Honeycomb structure

Abstract

In a honeycomb structure having multiple cells composed of partitions with internal spaces, the energy absorption efficiency is improved. [Solution] The honeycomb structure 10 has a double-walled partition wall 16 and comprises a plurality of cells arranged in a honeycomb pattern. The partition wall 16 has a joint portion 16a where two sheet materials are joined to each other and a gap portion 16b where two sheet materials are separated from each other. A portion of the partition wall 16 of each cell 14 is joined to a portion of the partition wall 16 of another cell adjacent in the first direction.

Description

Technical Field

[0001] The present invention relates to a honeycomb structure.

Background Art

[0002] Patent Document 1 discloses a honeycomb structure having a plurality of columnar cells extending in the vertical direction. The partition walls constituting each cell include a pair of double-wall structures arranged opposite to each other and extending in the same direction. A space is formed in a part of each double-wall structure to improve the compressive strength of the entire honeycomb structure.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, the honeycomb structure of Patent Document 1 improves the strength of the entire honeycomb structure by providing the above-mentioned space. On the other hand, the honeycomb structure is formed by bonding corrugated sheets in which ridges and valleys are alternately formed. When pressure is applied to the honeycomb structure from the vertical direction, peeling is likely to occur from the portion where the corrugated sheets are bonded among the substantially hexagonal partition walls constituting the cells. That is, when the honeycomb structure is used as an energy absorption member, there is a concern about a decrease in the energy absorption efficiency of the entire honeycomb structure due to the insufficient bonding strength of this portion.

[0005] An object of the present invention is to improve the energy absorption efficiency in a honeycomb structure having a plurality of cells constituted by partition walls having a space inside.

Means for Solving the Problems

[0006] A honeycomb structure according to one aspect of the present invention has a double-walled partition and comprises a plurality of cells arranged in a honeycomb pattern. The double-walled structure has a joint where two sheet materials are joined to each other and a gap where the two sheet materials are separated from each other. A portion of the partition of each cell is joined to a portion of the partition of another cell adjacent in the first direction. [Effects of the Invention]

[0007] According to the present invention, in a honeycomb structure having multiple cells composed of partitions with internal spaces, the energy absorption efficiency can be improved. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view of a honeycomb structure according to an embodiment. [Figure 2A] Figure 2A is a diagram illustrating the formation of a double-sheet material and cells according to the embodiment. [Figure 2B] Figure 2B is a diagram illustrating the formation of a double sheet material and cells according to the embodiment. [Figure 2C] Figure 2C is a diagram illustrating the formation of a double sheet material and cells according to the embodiment. [Figure 2D] Figure 2D is a diagram illustrating the formation of a double sheet material and cells according to the embodiment. [Figure 3] Figure 3 is a cross-sectional view of a first example of a honeycomb structure according to the embodiment. [Figure 4A] Figure 4A is a cross-sectional view of a second example of a honeycomb structure according to the embodiment. [Figure 4B] Figure 4B is a cross-sectional view of a third example of a honeycomb structure according to the embodiment. [Figure 5] Figure 5 shows an example of a joining method between two cells. [Modes for carrying out the invention]

[0009] The honeycomb structure 10 according to the embodiment will be described below with reference to the drawings. Elements having the same function will be denoted by the same reference numeral, and redundant explanations will be omitted. Also, for the sake of convenience of explanation, mutually orthogonal X direction, Y direction (first direction), and Z direction will be defined.

[0010] As shown in Figures 1 and 2A, the X direction is the ribbon direction of the sheet material 1 (double sheet material 11) and the direction in which the peaks 2 (peaks 12) and valleys 3 (valleys 13) constituting the sheet material 1 (double sheet material 11) are arranged alternately. The Y direction is the tension direction of the sheet material 1 (double sheet material 11), the stacking direction of the sheet material 1 (double sheet material 11), and the direction in which the multiple cells 14 are arranged in a line (see Figure 1). The Z direction is the height direction of the honeycomb structure 10 and the stretching direction of each cell 14.

[0011] Sheet material 1 is a so-called corrugated sheet formed in a wave shape. Sheet material 1 is, for example, a metal foil such as aluminum, a fiber-reinforced plastic (FRP) sheet, or a paper material. The thickness of the sheet material is not particularly limited, but is, for example, about 0.01 mm to 5 mm. FRP is, for example, aramid fiber reinforced plastic (AFRP), carbon fiber reinforced plastic (CFRP), glass fiber reinforced plastic (GFRP), etc. The matrix resin of FRP is, for example, a thermosetting resin such as epoxy resin, polyester resin, vinyl ester resin, or phenolic resin, or a thermoplastic resin such as polypropylene resin, polyamide resin, polycarbonate resin, or polyetherimide resin.

