Honeycomb structure panel and method for manufacturing honeycomb structure panel

Abstract

To provide a honeycomb structure panel that exhibits a light-shielding effect and has excellent design. [Solution] The honeycomb structure panel in this embodiment includes a rectangular frame extending in a first direction and a second direction perpendicular to each other in a plan view, and a shielding member disposed inside the frame and fixed thereto. The shielding member of the honeycomb structure panel is composed of a plurality of core units having a cylindrical honeycomb shape that is hexagonal in a plan view, which are arranged inside the frame in the first and second directions.

Description

[Technical Field]

[0001] SUMMARY OF THE INVENTION Embodiments of the present disclosure relate to honeycomb structure panels and methods for manufacturing honeycomb structure panels. [Background technology]

[0002] Background art in this technical field is found in Patent Document 1. This document discloses a shading member for a canopy provided on the exterior wall of a building, which comprises upper and lower panels having translucency, and a plurality of strip-shaped solar heat reflecting films formed alternately in a predetermined direction on at least two main surfaces of the upper and lower panels. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-038631 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the light blocking member of Patent Document 1 has an inorganic structure and lacks design appeal.

[0005] The problem to be solved by the present disclosure is to provide a honeycomb structure panel that exhibits a shading effect and has excellent design properties. [Means for solving the problem]

[0006] One aspect of the present disclosure provides a honeycomb structure panel including a rectangular frame body extending in a first direction X and a second direction Y that are perpendicular to each other in a plan view, and a shielding member disposed inside the frame body and fixed thereto, wherein the shielding member is made of a plurality of core units having a cylindrical honeycomb shape that is hexagonal in a plan view and that are arranged side by side in the first direction and the second direction inside the frame body. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram showing an example of a state in which the honeycomb structure panel according to the first embodiment is used. [Figure 2] FIG. 2 is a plan view of the honeycomb structure panel shown in FIG. [Figure 3] FIG. 3 is a perspective view of a portion of the honeycomb structure panel shown in FIG. [Figure 4] FIG. 4 is a diagram illustrating a cross-sectional structure of a portion of the honeycomb structure panel shown in FIG. [Figure 5] FIG. 5 is a diagram showing the structure of a core unit that constitutes a honeycomb structure panel. [Figure 6] FIG. 6 is an enlarged view of the half unit shown in FIG. [Figure 7] 7A is a diagram showing a state in which core assemblies are spread out inside a frame body, and FIG. 7B is a view seen from the direction of arrow B in FIG. 7A. [Figure 8] Fig. 8A is a diagram showing the structure of the adjustment core units disposed above and below the core assembly, and Fig. 8B is a side view of the lower end adjustment core unit. [Figure 9] FIG. 9 is a diagram showing an example of a state in which the honeycomb structure panel according to the second embodiment is used. [Figure 10] FIG. 10 is a front view of the honeycomb structure panel shown in FIG. [Figure 11] FIG. 11 is a diagram illustrating an example of the cross-sectional structure of the honeycomb structure panel shown in FIG. [Figure 12] FIG. 12 is a diagram showing a first example of use of the honeycomb structure panel according to the third embodiment. [Figure 13] FIG. 13 is a diagram showing a second example of use of the honeycomb structure panel according to the third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] 1. First Embodiment Hereinafter, a honeycomb structure panel 1 according to a first embodiment of the present disclosure will be described with reference to the drawings. In the present specification and the drawings, elements similar to those already described will be designated by the same reference numerals, and detailed description thereof will not be repeated.

[0009] (1.1. Honeycomb structure panel 1 in use) The use state of the honeycomb structure panel 1 according to the embodiment will be described with reference to the drawings. Fig. 1 is a diagram showing an example of the use state of the honeycomb structure panel 1 according to the first embodiment.

[0010] As shown in Figure 1, a honeycomb structure panel 1 is used by being placed on the top surface of the roof of a house 100. In the example shown, the roof is made of a light-transmitting material. In recent years, particularly in the summer, urban areas have been experiencing extreme heat. One of the causes of this is the generation of radiant heat, which is generated when a material is heated by sunlight, causing the surface temperature of the object to rise and radiate to the surrounding area.

