Panel structure

Abstract

To join a faceplate and a core member together with improved reliability.SOLUTION: A panel structure comprises: a sheet-shaped core member having a thermoplastic property and provided with a plurality of protruding portions on at least one surface; a sheet-shaped faceplate having a thermoplastic property and disposed on the plurality of protruding portions; and a fusing portion which is selectively formed between the faceplate and the plurality of protruding portions and which bonds the core member and the faceplate to each other.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a panel structure. [Background technology]

[0002] Highly rigid sandwich panels are used in the bodies of automobiles, trains, and other mobility products (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-53887 Summary of the Invention [Problem to be solved by the invention]

[0004] Typically, sandwich panels are constructed by placing a core member between two face plates and bonding them together with an adhesive. However, bonding using adhesives can result in poor adhesion between the face plate and the core member. When bolts or other fasteners are used to bond the face plate and the core member to strengthen the adhesive strength or improve the reliability of the bond, holes must be drilled in the face plate and the core member, which can reduce the mechanical strength of the sandwich panel, particularly when the material is fiber-reinforced resin. Furthermore, connecting the face plate and the core member with bolts or other fasteners can increase the weight and complicate the manufacturing process of the sandwich panel.

[0005] An object of the present disclosure is to provide a panel structure that can improve the reliability of the joint between a face plate and a core member. [Means for solving the problem]

[0006] A panel structure according to one aspect of the present disclosure comprises a plate-shaped core member having thermoplasticity and having a plurality of convex portions on at least one surface, a plate-shaped face plate having thermoplasticity and arranged on the plurality of convex portions, and fusion portions selectively formed between the face plate and the plurality of convex portions, which join the core member and the face plate. [Effects of the Invention]

[0007] According to the present disclosure, it is possible to improve the reliability of the joint between the face plate and the core member. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram schematically showing a cross section of a panel structure according to a first embodiment. [Figure 2] FIG. 2 is a diagram schematically showing the core member according to the first embodiment. [Figure 3] FIG. 3 is a diagram schematically showing a cross section of a panel structure according to the second embodiment. [Figure 4] FIG. 4 is a diagram schematically showing a core member according to the second embodiment. [Figure 5] FIG. 5 is a diagram schematically showing a cross section of a panel structure according to a third embodiment. [Figure 6] FIG. 6 is a diagram schematically showing a core member according to the third embodiment. [Figure 7] FIG. 7 is a diagram schematically showing a cross section of a panel structure according to a fourth embodiment. [Figure 8] FIG. 8 is a diagram schematically showing a cross section of a panel structure according to a fifth embodiment. [Figure 9] FIG. 9 is a diagram schematically showing a cross section of a panel structure according to a sixth embodiment. [Figure 10] FIG. 10 is a cross-sectional view schematically showing a cross section of a panel structure according to a modified example of the sixth embodiment. [Figure 11] FIG. 11 is a diagram schematically showing a cross section of a panel structure according to a seventh embodiment. [Figure 12] FIG. 12 is a diagram schematically showing a cross section of a panel structure according to a modified example of the seventh embodiment. [Figure 13] FIG. 13 is a diagram schematically showing a cross section of a panel structure according to the eighth embodiment. [Figure 14] FIG. 14 is a diagram schematically showing a cross section of a panel structure according to a ninth embodiment. [Figure 15] FIG. 15 is a diagram schematically showing a cross section of a panel structure according to a tenth embodiment. [Figure 16] FIG. 16 is a diagram schematically showing a cross section of a panel structure according to an eleventh embodiment. [Figure 17] FIG. 17 is a diagram schematically showing a cross section of a panel structure according to a twelfth embodiment. [Figure 18] FIG. 18 is a diagram schematically showing a cross section of a panel structure according to a modified example of the twelfth embodiment. [Figure 19] FIG. 19 is a diagram schematically showing a cross section of a panel structure according to a thirteenth embodiment. [Figure 20] FIG. 20 is a diagram schematically showing a core member according to the fourteenth embodiment. [Figure 21A] FIG. 21A is a diagram showing an example of a slit provided in a core member according to the fourteenth embodiment. [Figure 21B] FIG. 21B is a diagram showing an example of a groove provided in a core member according to the fourteenth embodiment. [Figure 21C] FIG. 21C is a diagram showing an example of a slit provided in a core member according to the fourteenth embodiment. [Figure 21D] FIG. 21D is a diagram showing an example of slits and grooves provided in a core member according to the fourteenth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to these embodiments, and when there are multiple embodiments, the present invention also includes configurations that combine the embodiments. Furthermore, in the following embodiments, the same components are designated by the same reference numerals, and redundant explanations will be omitted.

[0010] [First embodiment] The configuration of the panel structure according to the first embodiment will be described with reference to Figures 1 and 2. Figure 1 is a diagram schematically showing a cross section of the panel structure according to the first embodiment. Figure 2 is a diagram schematically showing a core member according to the first embodiment. The panel structure of the present disclosure can be applied to, for example, automobiles, trains, other mobility products, buildings, etc.

[0011] As shown in FIG. 1, the panel structure 10 includes a core member 12, a face plate 14, and a fused portion 16.

[0012] The core member 12 has thermoplastic properties. The core member 12 is formed into a plate shape from a thermoplastic resin. Examples of thermoplastic resins include, but are not limited to, polyamide resin, polypropylene resin, ABS resin, polyether ether ketone, polyether ketone ketone, and polyphenylene sulfide. The thermoplastic resin is preferably a thermoplastic fiber reinforced plastic (FRP: Fiber Reinforced Plastics) containing reinforcing fibers. Examples of the fiber reinforced plastic are preferably glass fiber reinforced plastics (GFRP: Glass Fiber Reinforced Plastics) and carbon fiber reinforced plastics (CFRP: Carbon Fiber Reinforced Plastics). The fiber reinforced plastic is not limited to these. The core member 12 has a plurality of protrusions 18 on one surface. The core member 12 has recesses 20 on the other surface at positions corresponding to the protrusions 18. As shown in FIG. 2, a plurality of protrusions 18 are formed on one surface of the core member 12.