[0012] As shown in Figure 2A, the sheet material 1 has peaks 2 and valleys 3. The peaks 2 and valleys 3 are arranged alternately in the X direction and extend parallel to each other in the Z direction. The peaks 2 protrude to one side in the Y direction relative to the XZ plane. Conversely, the valleys 13 are recessed to the other side in the Y direction relative to the XZ plane.

[0013] The ridge portion 2 has a planar portion (top portion) 6 that extends in the X and Z directions. The valley portion 3 also has a planar portion (bottom portion) 7 that extends in the X and Z directions. The planar portion 6 and the planar portion 7 are connected via the connecting portion 5. As will be described later, the planar portion 6 of the ridge portion 2 functions as the joint surface 20 between two double sheet materials 11 (described later). On the other hand, the planar portion 7 of the valley portion 3 functions as the joint surface for the planar portion 6 of the other sheet material 1.

[0014] On each side of the planar portion 7 in the X direction, an inclined portion 8 is provided. The inclined portion 8 is inclined at an angle smaller than that of the connecting portion 5 with respect to the central plane 4 of the sheet material 1. The inclined portion 8 is located at a position separated from the ridge portion 2 (i.e., the planar portion 6 and the connecting portion 5) of the other sheet material 1 in a state where two sheet materials 1 are overlapped. Thereby, a gap portion 16b described later is formed.

[0015] The honeycomb structure 10 according to the present embodiment is constituted by joining a plurality of double sheet materials 11 to which two sheet materials 1 are joined. FIGS. 2A to 2D are diagrams showing an example of the manufacturing process of the honeycomb structure 10.

[0016] As shown in FIG. 2A, first, two sheet materials 1 having the same cross-sectional shape are prepared. For the sake of convenience of explanation, one of the two sheet materials 1 is denoted by reference numeral 1A, and the other of the two sheet materials 1 is denoted by reference numeral 1B. As shown in FIG. 2A, the sheet material 1B faces the sheet material 1A in a turned-over state.

[0017] Next, the sheet materials 1A and 1B are joined so that the ridge portion 2 of the sheet material 1A and the valley portion 3 of the sheet material 1B overlap. The joining at this time is, for example, welding, adhesion, brazing, or the like. These methods are appropriately selected according to the material of the sheet material 1.

[0018] As shown in FIG. 2B, by joining the sheet materials 1A and 1B to each other, the flat portion 6 of the sheet material 1A is joined to the flat portion 7 of the sheet material 1B, forming a joint portion 16a. Also, the connecting portion 5 of the sheet material 1A is joined to the connecting portion 5 of the sheet material 1B, forming a joint portion 16a. Thereby, a double sheet material 11 functioning as a partition wall 16 of a double-wall structure is formed. The double sheet material 11 has a peak portion 12 and a valley portion 13. The peak portion 12 and the valley portion 13 are alternately arranged in the X direction and extend in the Z direction parallel to each other.

[0019] Note that even after the sheet materials 1A and 1B are joined, the inclined portion 8 of the sheet material 1A is separated from the peak portion 2 of the sheet material 1B. Similarly, the inclined portion 8 of the sheet material 1B is separated from the peak portion 2 of the sheet material 1A. Due to these separations, a gap portion 16b is formed in the double sheet material 11.

[0020] Two double sheet materials 11 are joined to each other in the Y direction. Specifically, as shown in FIG. 2C, in a state where one valley portion 13 of the two double sheet materials 11 faces the other peak portion 12, both are joined. By this joining, a plurality of cells 14 arranged in a honeycomb shape and the partition wall 16 thereof are formed (see FIG. 2D). Further, by repeating the joining of the double sheet materials 11, a plurality of cells 14 are arranged in a honeycomb shape.

[0021] As shown in FIG. 3, each cell 14 forms a space 15 having a polygonal (for example, substantially hexagonal) cross-section when viewed from the Z direction and extends in the Z direction. Two cells 14 adjacent in the Y direction are arranged in the Y direction via their respective partition walls 16.

