the linear direction of the line of action and extending from the peak regions to the adjacent peak regions in a direction transverse to the line of action while maintaining a valley fold hinge in the peak region. the step of applying a compressive force parallel to the line of action to the sheet material to overlap the valley regions according to the mountain folds of the mountain fold hinges and overlap the mountain regions according to the valley folds of the valley fold hinges. [Effects of the Invention]

[0008] As described above, according to the disclosed embodiments, a method for manufacturing a continuous hexagonal tube can be provided that can contribute to simplifying processing operations. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view showing a schematic structure of a continuous hexagonal tube according to an embodiment of the present invention; [Figure 2] FIG. 2 is an enlarged perspective view schematically illustrating the structure of one hexagonal tube. [Figure 3] FIG. 1 is a plan view of a sheet material used in manufacturing a continuous hexagonal cylinder. [Figure 4] 1A and 1B are schematic diagrams illustrating how a tensile force acts on a sheet material. [Figure 5] FIG. 10 is a schematic diagram illustrating mountain folds at the second fold lines and valley folds at the first fold lines established by a tensile force. [Figure 6] FIG. 10 is a schematic diagram illustrating the mountain folds of a mountain fold hinge and the valley folds of a valley fold hinge established by a compressive force. [Figure 7] FIG. 7A is a photograph corresponding to a plan view of a sheet material with a ratio r=0.5, and FIG. 7B is a photograph showing deformation when a tensile force is applied to the sheet material with a ratio r=0.5. [Figure 8] FIG. 8A is a photograph corresponding to a plan view of a sheet material with a ratio r=1.0, and FIG. 8B is a photograph showing deformation when a tensile force is applied to the sheet material with a ratio r=1.0. [Figure 9] FIG. 9A is a photograph corresponding to a plan view of a sheet material with a ratio r=1.5, and FIG. 9B is a photograph showing deformation when a tensile force is applied to the sheet material with a ratio r=1.5. [Figure 10] FIG. 10A is a photograph corresponding to a plan view of a sheet material with a ratio r=2.0, and FIG. 10B is a photograph showing deformation when a tensile force is applied to the sheet material with a ratio r=2.0. [Figure 11] 10 is a graph showing the relationship between the ratio r and the proportion of hexagonal tubes that are formed in response to the application of tensile force, based on verification. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0011] FIG. 1 schematically illustrates the structure of a continuous hexagonal tube body 11 according to an embodiment of the present invention. The continuous hexagonal tube body 11 is formed from a single plate material and includes a first half 15 that is continuous with a first stacking plate 13 and a second stacking plate 14 that are overlapped on a reference plane 12 and defines a space that contacts the reference plane 12 between the first stacking plate 13 and the second stacking plate 14, and a second half 18 that is continuous with a third stacking plate 16 and a fourth stacking plate 17 that are overlapped on the reference plane 12 and defines a space that contacts the reference plane 12 between the third stacking plate 16 and the fourth stacking plate 17. The first stacking plate 13 and the third stacking plate 16 are overlapped. The second stacking plate 14 and the fourth stacking plate 17 are overlapped. The first half 15 and the second half 18 form individual hexagonal tubes 21.

[0012] As shown in FIG. 2 , the upper end of the first overlapping plate 13 and the upper end of the third overlapping plate 16 are connected by a first mountain fold hinge 22. The first overlapping plate 13, the first mountain fold hinge 22, and the third overlapping plate 16 are continuous. The first mountain fold hinge 22 regulates the relative displacement of the first overlapping plate 13 and the third overlapping plate 16 about an axis 23. The upper end of the second overlapping plate 14 and the upper end of the fourth overlapping plate 17 are connected by a second mountain fold hinge 24. The second overlapping plate 14, the second mountain fold hinge 24, and the fourth overlapping plate 17 are continuous. The second mountain fold hinge 24 regulates the relative displacement of the second overlapping plate 14 and the fourth overlapping plate 17 about the axis 23. The axis 23 of the first mountain fold hinge 22 and the axis 23 of the second mountain fold hinge 24 are arranged coaxially. The first half 15 and the second half 18 are displaced relative to each other around an axis 23 .