[0013] The core member 12 is preferably formed from a material with low thermal conductivity, for example, to improve the heat insulation of the panel structure 10. In this case, the core member 12 may be formed from, for example, carbon fiber reinforced plastic, glass fiber reinforced plastic, a mixture of glass fiber reinforced plastic and carbon fiber reinforced plastic, short fiber carbon fiber reinforced plastic, or the like, all of which have low thermal conductivity.

[0014] The face plate 14 is disposed on one surface of the core member 12. The face plate 14 is disposed on the protrusion 18 on one surface of the core member 12. The face plate 14 has thermoplastic properties. The face plate 14 is formed into a plate shape from a thermoplastic resin. Examples of the thermoplastic resin include, but are not limited to, polyamide resin, polypropylene resin, ABS resin, polyetheretherketone, polyetherketoneketone, and polyphenylene sulfide. The thermoplastic resin is preferably a thermoplastic fiber-reinforced plastic containing reinforcing fibers. Examples of the fiber-reinforced plastic are preferably glass fiber-reinforced plastic and carbon fiber-reinforced plastic. The fiber-reinforced plastic is not limited to these. The core member 12 and the face plate 14 may be formed of the same material or different materials. For example, in this embodiment, the core member 12 may be formed using a typical thermoplastic resin, and the face plate 14 may be formed using a thermoplastic fiber-reinforced plastic. Alternatively, the core member 12 may be formed using a thermoplastic fiber-reinforced plastic, and the face plate 14 may be formed using a typical thermoplastic resin. The core member 12 and the face plate 14 may be formed of different types of thermoplastic resins. For example, in this embodiment, the core member 12 may be formed of a polyamide resin, and the face plate 14 may be formed of a polypropylene resin.

[0015] The fused portion 16 connects the core member 12 and the face plate 14. The fused portion 16 is formed between the top of the protrusion 18 and one surface of the face plate 14. The fused portion 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14. The fused portion 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14, for example, depending on the rigidity and impact resistance characteristics required for the panel structure 10. The fused portion 16 can be formed by heating and melting the joint between the top of the protrusion 18 and the face plate 14, and then placing the face plate 14 and cooling it. Heating can be performed using, for example, a heat source such as a heater or heating wire, ultrasonic vibration, electromagnetic induction using a magnetic field, or a laser, but is not limited to these methods.

[0016] In the panel structure 10 according to the first embodiment, the core member 12 and the face plate 14 are joined by the fused portion 16, thereby improving the reliability of the joint between the core member 12 and the face plate 14.

[0017] [Second embodiment] The configuration of the panel structure according to the second embodiment will be described with reference to Fig. 3 and Fig. 4. Fig. 3 is a diagram schematically showing a cross section of the panel structure according to the second embodiment. Fig. 4 is a diagram schematically showing a core member according to the second embodiment.

[0018] 3, the panel structure 10A includes a core member 12A, a face plate 14a, a face plate 14b, and a fusion-bonding portion 16. The panel structure 10A includes face plates on both sides of the core member 12A.

[0019] 1 in that the core member 12A has protrusions 18 on both sides. The core member 12A has recesses 20 on both sides at positions corresponding to the protrusions 18. As shown in FIG. 3, the core member 12A has a plurality of protrusions 18 and a plurality of recesses 20 on both sides.

[0020] The face plate 14a is disposed on one surface of the core member 12A. The face plate 14a is disposed on the protrusion 18 on one surface of the core member 12A. The face plate 14b is disposed on the other surface of the core member 12A. .centre The face plate 14b is disposed on the protrusion 18 on the other surface of the core member 12A. The panel structure 10A has an air layer between the core member 12A and the face plate 14a. The panel structure 10A has an air layer between the core member 12A and the face plate 14b.

[0021] The fused portion 16 connects the core member 12A and the face plate 14a on one surface of the core member 12A. The fused portion 16 is formed between the tops of the protrusions 18 and one surface of the face plate 14a. The fused portion 16 is selectively formed between the tops of the multiple protrusions 18 and one surface of the face plate 14a. The fused portion 16 is selectively formed between the tops of the multiple protrusions 18 and one surface of the face plate 14a, for example, depending on the rigidity and impact resistance characteristics required of the panel structure 10A. The fused portion 16 can be formed by heating and melting the joints between the tops of the protrusions 18 and the face plate 14a, and then placing the face plate 14a and cooling it.

[0022] The fused portion 16 connects the core member 12A and the face plate 14b on the other surface of the core member 12A. The fused portion 16 is formed between the tops of the protrusions 18 and one surface of the face plate 14b. The fused portion 16 is selectively formed between the tops of the multiple protrusions 18 and one surface of the face plate 14b. The fused portion 16 is selectively formed between the tops of the multiple protrusions 18 and one surface of the face plate 14b, for example, depending on the rigidity and impact resistance characteristics required of the panel structure 10A. The fused portion 16 can be formed by heating and melting the joints between the tops of the protrusions 18 and the face plate 14b, and then placing the face plate 14b and cooling it.

[0023] In the panel structure 10A according to the second embodiment, the core member 12A is joined to the face plates 14a and 14b by the fusion joints 16. This allows the second embodiment to improve the reliability of the joint between the core member 12A and the face plates 14a and 14b. Furthermore, in the panel structure 10A according to the second embodiment, the core member 12A is joined to the face plates 14a and 14b by the fusion joints 16, eliminating the need for joining members such as bolts and making it possible to suppress an increase in weight.

[0024] [Third embodiment] The configuration of a panel structure according to a third embodiment will be described with reference to Fig. 5 and Fig. 6. Fig. 5 is a diagram schematically showing a cross section of the panel structure according to the third embodiment. Fig. 6 is a diagram schematically showing a core member according to the third embodiment.

[0025] As shown in FIG. 5, the panel structure 10B includes a core member 12B, a face plate 14a, a face plate 14b, and a fused portion 16.

[0026] The core member 12B differs from the core member 12 shown in FIG. 1 in that it has wave portions 22. As shown in FIG. 6, the core member 12B is formed in a wave shape and has a plurality of wave portions 22. The wave shape may also be called a corrugated shape. The wave portions 22 are a type of convex portions 18 and concave portions 20. The panel structure 10B has an air layer between the core member 12B and the face plate 14a. The panel structure 10B has an air layer between the core member 12B and the face plate 14b.

