Resin honeycomb molded body, sandwich structure, and method for manufacturing the same

Abstract

To provide a sandwich structure that can increase the bonding strength between a resin honeycomb molded body and a dissimilar material, even when the amount of adhesive used is reduced. [Solution] The sandwich structure of the present invention comprises a resin honeycomb molded body made of a resin material having a plate-like portion having a main surface and partition walls provided in a direction intersecting the main surface and defining a plurality of cylindrical cells, and a plate-like dissimilar material component made of a material different from the resin material, laminated on the resin honeycomb molded body so as to sandwich the partition walls between the plate-like portion and the resin honeycomb molded body, wherein the resin honeycomb molded body has a crimping pin made of a resin material provided so as to extend in a direction intersecting the main surface on the side where the partition walls of the plate-like portion are located, the height of the crimping pin from the main surface is greater than the sum of the height of the partition walls from the main surface and the thickness of the dissimilar material component, the crimping pin penetrates a hole in the dissimilar material component, and the diameter of the penetrating tip is greater than the diameter of the hole.

Description

TECHNICAL FIELD

[0001] The present invention relates to a resin honeycomb molded body, a sandwich structure, and a method for producing the same. BACKGROUND ART

[0002] Conventionally, honeycomb structures have been widely used as shock absorbing components for automobiles, aircraft, and the like, since they can achieve weight reduction while improving mechanical strength.

[0003] For example, the floor surfaces of luggage compartments and trunk rooms in automobiles are required to withstand loads from luggage and the like, and are thus constructed from relatively high-strength floor materials. As this type of floor material, there is known a lightweight board material having a honeycomb sandwich panel structure in which a honeycomb is used as a core material and sandwiched between metal plates or the like.

[0004] Conventional methods for manufacturing honeycomb sandwich panels have required the use of adhesives, particularly in the field of automotive components. For example, the automotive floor board FB disclosed in Patent Document 1 consists of a board material BD in which a plate material 2 is laminated on the surface of a core material 1. The core material 1 is composed of a honeycomb board material with a sheet, which is formed by adhering a sheet material 12 to one side of a honeycomb structure material 11. The plate material 2 is composed of a metal plate or a resin plate, and is bonded to the surface of the sheet material 12 via a hot-melt adhesive film material 3. PRIOR ART DOCUMENTS PATENT DOCUMENTS

[0005] PATENT DOCUMENT 1 International Publication No. 2019 / 064326 SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0006] However, conventional honeycomb sandwich panels, as described above, required the use of a large amount of adhesive to ensure sufficient bonding strength. Using a large amount of adhesive during the manufacturing of honeycomb sandwich panels presented challenges such as increased material costs due to the adhesive and an increase in the mass of the adhesive portion.

[0007] This invention has been proposed in view of the above-mentioned conventional circumstances, and the object of this invention is to provide a resin honeycomb molded body that can increase the bonding strength between dissimilar materials such as metal plates even when the amount of adhesive used is reduced. Another object of this invention is to provide a sandwich structure that can increase the bonding strength between a resin honeycomb molded body and dissimilar materials such as metal plates even when the amount of adhesive used is reduced. Furthermore, another object of this invention is to provide a method for manufacturing a sandwich structure that can increase the bonding strength between a resin honeycomb molded body and dissimilar materials such as metal plates in a simple manner, even when the amount of adhesive used is reduced. [Means for solving the problem]