[0013] The first half 15 includes a first side plate 26 connected to the first stacking plate 13 at a first valley fold line 25, a second side plate 28 connected to the first side plate 26 at a first mountain fold line 27, and a third side plate 31 connected to the second side plate 28 at a second mountain fold line 29. The third side plate 31 is connected to the second stacking plate 14 at a second valley fold line 32. The first valley fold line 25, the first mountain fold line 27, the second mountain fold line 29, and the second valley fold line 32 are arranged parallel to one another. The valley fold at the first valley fold line 25, the mountain fold at the first mountain fold line 27, the mountain fold at the second mountain fold line 29, and the valley fold at the second valley fold line 32 form the ridge lines of the hexagonal tube 21.

[0014] The second half 18 includes a fourth side plate 35 connected to the third lap plate 16 at a third valley fold line 34, a fifth side plate 37 connected to the fourth side plate 35 at a third mountain fold line 36, and a sixth side plate 39 connected to the fifth side plate 37 at a fourth mountain fold line 38. The sixth side plate 39 is connected to the fourth lap plate 17 at a fourth valley fold line 41. The third valley fold line 34, the third mountain fold line 36, the fourth mountain fold line 38, and the fourth valley fold line 41 are arranged parallel to one another. The valley fold at the third valley fold line 34, the mountain fold at the third mountain fold line 36, the mountain fold at the fourth mountain fold line 38, and the valley fold at the fourth valley fold line 41 form the ridge lines of the hexagonal tube 21.

[0015] In the continuous hexagonal tube body 11, the hexagonal tubes 21 are arranged in a row in the linear direction of the axis 23. Between adjacent hexagonal tubes 21, the second stacking plate 14 and the fourth stacking plate 17 of one hexagonal tube 21 also serve as the first stacking plate 13 and the third stacking plate 16 of the other hexagonal tube 21. In each hexagonal tube 21, the first half 15 can be displaced relative to the second half 18 around the common axis 23.

[0016] In the continuous hexagonal tube body 11, multiple reference planes 12 are set parallel to each other at predetermined intervals. For each reference plane 12, the hexagonal tubes 21 are aligned in a row in the axial direction of the axis 23. The second side plate 28 of an adjacent hexagonal tube 21 is overlapped with the fifth side plate 37 of one hexagonal tube 21. The lower ends of the overlapping fifth side plate 37 and the second side plate 28 are connected to each other by a valley fold hinge 42. The valley fold hinge 42 regulates the relative displacement of the fifth side plate 37 and the second side plate 28 around the axis 43. When the second side plate 28 is overlapped with the fifth side plate 37, the sixth side plate 39, third overlapping plate 16, and fourth side plate 35 connected to the fifth side plate 37, and the third side plate 31, second overlapping plate 14, and first side plate 26 connected to the second side plate 28 form a single hexagonal tube 44.

[0017] In this embodiment, the second side plate 28 and the fifth side plate 37 are reduced as much as possible in the linear direction of the axis 43. Therefore, the hexagonal tube 21 approximates a square tube (rectangular tube). Because the first stacking plate 13, the second stacking plate 14, the third stacking plate 16, and the fourth stacking plate 17 are reduced as much as possible in the linear direction of the axis 23, the hexagonal tube 44 also approximates a square tube. When the intersection angle between the first side plate 26 and the third side plate 31 in the hexagonal tube 21 is set to 90°, a dihedral corner reflector array (DCRA) can be realized. Similarly, when a dihedral corner reflector array is realized, the intersection angle between the sixth side plate 39 and the fourth side plate 35 in the hexagonal tube 44 can be set to 90°. In addition, when the first side plate 26, the second side plate 28, the third side plate 31, the fourth side plate 35, the fifth side plate 37, and the sixth side plate 39 are set to have the same shape, the hexagonal tube 21 can be formed as a regular hexagonal tube. When the second overlapping plate 14 connecting the fourth side plate 35 to the sixth side plate 39 and the fourth overlapping plate 17 connecting the first side plate 26 to the third side plate 31 are set to have the same shape as the sixth side plate 39, the fourth side plate 35, the third side plate 31, and the first side plate 26, the hexagonal tube 44 can be formed as a regular hexagonal tube.