[0027] The fused portions 16 connect the core member 12B and the face plate 14a on one surface of the core member 12B. The fused portions 16 are formed between the crests of the waves 22 and one surface of the face plate 14a. The fused portions 16 are selectively formed between the crests of the multiple waves 22 and one surface of the face plate 14a. The fused portions 16 are selectively formed between the crests of the multiple waves 22 and one surface of the face plate 14a depending on, for example, the rigidity and impact resistance characteristics required for the panel structure 10B. The fused portions 16 can be formed by heating and melting the joints between the crests of the waves 22 and the face plate 14a, and then placing the face plate 14a and cooling it.

[0028] The fused portion 16 joins the core member 12B and the face plate 14b on the other surface of the core member 12B. The fused portion 16 is formed between the crests of the waves 22 and one surface of the face plate 14b. The fused portion 16 is selectively formed between the crests of the plurality of waves 22 and one surface of the face plate 14b. The fused portion 16 is selectively formed between the crests of the plurality of waves 22 and one surface of the face plate 14b, for example, depending on the rigidity and impact resistance characteristics required for the panel structure 10B. The fused portion 16 is formed by heating and melting the joints between the crests of the waves 22 and the face plate 14b, and then welding the face plate 14b. b and cooling.

[0029] In panel structure 10B according to the third embodiment, core member 12B is joined to face plates 14a and 14b by fusion joints 16. This allows the third embodiment to improve the reliability of the joint between core member 12B and face plates 14a and 14b. Furthermore, in panel structure 10B according to the third embodiment, joining core member 12B to face plates 14a and 14b by fusion joints 16 eliminates the need for joining members such as bolts, and makes it possible to suppress weight increase.

[0030] [Fourth embodiment] The configuration of the panel structure according to the fourth embodiment will be described with reference to Fig. 7. Fig. 7 is a diagram schematically showing a cross section of the panel structure according to the fourth embodiment.

[0031] 7, a panel structure 10C according to the fourth embodiment includes a core member 12B, face plates 14a, 14b, a fusion-bonding portion 16, and a metal thin film 24. The panel structure 10C differs from the panel structure 10B shown in FIG. 5 in that it includes the metal thin film 24.

[0032] In the example shown in FIG. 7, the metal thin film 24 is formed on one surface of the face plate 14b, but is not limited to this. The metal thin film 24 may be formed on at least one surface of at least one of the face plates 14a and 14b. The metal thin film 24 may be formed by, for example, vapor-depositing or plating a metal on the face plate 14b. The metal thin film 24 may be made of any metal. The metal thin film 24 may also be formed by other methods.

[0033] The panel structure 10C according to the fourth embodiment has a metal thin film 24 on at least one surface of at least one of the face plates 14a and 14b, which allows the fourth embodiment to reduce radiant heat generated by the panel structure 10C.

[0034] [Fifth embodiment] The configuration of the panel structure according to the fifth embodiment will be described with reference to Fig. 8. Fig. 8 is a diagram schematically showing a cross section of the panel structure according to the fifth embodiment.

[0035] 8, a panel structure 10D according to the fifth embodiment includes a core member 12Ba, a core member 12Bb, a face plate 14a, a face plate 14b, a face plate 14c, and a fusion portion 16. The panel structure 10D differs from the panel structure 10B shown in FIG. 5 in that the panel structure 10D includes a plurality of core members.

[0036] In this embodiment, the fusion section 16 connects the core member 12Ba to the face plate 14a on one side of the core member 12Ba. The fusion section 16 connects the core member 12Ba to the face plate 14c on the other side of the core member 12Ba. The fusion section 16 connects the core member 12Bb to the face plate 14c on one side of the core member 12Bb. The fusion section 16 connects the core member 12Bb to the face plate 14b on the other side of the core member 12Bb. Note that in the example shown in FIG. 8, the core members 12Ba and 12Bb are each connected to a single common face plate 14c, but the present disclosure is not limited thereto. For example, the face plate 14c may have a structure in which two face plates are joined or fused together: one face plate to which the core member 12Ba is connected and the other face plate to which the core member 12Bb is connected.

[0037] The core members 12Ba and 12Bb may be formed so that their tops are aligned, or may be misaligned.The core members 12Ba and 12Bb may have different shapes.

[0038] The panel structure 10D has an air layer between the core member 12Ba and the face plate 14a. The panel structure 10D has an air layer between the core member 12Ba and the face plate 14c. The panel structure 10D has an air layer between the core member 12Bb and the face plate 14c. The panel structure 10D has an air layer between the core member 12Bb and the face plate 14b. In other words, the panel structure 10D has a greater number of air layers than the panel structure 10B shown in FIG. 5.

[0039] In the panel structure 10D according to the fifth embodiment, the volume of the air layer can be increased by using multiple core members, such as core member 12Ba and core member 12Bb. This allows the fifth embodiment to improve heat insulation. Furthermore, the fifth embodiment also allows for improved sound insulation.

[0040] [Sixth embodiment] The configuration of the panel structure according to the sixth embodiment will be described with reference to Fig. 9. Fig. 9 is a diagram schematically showing a cross section of the panel structure according to the sixth embodiment.

[0041] 9, a panel structure 10E according to the sixth embodiment includes a core member 12B, face plates 14a, 14b, a fusion-bonding portion 16, and a filler member 26. The panel structure 10E differs from the panel structure 10B shown in FIG. 5 in that it includes the filler member 26.

[0042] The filler member 26 is disposed between the core member 12B and the face plates 14a and 14b. The filler member 26 may be selectively disposed between the core member 12B and the face plates 14a and 14b. The filler member 26 may be formed of a foam material having at least one of heat insulating properties and sound absorbing properties, such as urethane foam. Note that the filler member 26 is not limited to a foam material, and may be formed of other materials having at least one of heat insulating properties and sound absorbing properties.

[0043] An example of a method for disposing the filler member 26 between the core member 12B and the face plates 14a and 14b will be described. For example, before the core member 12B and the face plates 14a and 14b are heat-sealed together, the filler member 26 is formed into a predetermined shape and disposed in the space between the core member 12B and the face plates 14a and 14b. The filler member 26 melts due to the heat generated when the core member 12B and the face plates 14a and 14b are heat-sealed together, and adheres to the core member 12B and the face plates 14a and 14b. In this way, the filler member 26 is disposed between the core member 12B and the face plates 14a and 14b.