[0008] The problems described above are addressed by the present invention as follows. [1] A resin honeycomb molded body having a plate-like portion having a main surface, and partition walls extending from the main surface of the plate-like portion in a direction intersecting the main surface, defining a plurality of cylindrical cells, wherein the plate-like portion and the partition walls are made of a resin material, The plate-like portion has a crimping pin made of resin material, which is provided on the side where the partition wall is located so as to extend in a direction intersecting the main surface, A resin honeycomb molded body characterized in that the height of the crimping pin from the main surface is greater than the height of the partition wall from the main surface. [2] The resin honeycomb molded body according to [1], wherein the plate-like portion, the partition wall, and the crimping pin are integrally molded from the same resin material. [3] A resin honeycomb molded body having a plate-like portion having a main surface, and partition walls provided in a direction intersecting the main surface of the plate-like portion and defining a plurality of cylindrical cells, wherein the plate-like portion and the partition walls are made of a resin material, The resin honeycomb molded body is laminated with a plate-shaped dissimilar material component made of a different material from the resin material, with the partition wall sandwiched between the plate-shaped portion and the resin honeycomb molded body. The resin honeycomb molded body has a crimping pin made of resin material, which is provided on the side of the plate-shaped portion where the partition wall is located, extending in a direction intersecting the main surface, The height of the crimping pin from the main surface is greater than the sum of the height of the partition wall from the main surface and the thickness of the dissimilar material parts. The crimping pin penetrates the hole in the dissimilar material part, A sandwich structure characterized in that the diameter of the through-tip of the crimping pin is larger than the diameter of the hole. [4] The sandwich structure according to [3], wherein the resin honeycomb molded body comprises the plate-like portion, the partition wall, and the crimping pin, all integrally molded from the same resin material. [5] A resin honeycomb molded body having a plate-like portion having a main surface, a partition wall provided in a direction intersecting the main surface of the plate-like portion and defining a plurality of cylindrical cells, and a crimping pin provided on the side of the plate-like portion where the partition wall is located so as to extend in a direction intersecting the main surface, wherein the plate-like portion, the partition wall, and the crimping pin are made of a resin material, and a plate-like dissimilar material part made of a material different from the resin material, are laminated so as to sandwich the partition wall between the plate-like portion and the dissimilar material part, and the crimping pin is passed through a hole in the dissimilar material part, A method for manufacturing a sandwich structure, characterized by comprising the step of making the diameter of the tip of the crimping pin that penetrates the hole larger than the diameter of the hole. [6] A method for manufacturing a sandwich structure according to [5], wherein the step of making the diameter of the tip of the crimping pin that penetrates the hole larger than the diameter of the hole is performed by heating or pressurizing the tip of the crimping pin. [7] A method for manufacturing a sandwich structure according to [5] or [7], comprising the step of manufacturing the resin honeycomb molded body by integrally molding the main surface portion, the partition wall, and the crimping pin from the same resin material. [8] The method for manufacturing the resin honeycomb molded body, the method for manufacturing the resin honeycomb molded body, includes the step of bringing an ejector pin into contact with the tip of the crimping pin and extruding the hardened resin material from the mold, as described in [7]. [9] A method for manufacturing a sandwich structure according to [7] or [8], wherein in the process of manufacturing the resin honeycomb molded body, the height of the crimping pin is manufactured to be greater than the sum of the height of the partition wall and the thickness of the dissimilar material parts. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a resin honeycomb molded body that can increase the bonding strength between dissimilar materials such as metal plates, even when the amount of adhesive used is reduced. Furthermore, according to the present invention, it is possible to provide a sandwich structure that can increase the bonding strength between the resin honeycomb molded body and dissimilar materials such as metal plates, even when the amount of adhesive used is reduced. Moreover, according to the present invention, it is possible to provide a method for manufacturing a sandwich structure that can increase the bonding strength between the resin honeycomb molded body and dissimilar materials such as metal plates in a simple manner, even when the amount of adhesive used is reduced. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a cross-sectional view showing one example of the sandwich structure of the present invention. [Figure 2] Figure 2 is a cross-sectional view showing one example of the structure of a resin honeycomb molded body. [Figure 3] Figure 3 is a diagram illustrating the manufacturing method of a resin honeycomb molded body. [Figure 4] Figure 4 is a diagram illustrating the manufacturing method of the sandwich structure. [Detailed Description of the Invention]

[0011] Hereinafter, an exemplary embodiment of the present invention (hereinafter abbreviated as "the present embodiment") will be described in detail. The present invention is not limited to the present embodiment, and various modifications may be implemented within the scope of the gist of the present invention.

[0012] [1] Sandwich structure First, the sandwich structure of the present invention will be described. Figure 1 is a cross-sectional view showing one configuration example of the sandwich structure of the present invention, and Figure 2 is a cross-sectional view showing one configuration example of a resin honeycomb molded body. In the drawings, portions characterizing the invention may be shown in an exaggerated manner, and the dimensional ratios may differ from those of actual members.