[0018] Next, a method for manufacturing the continuous hexagonal tube 11 will be described. As shown in FIG. 3, a sheet material 51 is prepared. The sheet material 51 can be formed from a metal material such as aluminum or stainless steel, or a plastic material. The sheet material 51 has material properties that prevent the mountain fold hinges 22, 24 and the valley fold hinges 42 from breaking when the mountain fold hinges 22, 24 and the valley fold hinges 42 are deformed.

[0019] The sheet material 51 is defined with a valley region 53 sandwiched between a pair of first fold lines 52 parallel to the line of action of the force, and a peak region 55 disposed between the valley regions 53 and sandwiched between a pair of second fold lines 54 parallel to the line of action of the force. The first fold line 52 and the second fold line 54 are straight lines. Pre-treatment is performed on the first fold line 52 and the second fold line 54 from one side of the sheet material 51 to relatively weaken their rigidity. As a result of the pre-treatment, for example, perforations are formed in the first fold line 52 and the second fold line 54.

[0020] The sheet material 51 is provided with first notches 57 extending from a valley region 53 to an adjacent valley region 53 in a direction transverse to the line of action while maintaining mountain fold hinges 56 in the valley regions 53, and second notches 59 which are provided alternately with the first notches 57 in the linear direction of the line of action and extend from a peak region 55 to an adjacent peak region 55 in a direction transverse to the line of action while maintaining valley fold hinges 58 in the peak regions 55. The first notches 57 and the second notches 59 are provided on a straight line perpendicular to the first fold line 52 and the second fold line 54. Here, the distance H between the first notches 57 and the second notches 59 is set to be larger than the distance L between the valley regions 53 and the peak regions 55, at a ratio set in accordance with the rigidity of the mountain fold hinges 56 and the valley fold hinges 58.

[0021] As shown in FIG. 4, a tensile force S is applied to sheet material 51 parallel to the line of action of the force. When tensile force S is applied to sheet material 51 parallel to the line of action of the force, tensile force S is transmitted from mountain fold hinge 56 to valley fold hinge 58 and from valley fold hinge 58 to mountain fold hinge 56. When two valley fold hinges 58 that are spaced apart on a common line of action are pulled, a force component that moves them closer to each other acts on the two mountain fold hinges 56 located between them. Because mountain fold hinges 56 are separated by first notch 57, a mountain fold is induced at second fold line 54 in response to the mountain fold of mountain fold hinge 56, as shown in FIG. 5. A preliminary mountain fold is formed in mountain fold hinge 56. When two mountain fold hinges 56 that are spaced apart on a common line of action are pulled, a force component that moves them closer to each other acts on the two valley fold hinges 58 located between them. The valley fold hinges 58 are separated by the second cuts 59, and therefore valley folds are induced at the first fold lines 52 in response to the valley folding of the valley fold hinges 58. A preliminary valley fold is formed at the valley fold hinges 58.

[0022] Thereafter, when a compressive force C is applied to the sheet material 51 parallel to the line of action of the force, the mountain fold hinges 56 bend from the preliminary mountain fold to a further mountain fold, as shown in FIG. 6 . The valley regions 53 connected by the mountain fold hinges 56 overlap each other. Individual hexagonal tubes 21 are formed. The valley regions 53 form the first stacking plate 13 and the third stacking plate 16 connected by the first mountain fold hinge 22, and form the second stacking plate 14 and the fourth stacking plate 17 connected by the second mountain fold hinge 24.