[0044] The panel structure 10E according to the sixth embodiment has a filler member 26 between the core member 12B and the face plates 14a and 14b. This allows the sixth embodiment to improve heat insulation. The sixth embodiment also allows for improved sound insulation.

[0045] [Modification of the sixth embodiment] The configuration of a panel structure according to a modification of the sixth embodiment will be described with reference to Fig. 10. Fig. 10 is a schematic diagram showing a cross section of a panel structure according to a modification of the sixth embodiment.

[0046] As shown in FIG. 10 , a panel structure 10F according to a modification of the sixth embodiment includes core members 12Ba and 12Bb, face plates 14a, 14b, and 14c, a fusion-bonding portion 16, and a filler member 26. The panel structure 10F differs from the panel structure 10D shown in FIG. 8 in that it includes the filler member 26. In the example shown in FIG. 10 , the core members 12Ba and 12Bb are each bonded to a single face plate 14c, but the present disclosure is not limited to this. For example, the face plate 14c may have a structure in which two face plates are bonded or fused together: one to which the core member 12Ba is bonded, and the other to which the core member 12Bb is bonded.

[0047] 10, panel structure 10F receives heat or sound from a heat source or sound source (not shown) from core member 12Ba. In this case, filler member 26 is preferably formed between core member 12Ba and face plate 14a and face plate 14c. In other words, when there are multiple core members, filler member 26 is preferably formed on the heat source side or sound source side.

[0048] The panel structure 10F according to the sixth embodiment has a foam member formed between the core member 12Ba and the face plates 14a and 14c, thereby providing heat insulation or sound insulation from the side directly exposed to heat or sound. This improves the heat insulation performance of the sixth embodiment. Furthermore, the sixth embodiment also improves sound insulation performance.

[0049] [Seventh embodiment] The configuration of the panel structure according to the seventh embodiment will be described with reference to Fig. 11. Fig. 11 is a diagram schematically showing a cross section of the panel structure according to the seventh embodiment.

[0050] 11, a panel structure 10G according to the seventh embodiment includes a core member 12B, face plates 14a, 14b, a fused portion 16, and a flow path 28. The panel structure 10G differs from the panel structure 10B shown in FIG. 5 in that it includes the flow path 28.

[0051] The flow paths 28 are formed between the core member 12B and the face plates 14a and 14b. The flow paths 28 allow a fluid to flow between the core member 12B and the face plates 14a and 14b. The fluid may be, for example, a gas or a liquid. Specifically, the fluid may be, but is not limited to, air or water. The flow paths 28 cool the panel structure 10G by allowing the fluid to flow between the core member 12B and the face plates 14a and 14b. For example, if the panel structure 10G is installed in a vehicle, the flow paths 28 may cool or heat the air outside the vehicle, for example, in accordance with the temperature of the fluid flowing therethrough. In other words, in the seventh embodiment, the temperature of the temperature-control target can be cooled or heated based on the correlation between the temperature of the fluid flowing through the flow paths 28 and the temperature of the temperature-control target. For example, in the seventh embodiment, the temperature of the temperature-control target may be measured, and the temperature of the fluid may be determined by feedback control based on the temperature measurement results. As a result, in the seventh embodiment, by controlling the temperature of the fluid in accordance with the temperature of the temperature control object, the temperature control object can be appropriately cooled or heated.

[0052] In the seventh embodiment, sound insulation may be improved by flowing a fluid through the flow path 28. For example, sound propagation characteristics change depending on whether the fluid is a gas or a liquid. The sound propagation characteristics also change depending on the physical properties of the fluid, such as the viscosity of the fluid. That is, by selecting the state and physical properties of the fluid flowing through the flow path 28, it is possible to improve sound insulation against sound received by the panel structure 10G from a sound source (not shown). Furthermore, if the frequency band of sound to be insulated is known in advance, the sound can be effectively attenuated by selecting a fluid capable of attenuating sound in that frequency band and flowing it through the flow path 28. That is, in the seventh embodiment, sound insulation can be improved by selecting the state and physical properties, such as the viscosity, of the fluid flowing through the flow path 28 depending on the sound received by the panel structure 10G.

[0053] The panel structure 10G according to the seventh embodiment can cool the panel structure 10G by flowing a fluid between the core member 12B and the face plates 14a and 14b. This allows the seventh embodiment to improve heat insulation. Furthermore, the seventh embodiment can cool external air, such as the interior of a vehicle, by flowing a fluid with a temperature lower than that of the external heat through the flow path 28. Furthermore, the seventh embodiment can heat external air, such as the interior of a vehicle, by flowing a fluid with a temperature higher than that of the external heat through the flow path 28.

[0054] [Modification of the Seventh Embodiment] The configuration of a panel structure according to a modification of the seventh embodiment will be described with reference to Fig. 12. Fig. 12 is a diagram schematically showing a cross section of a panel structure according to a modification of the seventh embodiment.

[0055] 12, a panel structure 10H according to a modification of the seventh embodiment includes a core member 12Ba, a core member 12Bb, a face plate 14a, a face plate 14b, a face plate 14c, a fusion-bonding portion 16, and a flow path 28. The panel structure 10H differs from the panel structure 10D shown in FIG. 8 in that it includes the flow path 28.

[0056] 12, the panel structure 10H receives heat from a heat source (not shown) on the core member 12Ba side. In this case, the flow path 28 is preferably formed between the core member 12Ba and the face plates 14a and 14c. That is, when there are multiple core members, the flow path 28 is preferably formed on the heat source side.

[0057] In the panel structure 10H according to the modification of the seventh embodiment, a fluid is passed between the core member 12Ba and the face plates 14a and 14c, thereby cooling the side that is directly receiving heat. This allows the modification of the seventh embodiment to improve thermal insulation.

[0058] [Eighth embodiment] The configuration of the panel structure according to the eighth embodiment will be described with reference to Fig. 13. Fig. 13 is a diagram schematically showing a cross section of the panel structure according to the eighth embodiment.