[0022] Each cell 14 has a partition wall 16 that forms a space 15 inside it. As described above, the partition wall 16 has a double-wall structure by the joining of two sheet materials 1. Each cell 14 includes a pair of wall portions 17, 17 as a part of its partition wall 16. Also, each cell 14 has a pair of wall portions 18, 18 and a pair of wall portions 19, 19 as other parts of the partition wall 16. Each pair of wall portions is arranged to face each other across the space 15 of the cell 14, surrounds the space 15 of the cell 14 as a whole, and forms the cross-section of the polygonal cell 14.

[0023] A pair of wall sections 17, 17 are arranged in the Y direction. A pair of wall sections 18, 18 are arranged in a direction inclined to one side with respect to the Y direction. A pair of wall sections 19, 19 are arranged in a direction inclined to the other side with respect to the Y direction. In one cell 14, one wall section 17-19 of each pair is included in a part of one double sheet material 11 (e.g., a peak section 12). The other wall section 17-19 of each pair is included in a part of another double sheet material 11 (e.g., a valley section 13).

[0024] As shown in Figure 3, the wall portion 17 is formed by joining its cell 14 to another cell 14 adjacent to one or the other side of the cell 14 in the Y direction. That is, the wall portion 17 has a quadruple wall structure formed by joining two double sheet materials 11, 11.

[0025] The double sheet material 11 has a joint portion 16a and a gap portion 16b formed during its formation. The joint portion 16a is the portion of the double sheet material 11 where two sheet materials 1, 1 are joined to each other. On the other hand, the gap portion 16b is a region (part) of the double sheet material 11 formed by the separation of parts of the two sheet materials 1, 1 from each other. In a cross section perpendicular to the Z direction, if each cell 14 has a polygonal cross section, the maximum length Lb of the gap portion 16b is shorter than the length La of one side of the polygon. In this embodiment, the entire area of ​​one side of the polygon is not provided as a gap portion 16b, and a joint portion 16a exists on each side (i.e., wall portions 17 to 19). The inside of the gap portion 16b may be a cavity (space), or it may be filled with resin (not shown) or the like.

[0026] When the double sheet material 11 is formed by two sheet materials 1, 1 as shown in Figure 2A, the gap portion 16b is provided at the corners including the wall portion 17 in the polygonal cross-section formed by the cell 14. Therefore, when the cells 14 are arranged in a honeycomb pattern, as shown in Figure 3, the gap portions 16b are arranged at approximately equal angular intervals around one cell 14.

[0027] The wall section 17 is formed by joining the joint surfaces 20, 20 (see Figure 2C) of the double sheet material 11. The joint surface 20 is the flat portion 6 (see Figure 2A) of the peak portion of the sheet material 1, and it is joined to the other joint surface 20 over its entire length. In addition, in the quadruple wall structure of the wall section 17, in the portion where the joint section 16a is provided, all four sheet materials 1 are joined in the Y direction.

[0028] In a cross-section perpendicular to the Z-direction, the cross-sectional shape formed by the gap 16b is not limited to the triangle shown in Figure 3. For example, as shown in Figure 4A, the cross-sectional shape formed by the gap 16b may be a rectangle such as a trapezoid.

[0029] Furthermore, as shown in Figure 4B, the gap portion 16b may be formed in one of the multiple wall portions 17-19 that is not joined to the partition wall 16 of another cell 14. For example, in the example shown in Figure 4B, the gap portion 16b is provided in both wall portion 18 and wall portion 19, but not in wall portion 17. The cross-sectional shape of the gap portion 16b in a cross section perpendicular to the Z direction may be a circle as shown in Figure 4B, or it may be a rectangle or other polygon.

[0030] The joining of two adjacent cells 14, 14 in the Y direction among a plurality of cells 14 is not limited to welding and bonding with adhesive. For example, as shown in Figure 5, the two cells 14, 14 may be connected to each other by fastening components 30 such as rivets.

[0031] (1) The honeycomb structure 10 according to this embodiment has a double-walled partition wall 16 and comprises a plurality of cells 14 arranged in a honeycomb pattern. The partition wall 16 has a joint portion 16a where two sheet materials 1, 1 are joined to each other, and a gap portion 16b where the two sheet materials 1, 1 are separated from each other. A part of the partition wall 16 of each cell 14 is joined to a part of the partition wall 16 of another cell 14 adjacent in the Y direction.