[0023] At the same time, the valley fold hinges 42 fold further from the preliminary valley folds into valley folds. The peak regions 55 connected by the valley fold hinges 58 overlap each other. The hexagonal tubes 21 form a continuum. The hexagonal tubes 44 are formed between the hexagonal tubes 21. The peak regions 55 form the second side panel 28 and the fifth side panel 37, which are connected by the valley fold hinges 42.

[0024] Since the distance H between the first notch 57 and the second notch 59 is set larger than the distance L between the valley region 53 and the peak region 55 at a ratio set according to the rigidity of the mountain fold hinge 56 and the valley fold hinge 58, a valley fold can be formed at the first fold line 52 and a mountain fold can be formed at the second fold line 54 by tensile force alone, instead of pressing against a mold. The formation of a mountain fold at the first fold line 52 can be avoided. The formation of a valley fold at the second fold line 54 can be avoided. The complicated work required for pressing against a mold can be avoided. This manufacturing method can greatly contribute to simplifying the processing work.

[0025] In this embodiment, pre-processing is performed on the first fold line 52 and the second fold line 54 from one side of the sheet material 51 to relatively weaken its rigidity. The pre-processing is performed from one side of the sheet material 51. Therefore, the positional accuracy of the first fold line 52 and the second fold line 54 can be ensured with good accuracy. Alignment of the front and back can be avoided. At this time, perforations are formed on the first fold line 52 and the second fold line 54. The formation of the perforations can effectively weaken the rigidity of the first fold line 52 and the second fold line 54. A valley fold can be effectively achieved at the first fold line 52 in accordance with the tensile force S. A mountain fold can be effectively achieved at the second fold line 54.

[0026] In this embodiment, when compressive force C is applied to sheet material 51, each hexagonal tube 21 can be established solely by the action of compressive force C without being pressed against a mold. On the other hand, the first half 15 and the second half 18 of each hexagonal tube 21 may be pressed against a mold to be molded. The shape of the hexagonal tube 21 can be properly adjusted by pressing it against the mold.

[0027] Additionally, when forming the continuous hexagonal tube body 11, the height of the hexagonal tubes 21, 44 can be set depending on the distance H between the first cut 57 and the second cut 59 made in the sheet material 51. As described above, if the distance H is uniform, the heights of the hexagonal tubes 21, 44 can be made uniform. The shape of the upper end of the hexagonal tube 21 can be set depending on the shape of the first cut 57. As described above, if the first cut 57 is set on a line perpendicular to the first fold line 52 and the second fold line 54, the upper end of the hexagonal tube 21 can be divided by a single horizontal plane. If the first cut 57 is set at an inclination angle with respect to the line perpendicular to the first fold line 52 and the second fold line 54, the upper end of the hexagonal tube 21 can gradually change its position in the height direction. Similarly, the shape of the lower end of the hexagonal tube 21 can be set depending on the shape of the second cut 59. As described above, when the second cuts 59 are set on a straight line perpendicular to the first fold line 52 and the second fold line 54, the bottom of the hexagonal tube 21 can be partitioned by a single horizontal plane. When the second cuts 59 are set at an inclination angle with respect to the straight line perpendicular to the first fold line 52 and the second fold line 54, the bottom of the hexagonal tube 21 can be gradually changed in position in the height direction. When the height distribution of the hexagonal tubes 21 is established in forming the dihedral corner reflector array, a good viewing angle in the height direction can be ensured in the aerial image projection device.

[0028] The inventors tested a manufacturing method for the continuous hexagonal tube 11. For the test, a copper-containing film laminated to polyimide was used as the sheet material 51. A UV laser cutter was used to form the first incisions 57 and the second incisions 59. The UV laser cutter was used to form the first fold lines 52 and the second fold lines 54, creating perforations. Multiple test specimens were prepared. For all test specimens, the distance d between the first fold lines 52 that form the valley regions 53 was set to 0.50 mm. For all test specimens, the distance d between the second fold lines 54 that form the peak regions 55 was set to 0.50 mm. For all test specimens, the distance L between the valley regions 53 and the peak regions 55 was set to 2.5 mm. For each test specimen, the distance H between the first incisions 57 and the second incisions 59 was set to 1.25 mm, 2.0 mm, 2.25 mm, 2.5 mm, 2.75 mm, 3.0 mm, and 5.0 mm, respectively. The ratio r was calculated based on the spacing H / spacing L. A tensile force S was applied to each specimen parallel to the line of force action.

