Panel structure and method for manufacturing panel structure

Abstract

This panel structure comprises: two basic panels which each include a base plate and a cone plate having such a shape that a plurality of hollow quadrangular pyramid parts having the same shape and the same dimension are connected in a planar direction along the base plate so as to share a base or to be in a state in which the bases are spaced apart from each other in a direction perpendicular to the bases, the cone plate being joined to the base plate so that the quadrangular pyramid parts protrude, the two basic panels being disposed in a state in which the quadrangular pyramid parts face each other; and a wavy member which includes a wavy part where a recessed part and a protruding part are repeatedly formed in one direction along the entire inclined surfaces of the plurality of quadrangular pyramid parts of the cone plate, and which is sandwiched by the cone plates in the two basic panels.

Description

Panel structure and method for manufacturing the panel structure

[0001] The present disclosure relates to a panel structure and a method for manufacturing the panel structure.

[0002] Highly rigid panel structures such as honeycomb panels are used in the bodies of automobiles, trains, aircraft, and other mobility products. Another known example is a panel structure in which a conical plate having quadrangular pyramidal portions arranged lengthwise and widthwise is joined to a flat member, and the panels are joined so that the quadrangular pyramidal portions face each other (see, for example, Patent Document 1), but there are few examples in which this has been put into practical use.

[0003] U.S. Pat. No. 4,495,237

[0004] In the panel structure as described in Patent Document 1, a configuration with high rigidity and a high degree of freedom in design is required.

[0005] The present disclosure has been made in view of the above, and aims to provide a panel structure that is highly rigid and has a high degree of freedom in design, and a method for manufacturing the panel structure.

[0006] The panel structure of the present disclosure comprises a base plate, a conical plate having a shape in which a plurality of hollow quadrangular pyramidal portions of the same shape and dimensions share a base or are spaced apart in a direction perpendicular to the base, and connected in a planar direction along the base plate so that the quadrangular pyramidal portions protrude, and is joined to the base plate, and the conical plate is arranged with the quadrangular pyramidal portions facing each other, and a corrugated member having a corrugated portion in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the plurality of quadrangular pyramidal portions of the conical plate, and is sandwiched between the conical plates of the two basic panels.

[0007] The panel structure of the present disclosure comprises a base plate, a conical plate having a shape in which a plurality of hollow quadrangular pyramidal portions of the same shape and dimensions share a base or are spaced apart in a direction perpendicular to the base, and connected in a planar direction along the base plate so that the quadrangular pyramidal portions protrude, and is joined to the base plate, and the conical plate is arranged with the quadrangular pyramidal portions facing each other, and resin or foamed resin sandwiched between the conical plates of the two basic panels, the resin or foamed resin having a wavy portion in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the plurality of quadrangular pyramidal portions of the conical plate.

[0008] The manufacturing method of the panel structure according to the present disclosure includes the steps of: arranging two basic panels, each having a base plate and a conical plate joined to the base plate so that the quadrangular pyramidal portions protrude, and each having a shape connected in a planar direction along the base plate so that a plurality of hollow quadrangular pyramidal portions of the same shape and dimensions share a base or are spaced apart in a direction perpendicular to the base, with the quadrangular pyramidal portions facing each other; arranging a corrugated member between the two basic panels, the corrugated member having a corrugated portion in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the plurality of quadrangular pyramidal portions of the conical plate; and joining the corrugated member to each of the conical plates of the two basic panels so that the corrugated member is sandwiched between the conical plates of each of the two basic panels.

[0009] According to the present disclosure, it is possible to provide a panel structure having high rigidity and a high degree of freedom in design, and a method for manufacturing the panel structure.