[0011] When radiant heat from sunlight is transmitted to the surface of the honeycomb structure panel 1, the action of the shielding member 20 described below promotes reflection of infrared rays, thereby reducing the effects of the radiant heat. In other words, in a house 100 equipped with the honeycomb structure panel 1, the honeycomb structure panel 1 suppresses the transmission of radiant heat to the interior, thereby suppressing the temperature rise inside the house where people are present due to radiant heat from sunlight. The honeycomb structure panel 1 exhibits this effect particularly remarkably in the summer. In the illustrated example, the honeycomb structure panel 1 is placed on the upper surface of the roof of the house 100, but it may also be placed inside the house 100, such as on the ceiling. Furthermore, 1 is attached removably.

[0012] Fig. 2 is a plan view of the honeycomb structure panel 1 shown in Fig. 1. As shown in Fig. 2, the honeycomb structure panel 1 has a rectangular shape having long and short sides in a plan view. In the following description, the direction along the short sides of the honeycomb structure panel 1 is referred to as the longitudinal direction X (an example of a first direction), the direction along the long sides of the honeycomb structure panel 1 is referred to as the transverse direction Y (an example of a second direction), and the direction along the thickness of the honeycomb structure panel 1 is referred to as the thickness direction Z.

[0013] In the illustrated example, the honeycomb structure panel 1 is arranged to follow the movement of the sun. Specifically, the honeycomb structure panel 1 is preferably arranged so that the vertical direction X is aligned with the north-south direction and the horizontal direction Y is aligned with the east-west direction. This ensures a long-term shading effect against the movement of the sun moving from east to west relative to the earth's surface. The specific structure of such a honeycomb structure panel 1 will be described below.

[0014] (1.2. Structure of honeycomb structure panel 1 and components) Fig. 3 is a perspective view (photograph) of a portion of the structure of the honeycomb structure panel 1 shown in Fig. 1. As shown in Fig. 3, the honeycomb structure panel 1 includes a rectangular frame body 10 and a shielding member 20 disposed inside the frame body 10. The frame body 10 extends in a vertical direction X and a horizontal direction Y that are perpendicular to each other in a plan view. The shielding member 20 is disposed inside the frame body 10 and fixed to the frame body 10.

[0015] The shielding member 20 is formed by arranging a plurality of core units 21, each having a cylindrical honeycomb shape that is hexagonal in plan view, side by side in the vertical direction X and the horizontal direction Y inside the frame 10.

[0016] The core unit 21 is arranged such that the central axis of the honeycomb shape is inclined with respect to the thickness direction Z. In the example shown in Fig. 3, the cylindrical honeycomb shape, which is hexagonal in plan view, is arranged such that the central axis extends downward as it approaches the front side in the thickness direction Z.

[0017] FIG. 4 is a diagram illustrating a cross-sectional structure of a portion of the honeycomb structure panel 1 shown in FIG. 1. As shown in FIG. 4, the wall surfaces of the core unit 21 are inclined so as to extend northward as they extend upward. In a cross-sectional view, the angle of a line connecting the upper end of a certain wall surface and the lower end of an adjacent wall surface located to the north thereof (hereinafter referred to as the reference angle) is 79 degrees or more with respect to the horizontal plane. In the illustrated example, the reference angle is 79 degrees. The magnitude of the reference angle is set based on the standard solar altitude during the summer solstice, when the sun's altitude is highest in Japan. In other words, if the reference angle of the honeycomb-shaped wall surfaces is 79 degrees or more, the honeycomb-shaped wall surfaces lined up in the vertical direction X can block sunlight even during the summer solstice, when the sun's altitude is highest.