[0013] Further, in the following description, a case where the resin honeycomb molded body is an aggregate of a plurality of cells defined as polygons in plan view will be described as an example, but the shape is not limited thereto, and the resin honeycomb molded body includes an aggregate of a plurality of cells defined as regular hexagons, regular triangles, squares and the like in plan view. Further, a combination of a plurality of shapes such as a combination of regular octagons and squares may also be used.

[0014] A sandwich structure 1 includes: a resin honeycomb molded body 10 having a plate-shaped portion 11 having a main surface 11a, and partition walls 12 provided so as to extend from the main surface 11a of the plate-shaped portion 11 in a direction intersecting the main surface 11a and defining a plurality of cylindrical cells 13, wherein the plate-shaped portion 11 and the partition walls 12 are made of a resin material; and a plate-shaped dissimilar material component 20 laminated on the resin honeycomb molded body 10 so as to sandwich the partition walls 12 between the dissimilar material component 20 and the plate-shaped portion 11, and made of a material different from the resin material. Further, the resin honeycomb molded body 10 has caulking pins 15 which are provided on the side of the plate-shaped portion 11 where the partition walls 12 are disposed so as to extend in a direction intersecting the main surface 11a, and which are made of a resin material.

[0015] Furthermore, the sandwich structure 1 of the present invention is characterized in that, in the resin honeycomb molded body 10, the height (Hp) of the crimping pin 15 from the main surface 11a is greater than the sum of the height of the partition wall 12 (Hw) from the main surface 11a and the thickness (W) of the dissimilar material component 20 (Hp>Hw+W), the crimping pin 15 penetrates the hole 21 of the dissimilar material component 20, and the diameter (Dp) of the penetrating tip 15a of the crimping pin 15 is greater than the diameter (Dh) of the hole 21 (Dp>Dh).

[0016] With this configuration, it is possible to realize a sandwich structure 1 that can increase the bonding strength between the resin honeycomb molded body 10 and the dissimilar material parts 20, even when the amount of adhesive used is reduced.

[0017] Furthermore, because the amount of adhesive used can be reduced, it is possible to reduce the amount of adhesive used, thereby achieving weight reduction and contributing to a reduction in material costs.

[0018] While adhesive may be used to join the resin honeycomb molded body 10 and the dissimilar material parts 20, albeit in reduced amounts, it is more preferable not to use adhesive. By not using adhesive, further weight reduction and cost reduction can be achieved.

[0019] Furthermore, because no adhesive is used, or only a small amount is used, the parts can be easily separated after use, allowing each part to be recycled.

[0020] The dissimilar material part 20 is not particularly limited as long as it is a plate-shaped part made of a material different from the resin material that constitutes the resin honeycomb molded body 10. Examples include metal plates made of metal materials such as aluminum, resin plates made of resin materials different from the resin material that constitutes the resin honeycomb molded body 10, and plate materials made of wood or paper, and can be appropriately selected as needed.

[0021] <Resin honeycomb molded body> Here, we will describe the resin honeycomb molded body that comprises the sandwich structure of the present invention. Figure 2 is a longitudinal cross-sectional view showing one example of the structure of a resin honeycomb molded body. Note that the figure shows the resin honeycomb molded body in its standalone state before the crimping pins are attached.

[0022] The resin honeycomb molded body 10 has a plate-like portion 11 having a main surface 11a, and partition walls 12 that extend from the main surface 11a of the plate-like portion 11 in a direction intersecting the main surface 11a and define a plurality of cylindrical cells 13, and the plate-like portion 11 and the partition walls 12 are made of resin material.

[0023] In the example shown in the figure, the partition wall 12 is provided in a direction approximately perpendicular to the main surface 11a of the plate-like portion 11. The portion enclosed by the partition wall 12 becomes the cylindrical cell 13.

[0024] Furthermore, this resin honeycomb molded body 10 has a crimping pin 15 made of resin material, which is provided on the side of the plate-shaped portion 11 where the partition wall 12 is located, extending in a direction intersecting the main surface 11a, and is characterized in that the height of the crimping pin 15 from the main surface 11a (Hp) is higher than the height of the partition wall 12 from the main surface 11a (Hw) (Hp > Hw).