[0010] FIG. 1 is an exploded perspective view showing an example of a panel structure according to the present embodiment. FIG. 2 is a view showing an example of a corrugated member according to the present embodiment. FIG. 3A is a view showing an example of a corrugated member according to the present embodiment. FIG. 3B is an exploded perspective view showing an example of a corrugated member according to the present embodiment. FIG. 4 is a cross-sectional view showing an example of a panel structure. FIG. 5A is an exploded perspective view showing an example of a panel structure. FIG. 5B is a cross-sectional view showing an example of a panel structure. FIG. 6A is an exploded perspective view showing an example of a panel structure. FIG. 6B is a cross-sectional view showing an example of a panel structure. FIG. 7A is an exploded perspective view showing an example of a panel structure. FIG. 7B is a cross-sectional view showing an example of a panel structure. FIG. 8A is an exploded perspective view showing an example of a panel structure. FIG. 8B is a cross-sectional view showing an example of a panel structure. FIG. 9 is a cross-sectional view showing an example of a panel structure. FIG. 10 is a cross-sectional view showing an example of a panel structure. FIG. 11 is a cross-sectional view showing an example of a panel structure. FIG. 12 is a cross-sectional view showing an example of a panel structure. FIG. 13 is a cross-sectional view showing an example of a panel structure. FIG. 14 is a cross-sectional view showing an example of a panel structure. FIG. 15 is a cross-sectional view showing an example of a panel structure. FIG. 16 is a cross-sectional view showing an example of a panel structure. Fig. 17 is a cross-sectional view showing an example of a panel structure. Fig. 18 is a cross-sectional view showing an example of a panel structure. Fig. 19 is a cross-sectional view showing an example of a panel structure. Fig. 20 is a cross-sectional view showing an example of a panel structure. Fig. 21 is a cross-sectional view showing an example of a panel structure. Fig. 22 is a cross-sectional view showing an example of a panel structure. Fig. 23 is a cross-sectional view showing an example of a panel structure. Fig. 24 is a cross-sectional view showing an example of a panel structure. Fig. 25 is a flowchart showing an example of a method for manufacturing a panel structure. Fig. 26 is a diagram schematically showing an example of a joining method. Fig. 27 is a diagram schematically showing an example of a joining method. Fig. 28 is a diagram schematically showing an example of a joining method.

[0011] Hereinafter, embodiments of a panel structure and a method for manufacturing a panel structure according to the present disclosure will be described with reference to the drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially identical.

[0012] Fig. 1 is an exploded perspective view showing an example of a panel structure 100 according to this embodiment. As shown in Fig. 1, the panel structure 100 includes a basic panel 10 and a corrugated member 20. In Fig. 1, the corrugated member 20 is shown as a corrugated sheet 21, which will be described later. The panel structure 100 has a laminated body 30 in which the corrugated member 20 is sandwiched between two basic panels 10.

[0013] The basic panel 10 includes a base plate 11 and a conical plate 12. The base plate 11 is flat. The conical plate 12 has a shape in which multiple quadrangular pyramidal portions 12a are connected in a plane direction D along the base plate 11 so that they share a base or are spaced apart in a direction perpendicular to the base. In this embodiment, the multiple quadrangular pyramidal portions 12a are connected in the plane direction D so that their bases are spaced apart in a direction perpendicular to the base, forming a mesh-like portion 12b described below. Note that the multiple quadrangular pyramidal portions 12a may also be connected in the plane direction so that they share a base. In this embodiment, the quadrangular pyramidal portions 12a are square pyramidal. The quadrangular pyramidal portions 12a are configured with four slopes formed by a plate-like member, with chamfered ridges and a bottom surface, and the portion surrounded by these surfaces is hollow. The multiple quadrangular pyramidal portions 12a are configured with the bases of the quadrangular pyramids connected together. That is, the pyramidal plate 12 has a configuration in which quadrangular pyramidal portions 12a are connected vertically and horizontally. The plural quadrangular pyramidal portions 12a protrude in the same direction.