[0059] 13, a panel structure 10I according to the eighth embodiment includes a core member 12B, face plates 14a, 14b, fusion-bonded portions 16, and hole portions 30. The panel structure 10I differs from the panel structure 10B shown in FIG. 5 in that it includes hole portions 30.

[0060] The holes 30 may be formed in the core member 12B, the face plate 14a, and the face plate 14b. The holes 30 may be formed, for example, in at least one of the core member 12B, the face plate 14a, and the face plate 14b. By having the holes 30, the panel structure 10I absorbs sound generated by the sound resonance effect. Panel structure 10I For example, by having holes 30, the sound is reflected inside and the sound is cancelled.

[0061] The number of holes 30 and the positions at which the holes 30 are formed can be changed as desired depending on the design. For example, the number of holes 30 and the positions at which the holes 30 are formed can be changed as desired depending on the volume, frequency, and range of the sound to be absorbed. For example, even when multiple core members are used, holes 30 can be formed as desired in the multiple core members and face plate.

[0062] The panel structure 10I according to the eighth embodiment can absorb sound generated from the panel structure 10I by forming the holes 30, due to the sound resonance effect. This makes it possible to prevent noise generated on one of the face plates 14a and 14b from being transmitted to the other.

[0063] [Modification of the Eighth Embodiment] In the panel structure 10I shown in FIG. 13, at least one of the core member 12B, face plate 14a, and face plate 14b may be formed from a porous resin or a resin containing nonwoven carbon fiber. In this case, the resin is preferably a carbon fiber reinforced plastic containing porous resin or nonwoven carbon fiber. The core member 12B, face plate 14a, and face plate 14b, which are formed from a porous resin or the like, have minute holes. Therefore, by forming the core member 12B, face plate 14a, and face plate 14b from a porous resin or the like, sound can be resonated in the same way as when the hole 30 is formed. Note that in the modified example of the eighth embodiment, the hole 30 does not necessarily have to be formed.

[0064] [Ninth embodiment] The configuration of the panel structure according to the ninth embodiment will be described with reference to Fig. 14. Fig. 14 is a diagram schematically showing a cross section of the panel structure according to the ninth embodiment.

[0065] 14, a panel structure 10J according to the ninth embodiment includes a core member 12B, face plates 14a, 14b, a fused portion 16, and a sound-absorbing member 32. Panel structure 10J differs from panel structure 10B shown in FIG. 5 in that it includes sound-absorbing member 32.

[0066] The sound absorbing member 32 is disposed between the core member 12B and the face plates 14a and 14b. The sound absorbing member 32 may be selectively disposed between the core member 12B and the face plates 14a and 14b. The sound absorbing member 32 may be formed, for example, from any material that exhibits a sound absorbing effect.

[0067] A panel structure 10J according to the ninth embodiment has a sound absorbing member 32 between a core member 12B and face plates 14a and 14b, thereby improving sound insulation in the ninth embodiment.

[0068] [Tenth embodiment] The configuration of the panel structure according to the tenth embodiment will be described with reference to Fig. 15. Fig. 15 is a diagram schematically showing a cross section of the panel structure according to the tenth embodiment.

[0069] 15, a panel structure 10K according to the tenth embodiment includes a core member 12B, face plates 14a, 14b, adhesive portions 34, and a filler member 26. The panel structure 10K differs from the panel structure 10B shown in FIG. 5 in that it includes adhesive portions 34 instead of fusion portions 16, and in that it includes a filler member 26.

[0070] The adhesive 34 connects the core member 12B and the face plate 14a on one surface of the core member 12B. The adhesive 34 is formed between the crests of the waves 22 and one surface of the face plate 14a. The adhesive 34 is selectively formed between the crests of the waves 22 and one surface of the face plate 14a. The adhesive 34 is selectively formed between the crests of the waves 22 and one surface of the face plate 14a, for example, depending on the rigidity and impact resistance characteristics required of the panel structure 10K. The adhesive 34 can be formed, for example, by bonding the waves 22 and the face plate 14a together using a resin adhesive and then drying the adhesive. Any known resin adhesive may be used.

[0071] The adhesive 34 connects the core member 12B and the face plate 14b on the other surface of the core member 12B. The adhesive 34 is formed between the crests of the waves 22 and one surface of the face plate 14b. The adhesive 34 is selectively formed between the crests of the multiple waves 22 and one surface of the face plate 14b. The adhesive 34 is selectively formed between the crests of the multiple waves 22 and one surface of the face plate 14b, for example, depending on the rigidity and impact resistance characteristics required of the panel structure 10K. The adhesive 34 can be formed by bonding the waves 22 and the face plate 14b using a resin adhesive and drying the adhesive.

[0072] An example of a method for disposing the filler member 26 between the core member 12B and the face plates 14a and 14b will be described. For example, before bonding the core member 12B to the face plates 14a and 14b with an adhesive, the filler member 26 is formed into a predetermined shape and placed in the space between the core member 12B and the face plates 14a and 14b. After bonding the core member 12B to the face plates 14a and 14b with adhesive joints 34, the filler member 26 is melted by heating with a heat source (not shown) and adheres to the core member 12B and the face plates 14a and 14b. In this way, the filler member 26 is disposed between the core member 12B and the face plates 14a and 14b.

[0073] The panel structure 10K according to the tenth embodiment has a filler member 26 between the core member 12B and the face plates 14a and 14b, which are joined together by adhesive portions 34. This allows the tenth embodiment to improve the thermal insulation of the panel structure 10K, which is joined together by an adhesive.

[0074] In the tenth embodiment, in order to improve the heat insulating property of the panel structure 10K, a core member is used instead of the filling member 26. 12 Between B and the face plates 14a and 14b, the flow paths 28 through which the fluid flows shown in FIG. 11 may be formed.

[0075] [Eleventh embodiment] The configuration of the panel structure according to the eleventh embodiment will be described with reference to Fig. 16. Fig. 16 is a diagram schematically showing a cross section of the panel structure according to the eleventh embodiment.

[0076] 16, a panel structure 10L according to the eleventh embodiment includes a core member 12B, face plates 14a, 14b, adhesive portions 34, and sound-absorbing members 32. The panel structure 10L differs from the panel structure 10K shown in FIG. 15 in that the panel structure 10L includes sound-absorbing members 32 instead of filler members 26.