[0025] With this configuration, it is possible to realize a resin honeycomb molded body 10 that can increase the bonding strength between dissimilar material parts 20, even when the amount of adhesive used is reduced.

[0026] Preferably, the height (Hp) of the crimping pin 15 from the main surface 11a is greater than the sum of the height (Hw) of the partition wall 12 from the main surface 11a and the thickness (W) of the dissimilar material component 20 laminated on the resin honeycomb molded body 10 (Hp > Hw + W). This makes it possible to create a resin honeycomb molded body 10 that can further increase the bonding strength between dissimilar material parts 20, even when the amount of adhesive used is reduced.

[0027] In the resin honeycomb molded body 10, it is preferable that the plate-like portion 11, the partition wall 12, and the crimping pin 15 are integrally molded from the same resin material, from the viewpoint of simplifying the manufacturing process. However, if the plate-like portion 11 and the partition wall 12 and the crimping pin 15 are molded from different resin materials, they may be molded by two-color molding.

[0028] In this case, it is preferable to manufacture the product such that the height (Hp) of the crimping pin 15 from the main surface 11a is greater than the sum of the height (Hw) of the partition wall 12 from the main surface 11a and the thickness (W) of the dissimilar material part 20 (Hp > Hw + W). This makes it possible to manufacture a resin honeycomb molded body 10 having crimping pins 15 without complicating the manufacturing process.

[0029] Furthermore, it is preferable that the crimping pin 15 has a length sufficient to match the sum of the height of the partition wall 12 (Hw) and the thickness of the dissimilar material part 20 (W) (Hw+W), in order to make the tip 15a that penetrates the hole 21 of the dissimilar material part 20 larger than the diameter of the hole 21.

[0030] Specifically, for example, the resin honeycomb molded body 10 is manufactured as follows. Figure 3 is a diagram illustrating the manufacturing method of the resin honeycomb molded body. Specifically, molten resin material is injected into a mold 100 having a bottom surface 110 and a plurality of independent pins 120 arranged in a direction intersecting the bottom surface 110 and separated by slits. After the resin material hardens, the resin honeycomb molded body 10 is removed from the mold 100 as a molded product.

[0031] The crimping pin 15 may also be a pin boss used in the manufacturing of the resin honeycomb molded body 10, where an ejector pin 130 is brought into contact with the tip of the crimping pin 15 to push the hardened resin material out of the mold when removing the hardened resin material from the mold 100.

[0032] Specifically, as shown in Figure 3, for example, the molded product made of resin material that has hardened in the mold 100 is ejected from the bottom surface 110 of the mold 100 using an ejector pin 130, thereby removing the resin honeycomb molded body 10 as a molded product from the mold 100.

[0033] At this time, the ejector pin 130 pushes out the resin honeycomb molded body 10 from the mold 100 by contacting and pushing up the tip of the crimping pin 15, that is, by pushing up the portion of the crimping pin 15 as a pin boss. This allows the resin honeycomb molded body 10 to be conveniently removed from the mold 100.

[0034] [2] Method for manufacturing a sandwich structure Next, a method for manufacturing the sandwich structure of the present invention will be described. Figure 4 illustrates the method for manufacturing the sandwich structure of the present invention.

[0035] The present invention provides a method for manufacturing a sandwich structure, comprising: a first step of stacking a resin honeycomb molded body 10, which has a plate-like portion 11 having a main surface 11a; a partition wall 12 provided on the plate-like portion 11 in a direction intersecting the main surface 11a and defining a plurality of cylindrical cells 13; and a crimping pin 15 provided on the side of the plate-like portion 11 where the partition wall 12 is located, extending in a direction intersecting the main surface 11a, wherein the plate-like portion 11, the partition wall 12, and the crimping pin 15 are made of a resin material; and a plate-like dissimilar material component 20 made of a material different from the resin material, so as to sandwich the partition wall 12 between the plate-like portion 11 and the dissimilar material component 20, and passing the crimping pin 15 through a hole 21 in the dissimilar material component 20; and a second step of making the diameter (Dp) of the tip 15a of the crimping pin 15 that has passed through the hole 21 larger than the diameter (Dh) of the hole 21.