[0018] Next, we will explain the component configuration and assembly process of the honeycomb structure panel 1. Figure 5 is a diagram showing an example of the structure of a core unit 21 that constitutes the honeycomb structure panel 1. The names of the components are as follows. Core unit 21: A structure in which three honeycomb shapes are formed, which is a unit of the shielding member 20, and is formed by combining two half units 21A. Half unit 21A: A material that constitutes half of the core unit 21, formed by pressing a plate. Plate: Plate material before press bending to become half unit 21A, for example, aluminum material Core assembly 22: A structure in which multiple core units 21 are connected side by side Shielding member 20: A structure in which multiple core assemblies 22 are stacked inside the frame 10

[0019] 5, the core assembly 22 is made up of four core units 21. The core unit 21 is made up of two half units 21A. The half units 21A are made up of first to seventh units which have different structures from each other.

[0020] In the illustrated example, the leftmost core unit 21 is configured by combining a first half unit 21A and a second half unit 21A. The core unit 21 adjacent to it on the right is configured by combining a fifth half unit 21A and a seventh half unit 21A. The core unit 21 adjacent to it on the right is configured by combining a sixth half unit 21A and a seventh half unit 21A. And the rightmost core unit 21 is configured by combining a third half unit 21A and a fourth half unit 21A.

[0021] Fig. 6 is an enlarged view of the half unit 21A shown in Fig. 5. This figure shows the first half unit 21A and the second half unit 21A that constitute the leftmost core unit 21 in Fig. 5. Each half unit 21A is formed, at both end edges in the thickness direction Z, with a radial fitting convex portion 41 that protrudes outward in the thickness direction Z and a radial fitting concave portion 42 that recesses inward in the thickness direction Z. A plurality of radial fitting convex portions 41 and a plurality of radial fitting concave portions 42 are arranged at intervals in the lateral direction Y.

[0022] 5, in half units 21A configured from multiple types, the arrangement pattern of radially mating convex portions 41 and radially mating concave portions 42 differs depending on the position of the half unit 21A in the core assembly 22. The multiple types of half units 21A are provided mainly due to differences in the arrangement patterns of the radially mating convex portions 41 and radially mating concave portions 42.

[0023] 6, in two half units 21A facing each other in the vertical direction X, a radial mating convex portion 41 and a radial mating concave portion 42 located in the middle in the horizontal direction Y constitute a joining crimping portion 31 (first crimping portion) that joins the half units 21A that are close to each other in the vertical direction X. The joining crimping portion 31 is composed of the radial mating convex portion 41 and the radial mating concave portion 42 that join the two half units 21A to each other. In the joining crimping portion 31, the radial mating convex portion 41 is bent so as to fit into the radial mating concave portion 42, thereby joining the two half units 21A to each other.

[0024] Specifically, as shown in the enlarged view of FIG. 6 , with the first half unit and the second half unit facing each other and overlapping each other, the radially mating convex portion 41 of the second half unit is bent so as to fit into the radially mating concave portion 42 of the first half unit. As a result, the radially mating convex portion 41 is bent from the front side to the back side of the honeycomb structure panel 1 and overlaps the inside of the radially mating concave portion 42. This joins the first half unit and the second half unit. By forming the joining crimping portion 31 in this way using the radially mating convex portion 41 and the radially mating concave portion 42, misalignment in the lateral direction Y is prevented and the dimensions during assembly are fixed. Furthermore, the radially mating convex portion 41 and the radially mating concave portion 42 act as guides during assembly, making it easier to align the first half unit and the second half unit.

[0025] 5, a connecting crimping portion 32 (second crimping portion) that connects adjacent core units 21 in the horizontal direction Y is formed at an end of the core unit 21 in the horizontal direction Y. The connecting crimping portion 32 is composed of a radially mating convex portion 41 formed at one end of the core unit 21 in the horizontal direction Y and three radially mating concave portions 42. In the connecting crimping portion 32, the radially mating convex portion 41 is fitted into a radially mating concave portion 42 formed at the other end of another core unit 21 adjacent to the core unit 21 in the horizontal direction Y, thereby connecting the adjacent core units 21 to each other.

[0026] In other words, the connecting crimping portion 32 is composed of one radially mating convex portion 41 formed on the half unit 21A and three radially mating concave portions 42 formed on the half unit 21A. In the connecting crimping portion 32, the radially mating convex portion 41 is bent so as to fit into the three radially mating concave portions 42, thereby connecting the two core units 21 together. Then, the core assembly 22 is configured with the four core units 21 connected in the horizontal direction Y.