[0029] As shown in Figure 7, when the ratio r = 0.5, the sheet material 51 of Figure 7A was pulled, resulting in alternating valley folds and mountain folds being formed at the first fold line 52, as shown in Figure 7B. Correspondingly, alternating mountain folds and valley folds appeared at the second fold line 54. Figure 7B diagrams the shape of the test specimen.

[0030] As shown in Fig. 8, when ratio r = 1.0, sheet material 51 in Fig. 8A was pulled, resulting in alternating valley folds and mountain folds at first fold line 52, as shown in Fig. 8B. Correspondingly, mountain folds and valley folds alternated at second fold line 54. As shown in Fig. 9, when ratio r = 1.5, sheet material 51 in Fig. 9A was pulled, resulting in a mixture of areas at first fold line 52 where valley folds were maintained and areas where valley folds and mountain folds were alternated, as shown in Fig. 9B. Correspondingly, areas at second fold line 54 where mountain folds were maintained and areas where mountain folds and valley folds were alternated were mixed.

[0031] As shown in Figure 10, when the ratio r = 2.0, sheet material 51 in Figure 10A was pulled, resulting in only valley folds being formed at first fold line 52, as shown in Figure 10B. Correspondingly, only mountain folds appeared at second fold line 54. Figure 10B diagrams the shape of the test specimen.

[0032] As shown in Fig. 11, only the configuration shown in Fig. 7B appeared up to a ratio r of 1.1. It was confirmed that only the configuration shown in Fig. 10B was obtained when the ratio r was 2.0 or greater. Here, it was proven that the distance H between the first notch 57 and the second notch 59 should be set larger than the distance L between the valley region 53 and the peak region 55 when the ratio r was 2.0 or greater, which is set depending on the rigidity of the mountain fold hinge 56 and the valley fold hinge 58. [Explanation of symbols]

[0033] 11 Hexagonal tube continuum 51 Sheet material 52 First fold line 53 Valley area 54 Second fold line 55 Mountain area 56 Mountain fold hinge 57 First cut 58 Valley fold hinge 59 Second cut H (notch) spacing L (area) spacing S Pulling force

Claims

1. A valley region sandwiched between a pair of first fold lines parallel to the line of action of the force in the sheet material; a peak region disposed between the valley regions and sandwiched between a pair of second fold lines parallel to the line of action; and a first notch extending from one valley region to an adjacent valley region transverse to the line of action while maintaining a mountain fold hinge at the valley region; and a second notch that is alternately set with the first notch in the direction of the line of action and extends from one peak region to an adjacent peak region in a direction transverse to the line of action while maintaining a valley fold hinge in the peak region; a distance between the first notch and the second notch being greater than a distance between the valley region and the peak region at a ratio set according to the rigidity of the valley fold hinge and the peak fold hinge; applying a tensile force to the sheet material parallel to the line of action to cause mountain folds at the mountain fold hinges and valley folds at the valley fold hinges; applying a compressive force parallel to the line of action to overlap the valley regions according to the mountain folds of the mountain fold hinges and overlap the peak regions according to the valley folds of the valley fold hinges; A method for manufacturing a continuous hexagonal tube comprising:

2. The first folding line and the second folding line are subjected to pre-treatment from one side of the sheet material to relatively weaken its rigidity. The method for manufacturing the continuous hexagonal tube according to claim 1.

3. Perforations are formed on the first folding line and the second folding line. The method for manufacturing the continuous hexagonal tube according to claim 2.

4. The mountain folds of the mountain fold hinges and the valley folds of the valley fold hinges are caused by the pulling force alone. The method for manufacturing the continuous hexagonal tube according to claim 1.

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