[0036] With this configuration, it is possible to realize a manufacturing method for a sandwich structure 1 that can increase the bonding strength between the resin honeycomb molded body 10 and the dissimilar material parts 20 in a simple manner, even when the amount of adhesive used is reduced.

[0037] Furthermore, because the amount of adhesive used can be reduced, it is possible to reduce the amount of adhesive used, thereby achieving weight reduction and contributing to a reduction in material costs.

[0038] While adhesive may be used to join the resin honeycomb molded body 10 and the dissimilar material parts 20, albeit in reduced amounts, it is more preferable not to use adhesive. By not using adhesive, further weight reduction and cost reduction can be achieved.

[0039] Furthermore, by not using adhesives, for example, if the dissimilar material part 20 is a metal plate, surface treatment of the metal plate becomes unnecessary. In addition, temperature control, mixing amount control, and the time required for the adhesive to solidify are eliminated, simplifying the process. Moreover, since the time required for the adhesive to solidify is eliminated, productivity is improved, leading to further cost reduction and weight reduction.

[0040] The manufacturing method for the sandwich structure 1 may further include, prior to the first step, a step (molding step) of manufacturing a resin honeycomb molded body 10 by integrally molding the plate-shaped portion 11, the partition wall 12, and the crimping pin 15 from the same resin material.

[0041] This makes it possible to manufacture a resin honeycomb molded body 10 having crimping pins 15 without complicating the manufacturing process. The resin honeycomb molded body 10 can be manufactured by the method described above.

[0042] Furthermore, the process of manufacturing the resin honeycomb molded body 10 may include a step of bringing the ejector pin 130 into contact with the tip of the crimping pin 15 to extrude the hardened resin material from the mold.

[0043] (1) First process In the first step, as shown in Figures 4(a) and (b), a plate-shaped dissimilar material component 20 made of a material different from the resin material is laminated on the side of the resin honeycomb molded body 10 opposite to the main surface 11a, and a crimping pin 15 is passed through the hole 21 of the dissimilar material component 20.

[0044] In this case, the height (Hp) of the crimping pin 15 from the main surface 11a is greater than the sum of the height (Hw) of the partition wall 12 from the main surface 11a and the thickness (W) of the dissimilar material part 20 (Hp > Hw + W), so the tip 15a of the crimping pin 15 protrudes from the hole 21 of the dissimilar material part 20.

[0045] (2) Second process In the second step, as shown in Figure 4(c), the diameter (Dp) of the tip 15a of the crimping pin 15 that penetrates the hole 21 of the dissimilar material part 20 is made larger than the diameter (Dh) of the hole 21 (Dp>Dh).

[0046] Specifically, for example, if the crimping pin 15, i.e., the resin material constituting the resin honeycomb molded body 10, is a thermoplastic resin, this can be done by heating and softening the tip 15a of the crimping pin 15 protruding from the hole 21 of the dissimilar material part 20, expanding it so that its diameter (Dp) is larger than the diameter (Dh) of the hole 21, and then hardening it.

[0047] There are no particular limitations on how to make the diameter (Dp) of the tip 15a of the crimping pin 15 that penetrates the hole 21 larger than the diameter of the hole 21 in the dissimilar material part 20, but it is preferable to do so by heating or pressurizing, for example. An example of a heating method is ultrasonic heating. This makes it easy and reliable to make the diameter of the tip 15a of the crimping pin 15 larger than the diameter of the hole 21.

[0048] In addition, regarding the shape of the tip 15a of the crimping pin 15 after its diameter has been increased, the figure shows the case where the surface is flat, but it is not limited to this, and for example, it may be hemispherical (a shape with a raised center) or concave in the center.

[0049] By making the diameter (Dp) of the tip 15a of the crimping pin 15 larger than the diameter (Dh) of the hole 21, the dissimilar material part 20 is prevented from falling off the crimping pin 15 (it is crimped), and as a result, even when the amount of adhesive used is reduced, the resin honeycomb molded body 10 and the dissimilar material part 20 can be joined with high bonding strength using a simple method.