[0027] Fig. 7A is a diagram showing a state in which core assemblies 22 are laid out inside the frame 10, and Fig. 7B is a view taken along the arrow B in Fig. 7A. In Fig. 7A, the core assembly 22 located at the top in the illustrated state is shown at a distance in order to facilitate understanding of the stacked core assemblies 22 as a unit. Also, in this figure, the upper and lower ends of the stacked core assemblies 22 are not shown.

[0028] 7A, the core unit 21 is formed with a lamination crimping portion 33 (third crimping portion) that joins adjacent core assemblies 22 in the vertical direction X, which is the lamination direction. The lamination crimping portion 33 is configured by a portion of the radial mating convex portion 41 and radial mating concave portion 42 formed in the core unit 21 that is not used as the joining crimping portion 31 or the connecting crimping portion 32. Specifically, the radial mating convex portion 41 and the radial mating concave portion 42 formed on one side of the honeycomb shape of the core unit 21 function as the lamination crimping portion 33. When the core assemblies 22 are stacked, the lamination crimping portion 33 joins the two core assemblies 22 to each other by bending the radial mating convex portion 41 located on the lower side so that it fits inside the radial mating concave portion 42 located on the upper side.

[0029] The core assembly 22 is stacked and fitted inside the frame body 10. As shown in Fig. 7B, a plurality of slits 11 extending at an angle with respect to the thickness direction Z are formed inside the frame body 10. The slits 11 are arranged at equal intervals in the vertical direction X. As shown in Fig. 7A, the core assembly 22 made up of a plurality of core units 21 is fixed to the frame body 10 by bending the ends E of the core units 21 outward with their ends E in the horizontal direction Y inserted into the slits 11 of the frame body 10 (see the view seen from the arrow C).

[0030] In this way, by bending the end E of the core assembly 22 in the horizontal direction Y outside the slit 11 of the frame body 10, the core assembly 22 and the frame body 10 are firmly fixed together, preventing the core assembly 22 from falling off from the frame body 10. In this way, the end E of the core assembly 22 and the slit 11 form a fourth crimping portion 34 that fixes the core assembly 22 to the frame body 10.

[0031] FIG. 8A is a diagram showing the structure of the adjusting core units 23 arranged above and below the core assembly 22. FIG. 8B is a side view of the adjusting core unit 23 at the lower end. As shown in FIG. 8A, the adjusting core units 23 are arranged at the upper and lower ends of the core assembly 22. The adjusting core units 23 are made up of a plurality of panels. In the illustrated example, five adjusting core units 23 are arranged side by side in the horizontal direction Y. As shown in FIG. 8B, a portion of the adjusting core units 23 (adjusting core unit 23a) is fixed to the lower end or upper end of the frame body 10 by rivets 23A. This allows the adjusting core units 23 to be firmly fixed to the frame body 10 without misalignment.

[0032] The honeycomb structure panel 1 is manufactured by the following steps. First step: forming the core unit 21 Second step: forming the core assembly 22 Third step: A step of stacking the core assembly 22 inside the frame 10 Fourth step: A step of fixing the core assembly 22 to the inside of the frame 10

[0033] In the first step, first, a plurality of plates are press-bent, and two half units 21A obtained thereby are combined and joined by a joining crimping portion 31. In this way, a core unit 21 having a plurality of cylindrical honeycomb shapes is formed.

[0034] In the second step, the core units 21 manufactured in the first step are arranged so that the honeycomb shapes are aligned along the horizontal direction Y. Adjacent core units 21 are then connected to each other by connecting crimped portions 32. In this way, a core assembly 22 consisting of the core units 21 is formed.

[0035] In the third step, the plurality of core assemblies 22 manufactured in the second step are stacked in the vertical direction X and joined by the stacking crimping portions 33. As a result, the core assemblies 22 aligned vertically are joined together.