[0032] When the honeycomb structure 10 is subjected to a relatively large load (pressure) such as an impact from the Z direction, a compressive force that induces buckling is applied to the partition wall 16. The gap portion 16b improves the strength of the partition wall 16 against this compressive force. On the other hand, in the wall portion 17, a force is generated that opens the two sheet materials 1, 1 that are its constituent members to one side and the other side in the Y direction. In other words, a force is generated in the partition wall 16 that separates two adjacent cells 14, 14 in the Y direction. However, in this embodiment, the entire area of ​​the joint surfaces 20, 20 (see Figure 2C) of the double sheet materials 11, 11 is joined to each other. Therefore, compared to the case where a gap is provided in the partition wall of the double wall structure between cells, the joining area between cells 14 can be increased and the joining strength can be increased. Thus, even in a honeycomb structure having multiple cells composed of partition walls with internal spaces, the energy absorption efficiency can be improved.

[0033] (2) In a cross section perpendicular to the Z direction, each cell 14 has a polygonal cross section, and the maximum length Lb of the gap 16b may be shorter than the length La of one side of the polygon. In this case, a joint 16a is provided in the partition wall 16 that constitutes the side. Thus, in a partition wall 16 having at least a double-wall structure, the joint between the sheet materials 1, 1 can be ensured and the strength of the partition wall 16 against compressive force can be improved.

[0034] (3) The partition wall 16 includes a plurality of wall portions 17 to 19 that form a polygonal cross-section, and the joint portion 16a may be formed in each of the plurality of wall portions 17 to 19. In a partition wall 16 having at least a double-wall structure, the joint between the sheet materials 1, 1 can be ensured and the strength of the partition wall 16 against compressive force can be improved.

[0035] (4) Two adjacent cells in the Y direction among the multiple cells 14 may be connected to each other by fastening components. In this case, a higher bonding strength between cells 14, 14 can be obtained than by welding or bonding.

[0036] (5) The gap portion 16b may be provided at the corner of the polygon. In this case, the strength of the corner can be improved and buckling in the straight portion of the cell 14 can be promoted. Also, because the length of the straight portion is shortened due to the presence of the gap portion 16b, buckling at a finer pitch can be more easily generated, and the energy absorption efficiency (amount) can be improved.

[0037] (6) The gap 16b may be formed in one of the multiple wall sections 17-19 that is not joined to the partition wall 16 of another cell 14. The presence of the gap 16b reduces the buckling pitch of that wall section. This increases the degree to which it has an effect on reducing the buckling pitch of the surrounding wall sections. Therefore, the energy absorption efficiency can be improved.

[0038] (7) The two sheet materials may be two corrugated sheets having the same cross-sectional shape and stacked in the first direction. The honeycomb structure according to this embodiment is composed of multiple sheet materials having the same cross-sectional shape for the peaks and valleys. In other words, manufacturing costs can be reduced by using corrugated sheets having this cross-sectional shape. Also, if the cross-sectional shape of a cell needs to be changed, only the replacement of sheet materials having the same cross-sectional shape is required. This also contributes to reducing manufacturing costs.

[0039] The embodiments and modifications described above are merely illustrative examples provided to facilitate understanding of the invention. The technical scope of the invention is not limited to the specific technical matters disclosed in the embodiments and modifications above, but also includes various modifications, changes, and alternative technologies that can be easily derived therefrom. [Explanation of symbols]

[0040] 1 Sheet material 10 Honeycomb structure 11 Double-layered sheet material 12 Yamabe 13 Tanibe 14 cells 16 Bulkhead 16a Joint 16b Gap 17 Wall 18. Wall section 19. Wall section

Claims

1. It has a double-walled partition and is equipped with multiple cells arranged in a honeycomb pattern. The partition wall has a joint where two sheet materials are joined together and a gap where the two sheet materials are separated from each other. A portion of the partition wall of each cell is joined to a portion of the partition wall of another cell adjacent in the first direction. Honeycomb structure.

2. In a cross-section perpendicular to the extension direction of the plurality of cells, each cell has a polygonal cross-section, and the maximum length of the gap is shorter than the length of one side of the polygon. The honeycomb structure according to claim 1.

3. The partition wall includes a plurality of wall portions that form the polygonal cross-section, The joint is formed in each of the plurality of wall portions. The honeycomb structure according to claim 2.

4. Two of the aforementioned plurality of cells that are adjacent in the first direction are connected to each other by fastening components. The honeycomb structure according to claim 1.

5. The gap portion is provided at the corner of the polygon. The honeycomb structure according to claim 3.

6. The gap is formed in the wall portion of the plurality of wall portions that is not joined to the partition wall of the other cell. The honeycomb structure according to claim 3.

7. The two sheet materials are two corrugated sheets having the same cross-sectional shape and stacked in the first direction. A honeycomb structure according to any one of claims 1 to 6.

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