[0050] Furthermore, it is preferable that multiple joining points by crimping pins 15 are provided in a plan view of the resin honeycomb molded body 10 and the sandwich structure 1, between the resin honeycomb molded body 10 and the dissimilar material component 20. This allows for a more reliable and strong joining of the resin honeycomb molded body 10 and the dissimilar material component 20.

[0051] While embodiments of the present invention have been described above, the present invention is not limited thereto and can be modified as appropriate without departing from the spirit of the invention. [Industrial applicability]

[0052] By using the sandwich structure according to the present invention, it is possible to increase the bonding strength between dissimilar materials such as metal plates, even when the amount of adhesive used is reduced, and it can be widely used as an impact-absorbing component in automobiles, aircraft, and the like. [Explanation of Symbols]

[0053] 10: Resin honeycomb molded body, 11: Plate-like part, 11a: Main surface, 12: Partition wall, 13: Cylindrical cell, 15: Pin (crimping pin), Hp: Height

Claims

1. A resin honeycomb molded body having a plate-like portion having a main surface, and partition walls extending from the main surface of the plate-like portion in a direction intersecting the main surface, defining a plurality of cylindrical cells, wherein the plate-like portion and the partition walls are made of a resin material, The plate-like portion has a crimping pin made of resin material, which is provided on the side where the partition wall is located so as to extend in a direction intersecting the main surface, A resin honeycomb molded body characterized in that the height of the crimping pin from the main surface is greater than the height of the partition wall from the main surface.

2. The resin honeycomb molded body according to claim 1, wherein the plate-like portion, the partition wall, and the crimping pin are integrally molded from the same resin material.

3. A resin honeycomb molded body having a plate-like portion having a main surface, and partition walls provided in a direction intersecting the main surface of the plate-like portion and defining a plurality of cylindrical cells, wherein the plate-like portion and the partition walls are made of a resin material, The resin honeycomb molded body is laminated with a plate-shaped dissimilar material component made of a different material from the resin material, with the partition wall sandwiched between the plate-shaped portion and the resin honeycomb molded body. The resin honeycomb molded body has a crimping pin made of resin material, which is provided on the side of the plate-shaped portion where the partition wall is located, extending in a direction intersecting the main surface, The height of the crimping pin from the main surface is greater than the sum of the height of the partition wall from the main surface and the thickness of the dissimilar material parts. The crimping pin penetrates the hole in the dissimilar material part, A sandwich structure characterized in that the diameter of the through-tip of the crimping pin is larger than the diameter of the hole.

4. The sandwich structure according to claim 3, wherein the resin honeycomb molded body is integrally molded from the same resin material as the plate-like portion, the partition wall, and the crimping pin.

5. A resin honeycomb molded body having a plate-like portion having a main surface, a partition wall provided in a direction intersecting the main surface of the plate-like portion and defining a plurality of cylindrical cells, and a crimping pin provided on the side of the plate-like portion where the partition wall is located so as to extend in a direction intersecting the main surface, wherein the plate-like portion, the partition wall, and the crimping pin are made of a resin material, and a plate-like dissimilar material part made of a material different from the resin material, are laminated so as to sandwich the partition wall between the plate-like portion and the dissimilar material part, and the crimping pin is passed through a hole in the dissimilar material part, A method for manufacturing a sandwich structure, characterized by comprising the step of making the diameter of the tip of the crimping pin that penetrates the hole larger than the diameter of the hole.

6. The method for manufacturing a sandwich structure according to claim 5, wherein the step of making the diameter of the tip of the crimping pin that penetrates the hole larger than the diameter of the hole is performed by heating or pressurizing the tip of the crimping pin.

7. A method for manufacturing a sandwich structure according to claim 5 or 6, comprising the step of manufacturing the resin honeycomb molded body by integrally molding the main surface portion, the partition wall, and the crimping pin from the same resin material.

8. The method for manufacturing a sandwich structure according to claim 7, wherein the step of manufacturing the resin honeycomb molded body includes a step of bringing an ejector pin into contact with the tip of the crimping pin and extruding the hardened resin material from the mold.

9. The method for manufacturing a sandwich structure according to claim 7, wherein in the process of manufacturing the resin honeycomb molded body, the height of the crimping pin is manufactured to be greater than the sum of the height of the partition wall and the thickness of the dissimilar material parts.

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