[0036] In the fourth step, the core assemblies 22 stacked in the third step are fixed inside the frame body 10. At this time, the end E of the core unit 21 of the core assembly 22 located at the outer end in the horizontal direction Y is inserted into the slit 11 formed inside the frame body 10, and the end E is bent to form a fourth crimped portion 34, thereby fixing the core assembly 22 to the frame body 10. Finally, the adjustable core units 23 are placed at the uppermost and lowermost ends of the core assembly 22, and parts of the adjustable core units 23 are fixed to the frame body 10 with rivets 23A. With the above steps, the honeycomb structure panel 1 is completed.

[0037] (1.3.Summary) As described above, the honeycomb structure panel 1 according to the present disclosure includes a frame body 10 and a shielding member 20 disposed and fixed inside the frame body 10. The shielding member 20 has core units 21, each hexagonal in plan view, that are arranged side by side inside the frame body 10. This makes it possible to provide a honeycomb structure panel 1 that exhibits a shading effect while also having excellent design.

[0038] Furthermore, the core unit 21 is arranged so that the central axis of the honeycomb shape is inclined with respect to the thickness direction Z. Therefore, when the honeycomb structure panel 1 is arranged so that the thickness direction Z of the honeycomb structure panel 1 is aligned with the vertical direction, sunlight can be effectively blocked by the wall surface of the honeycomb-shaped cylindrical body.

[0039] Furthermore, the core unit 21 is fixed to the frame body 10 by inserting its end E into the slit 11 and bending it to form the fourth crimped portion 34. This makes it possible to prevent the core unit 21 and the frame body 10 from being misaligned.

[0040] Furthermore, crimped portions are formed on the ends of the core units 21 in the first direction to connect adjacent core units 21. Therefore, the plurality of core units 21 can be fixed by connecting the members together.

[0041] The crimping portion has an engaging protrusion and an engaging recess, and the engaging protrusion fits into the engaging recess to connect adjacent core units 21. In this way, by fitting the engaging protrusion of the pre-formed core unit 21 into the engaging recess, it is possible to firmly fix the core units 21 with a simple configuration without requiring any other fastening parts.

[0042] Additionally, adjustment core units 23 are disposed at the uppermost and lowermost ends of core assembly 22, and portions of adjustment core unit 23 are fixed to frame body 10 by rivets 23A. In this manner, gaps at the upper and lower ends inside frame body 10 can be filled, and core assembly 22 can be fixed to frame body 10 more firmly.

[0043] 2. Second Embodiment Next, the structure of the honeycomb structure panel 1 according to the second embodiment will be described. Note that the same components as those in the first embodiment will be assigned the same reference numerals, and repeated explanations will be omitted. Fig. 9 is a diagram showing an example of a state in which the honeycomb structure panel 1 according to the second embodiment is used. Fig. 9 is a front view of the honeycomb structure panel 1 shown in Fig. 9.

[0044] As shown in Fig. 9, the honeycomb structure panel 1 according to this embodiment is further used as a screen for a house 200 or the like. In the illustrated example, the honeycomb structure panel 1 is erected on the outside of the house 200. As shown in Fig. 10, the honeycomb structure panel 1 is arranged so that the longitudinal direction X is along the up-down direction and the lateral direction Y is along the left-right direction. Note that the honeycomb structure panel 1 may also be arranged inside the house 200, as indicated by the dashed line in Fig. 9.

[0045] Fig. 11 is a diagram illustrating the cross-sectional structure of a honeycomb structure panel 1. As shown in Fig. 11, the honeycomb structure panel 1 is arranged so that the central axis of the honeycomb shape extends downward as it moves from the inside to the outside of the house. This effectively blocks the view from the outside to the inside of the house. Note that the honeycomb structure panel 1 may also be arranged so that the central axis of the honeycomb shape extends downward as it moves from the outside to the inside of the house, as indicated by the symbol 1B.

[0046] 3. Third Embodiment Next, applications of the honeycomb structure panel 1 according to the third embodiment will be described with reference to FIGS. 12 and 13. FIG. 12 shows a first example of use of the third embodiment. As shown in FIG. 12, the honeycomb structure panel 1 may be used as a partition inside a house 300. In this case, since the honeycomb-shaped wall surfaces are inclined, it is possible to block the view from one side of the honeycomb structure panel 1 in the thickness direction Z to the other side, while ensuring ventilation and achieving a wind-regulating effect. The honeycomb structure panel 1 may be placed inside the house 300, as shown by the dashed line in FIG. 12, or may be placed on a window or ceiling as a decorative panel for decorating the interior, as shown by the symbol 1C.