[0077] The sound absorbing member 32 is disposed between the core member 12B and the face plates 14a and 14b, which are joined by adhesive portions 34. The sound absorbing member 32 may be selectively disposed between the core member 12B and the face plates 14a and 14b. The sound absorbing member 32 may be formed, for example, from any material that exhibits a sound absorbing effect.

[0078] The panel structure 10L according to the eleventh embodiment has a sound absorbing member 32 between the core member 12B, the face plate 14a, and the face plate 14b, which are joined together by adhesive portions 34. This allows the eleventh embodiment to improve sound insulation.

[0079] In the eleventh embodiment, in order to improve the sound insulation of the panel structure 10L, the hole portion 30 shown in FIG. 13 may be formed in at least one of the core member 14B, the face plate 14a, and the face plate 14b instead of the sound-absorbing member 32.

[0080] Furthermore, the present disclosure is not limited to the forms shown in the 10th and 11th embodiments, and each core member and each face plate shown in the first to 9th embodiments may be bonded with a resin adhesive instead of being fused.

[0081] [Twelfth embodiment] The configuration of the panel structure according to the twelfth embodiment will be described with reference to Fig. 17. Fig. 17 is a diagram schematically showing a cross section of the panel structure according to the twelfth embodiment.

[0082] 17, a panel structure 10M according to the twelfth embodiment includes a core member 12B, a face plate 14a, a face plate 14b, a fusion-bonding portion 16, and a latent heat storage material 36. The panel structure 10M differs from the panel structure 10B shown in FIG. 5 in that it includes the latent heat storage material 36.

[0083] The latent heat storage material 36 is filled between the core member 12B and the face plates 14a and 14b. The latent heat storage material 36 has a temperature adjustment function. The latent heat storage material 36 can be made of, for example, paraffin processed into capsules. For example, when the panel structure 10M filled with the latent heat storage material 36 is used as a battery case, if the battery is in an overheated state, the latent heat storage material 36 absorbs the heat of the battery, thereby maintaining the battery temperature within a certain range. For example, if the battery is in a low temperature state in a cold region, the latent heat storage material 36 releases heat, thereby maintaining the battery temperature within a certain range.

[0084] In the twelfth embodiment, by filling the gaps between the core member 12B and the face plates 14a and 14b with latent heat storage material 36, it is possible to impart a temperature adjusting function to the panel structure 10M.

[0085] [Modification of the twelfth embodiment] The configuration of a panel structure according to a modification of the twelfth embodiment will be described with reference to Fig. 18. Fig. 18 is a diagram schematically showing a cross section of a panel structure according to a modification of the twelfth embodiment.

[0086] As shown in FIG. 18 , in a panel structure 10N according to a modification of the twelfth embodiment, the latent heat storage material 36 may be included in the core member 12B, the face plate 14a, and the face plate 14b. For example, in the modification of the twelfth embodiment, the core member 12B, the face plate 14a, and the face plate 14b may be formed using a resin mixed with the latent heat storage material 36. In the modification of the twelfth embodiment, the latent heat storage material 36 may be included in at least one of the core member 12B, the face plate 14a, and the face plate 14b. The latent heat storage material 36 in the twelfth embodiment and the latent heat storage material 36 in the modification of the twelfth embodiment may be the same or different.

[0087] As shown in the modified example of the twelfth embodiment, the panel structure 10N can also be provided with a temperature adjusting function by including a latent heat storage material 36 in at least one of the core member 12B, the face plate 14a, and the face plate 14b.

[0088] The twelfth embodiment may be combined with the modified example of the twelfth embodiment. Specifically, the latent heat storage material 36 may be filled between the core member 12B and the face plate 14a and face plate 14b, and the latent heat storage material 36 may be contained in at least one of the core member 12B, the face plate 14a, and the face plate 14b.

[0089] [Thirteenth embodiment] The configuration of the panel structure according to the thirteenth embodiment will be described with reference to Fig. 19. Fig. 19 is a diagram schematically showing a cross section of the panel structure according to the thirteenth embodiment.

[0090] 19, a panel structure 10O according to the twelfth embodiment includes a core member 12B, face plates 14a, 14b, a fused portion 16, and a fire extinguishing agent 38. The panel structure 10O differs from the panel structure 10B shown in FIG. 5 in that it includes the fire extinguishing agent 38.

[0091] The extinguishing agent 38 is filled between the core member 12B and the face plates 14a and 14b. The extinguishing agent 38 may be any of a solid, liquid, and gas. If the extinguishing agent 38 is a solid, the extinguishing agent 38 may be, for example, powdered ammonium phosphate or potassium bicarbonate. If the extinguishing agent 38 is a liquid, the extinguishing agent 38 may be, for example, potassium carbonate. If the extinguishing agent 38 is a gas, the extinguishing agent 38 may be carbon dioxide, nitrogen, or the like. The extinguishing agent 38 may be any other substance.

[0092] In the thirteenth embodiment, for example, if the panel structure 10O burns due to ignition or fire, the core member 12B, the face plates 14a, and the face plates 14b melt, and the fire extinguishing agent 38 is discharged to the outside. By discharging the fire extinguishing agent 38 from the panel structure 10O to the outside, the area around the panel structure 10O can be extinguished. The panel structure 10O can be suitably used in locations where relatively strict explosion-proof properties are required, such as the battery peripheral structure of an electric vehicle.

[0093] 19, the extinguishing agent 38 is filled between the core member 12B and the face plates 14a and 14b, but the present disclosure is not limited to this. The extinguishing agent 38 may be contained in, for example, at least one of the core member 12B, the face plates 14a, and the face plates 14b. Alternatively, the extinguishing agent 38 may be filled between the core member 12B and the face plates 14a and 14b, and may be contained in at least one of the core member 12B, the face plates 14a, and the face plates 14b.

[0094] In the thirteenth embodiment, a fire extinguishing function can be imparted to the panel structure 10O by filling the spaces between the core member 12B and the face plates 14a and 14b with a fire extinguishing agent 38.

[0095] [Fourteenth embodiment] The configuration of the core member according to the fourteenth embodiment will be described with reference to Fig. 20. Fig. 20 is a diagram schematically showing the core member according to the fourteenth embodiment.