[0047] Fig. 13 is a diagram showing a second use example of the third embodiment. As shown in Fig. 13, the honeycomb structure panel 1 may be used as a flower block to be placed on a terrace. That is, by placing the honeycomb structure panel 1 upright on a terrace, it is possible to block views from the outside while letting in soft light and breezes. Furthermore, since the honeycomb structure panel 1 is constructed in a cylindrical honeycomb shape, it has excellent breathability and can also provide security by ensuring partial visibility from the inside of the house to the outside.

[0048] <4. Other Modifications> The configuration of the honeycomb structure panel 1 has been described above, but the application of the technical idea of ​​the present disclosure is not limited to the above embodiment. For example, although an example in which one core assembly 22 is composed of four core units 21 has been shown for the honeycomb structure panel 1, this is not limitative. The number of core units 21 that compose the core assembly 22 can be changed as desired.

[0049] In the above embodiment, the honeycomb structure panel 1 has the core assemblies 22 stacked in the vertical direction X, but this is not limiting. That is, the core assemblies 22 may be stacked in the horizontal direction Y.

[0050] Furthermore, although the configuration in which the core unit 21 has three honeycomb shapes has been shown, the number of honeycomb shapes that the core unit 21 has can be changed as desired. Furthermore, the core unit 21 may be a cylindrical structure having a polygonal shape other than a hexagon.

[0051] It is also possible to realize a honeycomb structure panel that has at least two or more of the functions of the first to third embodiments. That is, it is also possible to realize a honeycomb structure panel that has at least two or more of the light-blocking property of the honeycomb structure panel 1 of the first embodiment, the privacy function of the honeycomb structure panel 1 of the second embodiment, and the design and ventilation functions of the honeycomb structure panel 1 of the third embodiment.

[0052] Although several embodiments of the present disclosure have been illustrated above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, combinations, modifications, etc. can be made. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the inventions and their equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other. [Explanation of symbols]

[0053] 1: honeycomb structure panel, 10: frame body, 11: slit, 20: shielding member, 21 core unit, 21A: half unit, 22: core assembly, 23: adjustment core unit, 31: connecting crimped portion (first crimped portion), 32: connecting crimped portion (second crimped portion), 33: stacking crimped portion (third crimped portion), 34: fourth crimped portion, 41: diameter fitting convex portion, 42: diameter fitting concave portion

Claims

1. a first step of press-bending a plurality of plates, combining two press-bent half units, and joining them with first crimping portions to form a core unit having a plurality of cylindrical honeycomb shapes; a second step of arranging a plurality of the core units so that the honeycomb shapes are aligned along a first direction and connecting adjacent core units to each other with second crimping portions to form a core assembly consisting of the plurality of core units; a third step of stacking the core assemblies in a second direction perpendicular to the first direction and joining the core assemblies with third crimping portions; a fourth step of fixing the core assembly to the inside of a rectangular frame body by a fourth crimping portion; In the fourth step, A method for manufacturing a honeycomb structure panel, wherein the core assembly is fixed to the frame body by inserting the end of the core unit located at the end in the first direction into a slit formed inside the frame body and bending it.

2. The slits are oriented in a third direction perpendicular to both the first direction and the second direction. The frame is formed inside the frame so as to extend at an angle.

2. The method for manufacturing a honeycomb structure panel according to claim 1, wherein in the fourth step, the end portions of the core units are bent while being inserted into the slits.

3. The method for manufacturing a honeycomb structure panel according to claim 1, further comprising the steps of: arranging a plurality of adjusting core units at at least one of the uppermost end and the lowermost end of the core assembly; and fixing the adjusting core units to a frame.

4. 4. The method for manufacturing a honeycomb structure panel according to claim 3, wherein in the step of fixing the frame body, the adjusting core unit is fixed to the frame body by rivets.

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