[0096] As shown in FIG. 20 , the core member 12C differs from the core member 12B shown in FIG. 6 in that it includes slits 40. The core member 12B is easy to shape in the direction of the peaks 22a or valleys 22b, but is difficult to shape in the direction perpendicular to the peaks 22a or valleys 22b due to its high rigidity. As shown in FIG. 20 , in the fourteenth embodiment, slits 40 are provided in a direction perpendicular to the peaks 22a or valleys 22b to improve shapeability. In the example shown in FIG. 20 , multiple slits 40 are provided in the valleys 22b. In the fourteenth embodiment, at least one slit 40 may be provided in the peaks 22a or valleys 22b. The slits 40 may be provided in consideration of the strength and shapeability required of the core member 12C. Grooves may be provided in the direction perpendicular to the peaks 22a or valleys 22b.

[0097] The slits or grooves provided in the core member according to the fourteenth embodiment will be described using Fig. 21A, Fig. 21B, Fig. 21C, and Fig. 21D. Fig. 21A is a diagram showing an example of a slit provided in the core member according to the fourteenth embodiment. Fig. 21B is a diagram showing an example of a groove provided in the core member according to the fourteenth embodiment. Fig. 21C is a diagram showing an example of a slit provided in the core member according to the fourteenth embodiment. Fig. 21D is a diagram showing an example of a slit and groove provided in the core member according to the fourteenth embodiment. Figs. 21A to 21D are diagrams showing the wave portion 22 as viewed from the side.

[0098] The arrows shown in Figures 21A, 21B, 21C, and 21D indicate the shaping direction of the core member 12C. Note that the shaping directions shown in Figures 21A, 21B, 21C, and 21D are examples, and the shaping directions according to the present disclosure are not limited to these.

[0099] 21A, the slits 40 are provided, for example, so as to intersect the valley portions 22b at right angles. If the slits 40 are made larger, the formability of the core member 12C in the direction perpendicular to the shaping direction improves, but the strength of the core member 12C decreases. The size of the slits 40 can be determined taking into account the formability and strength.

[0100] As shown in Figure 21B, V-shaped grooves 42 may be provided on the valley portion 22b side instead of the slits 40. The grooves 42 are provided so as to be perpendicular to the valley portion 22b. If the grooves 42 are made larger, the formability of the core member 12C in the direction perpendicular to the shaping direction improves, but the strength of the core member 12C decreases. The size of the grooves 42 may be determined taking into account the formability and strength.

[0101] 21B, slits 44 may be provided in the face plate 14b at positions corresponding to the grooves 42. The slits 44 may be V-shaped grooves. The slits 44 or V-shaped grooves may be provided in the face plates on both sides of the core member 12C.

[0102] As shown in Fig. 21C, slits 40 may be provided in both the peaks 22a and the valleys 22b. In Fig. 21C, grooves 42 may be provided in both the peaks 22a and the valleys 22b. By providing slits 40 or grooves 42 in both the peaks 22a and the valleys 22b, the shapeability can be further improved.

[0103] 21D, in core member 12C, slits 40 may be provided so as to intersect with peaks 22a at right angles, and grooves 42 may be provided so as to intersect with valleys 22b at right angles. Alternatively, grooves 42 may be provided so as to intersect with peaks 22a at right angles, and slits 40 may be provided so as to intersect with valleys 22b at right angles. That is, in core member 12C, by providing slits 40 in one of peaks 22a and valleys 22b and grooves 42 in the other, it is possible to further improve the formability.

[0104] 21A, 21B, 21C, and 21D show multiple slits, but the present disclosure is not limited thereto. In the present disclosure, for example, slits 40 or grooves 42 may be provided in at least one of peaks 22a or valleys 22b. The positions at which slits 40 or grooves 42 are provided may be determined depending on the three-dimensional shape to be formed by molding.

[0105] In the fourteenth embodiment, the core member 12C has slits 40 or grooves 42 that are perpendicular to the peaks 22a or valleys 22b, thereby improving the shapeability in the direction perpendicular to the peaks 22a or valleys 22b.

[0106] [effect] The panel structure described in the embodiment can be understood, for example, as follows.

[0107] The panel structure of the first embodiment comprises a plate-shaped core member 12 having thermoplastic properties and having a plurality of protrusions 18 on at least one surface thereof, a plate-shaped face plate 14 having thermoplastic properties and arranged on the plurality of protrusions 18, and a fusion portion 16 selectively formed between the face plate 14 and the plurality of protrusions 18 to join the core member 12 and the face plate 14.

[0108] In the panel structure of the first embodiment, the core member 12 and the face plate 14 are joined by a fusion portion 16 formed by thermal fusion. This allows the panel structure of the first embodiment to improve the reliability of the joint between the core member 12 and the face plate 14. Furthermore, in the panel structure of the first embodiment, by joining the core member 12 and the face plate 14 by the fusion portion 16, joining members such as bolts are not required, and an increase in weight can be suppressed.

[0109] In the panel structure of the second aspect, the protrusions 18 are formed on both sides of the core member 12. This enables the panel structure of the second aspect to improve the reliability of the bond between the core member 12 and the face plate 14 on both sides of the core member 12.

[0110] In the panel structure of the third embodiment, the convex portions 18 are continuous corrugated portions 22 formed on the surface of the core member 12. This allows the panel structure of the third embodiment to improve the reliability of the bond between the core member 12 and the face plate 14 when the core member 12 has a corrugated shape.

[0111] The panel structure of the fourth aspect includes a metal thin film formed on at least one surface of the face plate 14. This allows the panel structure of the fourth aspect to reduce radiant heat.

[0112] The panel structure of the fifth embodiment includes a filler member 26 disposed in the space between the core member 12 and the face plate 14. This allows the panel structure of the fifth embodiment to improve heat insulation. Also, the panel structure of the fifth embodiment allows for improved sound insulation.

[0113] The panel structure of the sixth aspect includes a plurality of core members 12. This allows the panel structure of the sixth aspect to have a large number of internal air layers. As a result, the panel structure of the sixth aspect can improve heat insulation. Furthermore, the panel structure of the sixth aspect can improve sound insulation.

[0114] The panel structure of the seventh embodiment includes a flow path 28 through which a fluid flows between the core member 12 and the face plate 14. This allows the panel structure of the seventh embodiment to cool the interior. As a result, the panel structure of the seventh embodiment can improve thermal insulation. Furthermore, the panel structure of the seventh embodiment can cool or heat the temperature inside a vehicle by appropriately adjusting the temperature of the fluid.

[0115] In the panel structure of the eighth aspect, the fluid is a liquid or a gas. This allows the interior of the panel structure of the eighth aspect to be easily cooled using any fluid. As a result, the panel structure of the eighth aspect can easily improve thermal insulation. Furthermore, the panel structure of the eighth aspect can cool or heat the temperature inside a vehicle, for example, using any fluid.

[0116] The panel structure of the ninth aspect has holes 30 selectively formed in at least one of the core member 12 and the face plate 14. This allows the panel structure of the ninth aspect to resonate sound internally. As a result, the panel structure of the ninth aspect can prevent noise generated on one side of the face plate 14 from being transmitted to the other side, thereby improving sound insulation.

[0117] In the panel structure of the tenth aspect, the face plate 14 is formed of porous resin or nonwoven carbon fiber-containing resin. This allows the panel structure of the tenth aspect to resonate sound internally. As a result, the panel structure of the tenth aspect can improve sound insulation.

[0118] The panel structure of the eleventh embodiment includes a sound-absorbing member 32 disposed between the core member 12 and the face plate 14. This allows the panel structure of the eleventh embodiment to absorb sound internally. As a result, the panel structure of the eleventh embodiment can improve sound insulation.

[0119] The panel structure of the twelfth embodiment includes a latent heat storage material 36 disposed in the space between the core member 12 and the face plate 14. When the panel structure of the twelfth embodiment is applied to a battery case or the like, the latent heat storage material 36 provides heat to the battery or absorbs the battery temperature according to the battery temperature. This allows the panel structure of the twelfth embodiment to maintain a constant battery temperature.

[0120] In the panel structure of the thirteenth aspect, at least one of the core member 12 and the face plate 14 includes a latent heat storage material 36. When the panel structure of the thirteenth aspect is applied to a battery case or the like, the latent heat storage material 36 provides heat to the battery or absorbs the battery temperature according to the battery temperature. As a result, the panel structure of the thirteenth aspect can maintain a constant battery temperature.

[0121] The panel structure of the fourteenth aspect includes a fire extinguishing agent 38 filled between the core member 12 and the face plate 14. In the event of a fire or the like, the core member 12 or the face plate 14 melts, releasing the fire extinguishing agent 38 to extinguish the fire. This allows the panel structure of the fourteenth aspect to improve safety.

[0122] In the panel structure of the fifteenth aspect, at least one of the core member 12 and the face plate 14 contains a fire extinguishing agent 38. In the case of a fire or the like occurring in the panel structure of the fifteenth aspect, the core member 12 or the face plate 14 melts, releasing the fire extinguishing agent 38 to extinguish the fire. This allows the panel structure of the fifteenth aspect to improve safety.

[0123] In the panel structure of the sixteenth aspect, the wave portions 22 have slits or grooves in at least one of the peaks 22 a and the valleys 22 b along a direction perpendicular to the shaping direction of the peaks 22 a and the valleys 22 b, thereby improving the shaping property of the panel structure of the sixteenth aspect in the direction perpendicular to the shaping direction of the wave portions 22.

[0124] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the contents of these embodiments. Furthermore, the above-described components include those that can be easily imagined by a person skilled in the art, those that are substantially the same, and those that are within the so-called equivalent range. Furthermore, the above-described components can be combined as appropriate. Furthermore, various omissions, substitutions, or modifications of the components can be made without departing from the spirit of the above-described embodiments. [Explanation of symbols]

[0125] 10 Panel structure 12 Core member 14 Faceplate 16 Fusion part 18 Convex part 20 recess 22 Wave part 24 Metallic thin film 26 Filler material 28 Flow path 30 Hole 32 Sound-absorbing materials 34 Adhesive part 36 Latent heat storage material 38 Fire extinguishing agents 40 slits 42 Groove

Claims

1. a plurality of plate-shaped core members each having thermoplasticity and each having a plurality of protrusions on at least one surface; a plate-shaped face plate having thermoplasticity and disposed on the plurality of protrusions; a fusion portion selectively formed between the face plate and the plurality of protrusions, and connecting the core member and the face plate; a filler member disposed in a space between the core member and the face plate, the filling member is formed only in a space between the face plate and one of the plurality of core members that receives heat or sound from a heat source or a sound source, Panel structure.

2. The protrusions are formed on both surfaces of the core member. The panel structure according to claim 1 .

3. The convex portion is a continuous wave portion formed on the surface of the core member. The panel structure according to claim 1 or 2.

4. The wave portion has a slit or groove portion in at least one of the peak portion and the valley portion along a direction perpendicular to the shaping direction of the peak portion or the valley portion, The panel structure according to claim 3 .

5. a thin metal film formed on at least one surface of the face plate; The panel structure according to any one of claims 1 to 4.

6. The filling member is a latent heat storage material. The panel structure according to any one of claims 1 to 5.

7. At least one of the core member and the face plate contains a latent heat storage material. The panel structure according to any one of claims 1 to 6.

8. A plurality of the core members are provided. The panel structure according to any one of claims 1 to 7.

9. A flow path through which a fluid flows is provided between the core member and the face plate. The panel structure according to any one of claims 1 to 8.

10. The fluid is a liquid or a gas. The panel structure according to claim 9.

11. a hole selectively formed in at least one of the core member and the face plate; The panel structure according to any one of claims 1 to 10.

12. The face plate is formed of a porous resin or a resin containing nonwoven carbon fiber. The panel structure according to any one of claims 1 to 11.

13. a sound absorbing member disposed between the core member and the face plate; The panel structure according to any one of claims 1 to 12.

14. A fire extinguishing agent is filled between the core member and the face plate. The panel structure according to any one of claims 1 to 13.

15. At least one of the core member and the face plate contains a fire extinguishing agent. The panel structure according to any one of claims 1 to 14.

Images