[0014] The conical plate 12 is joined to the base plate 11 so that the multiple quadrangular pyramidal portions 12a protrude from the first surface 11a of the base plate 11 in the normal direction of the first surface 11a. Therefore, the basic panel 10 is configured such that the conical plate 12 is joined to the base plate 11 so that the multiple quadrangular pyramidal portions 12a protrude from the base plate 11. In this embodiment, the base plate 11 is joined to the mesh-like portions 12b (see FIG. 3B ) that are located along the boundaries between the multiple quadrangular pyramidal portions 12a of the conical plate 12. This allows the base plate 11 and the conical plate 12 to be joined easily and firmly.

[0015] The two basic panels 10 are arranged in a state in which the quadrangular pyramidal portions 12a of the two basic panels 10 face each other at positions shifted by half a pitch in the first direction D1 and the second direction D2.

[0016] The corrugated member 20 has corrugated portions 20a in which recesses and protrusions are repeatedly formed in one direction along the entire slopes of the multiple quadrangular pyramidal portions 12a of the conical plate 12. Figures 2, 3A, and 3B are views showing an example of the corrugated member 20 according to this embodiment. In this embodiment, at least one of the corrugated plate 21 shown in Figure 2 and the double-sided quadrangular pyramidal member 22 shown in Figure 3 is used as the corrugated member 20. Note that Figure 3B is an exploded perspective view showing an example of the double-sided quadrangular pyramidal member 22 according to this embodiment.

[0017] Here, the base plate 11, the conical plate 12, and the corrugated member 20 are formed of thermoplastic resins such as polyolefin, polyamide (PA), polycarbonate (PC), polyphenylene sulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polyethersulfone (PES), polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polyamideimide (PAI), etc. These are preferably thermoplastic fiber-reinforced plastics containing reinforcing fibers such as carbon fiber, glass fiber, and aramid fiber.

[0018] As shown in Fig. 2, the corrugated sheet 21 is a plate-like member formed in a rectangular wave shape. In the corrugated sheet 21, protruding portions on the first surface 21a become recessed portions on the second surface 21b. In addition, in the corrugated sheet 21, recessed portions on the first surface 21a become protruding portions on the second surface 21b. In other words, the corrugated sheet 21 has a wave-like portion 20a formed on both the first surface 21a and the second surface 21b, in which rectangular wave-like recesses and protrusions are repeated in one direction (first direction D1). Note that a second direction D2, which is perpendicular to the first direction D1 in the planar direction, is the direction in which the recesses and protrusions extend.

[0019] As shown in Figures 3A and 3B, the double-sided pyramidal member 22 has a shape formed by joining two pyramidal plates 12 having the same shape and dimensions, each having a pyramidal portion 12a of the same shape and size, so that the pyramidal portions 12a protrude in opposite directions. The double-sided pyramidal member 22 is configured by joining two pyramidal plates 12 so that the bases of the pyramidal portions 12a overlap. In this case, the mesh portions 12b of each pyramidal plate 12 are joined together. The double-sided pyramidal member 22 is configured such that the slopes of the pyramidal portions 12a are arranged in a wavy pattern in the first direction D1 and the second direction D2. Therefore, the double-sided pyramidal member 22 has a configuration in which wavy portions 20a that conform to the pyramidal portions 12a of the pyramidal plates 12 are formed on both sides.

[0020] Examples of the panel structure will be described below. Figures 4 to 23 are diagrams showing examples of the panel structure. Each figure shows a schematic cross section of each component of the panel structure.

[0021] FIG. 4 is a cross-sectional view showing an example of a panel structure 101. The panel structure 101 shown in FIG. 4 has the same configuration as the panel structure 100 described above (see FIG. 1 for an exploded perspective view). The panel structure 101 shown in FIG. 4 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. The corrugated portions 20a on both sides of the corrugated sheet 21 are shaped to conform to the quadrangular pyramidal portions 12a of the basic panels 10, respectively. Therefore, the quadrangular pyramidal portions 12a are arranged so that they are in close contact with the corrugated portions 20a of the corrugated sheets 21 on both sides. By arranging the corrugated sheets 21 in this manner, strength can be increased in the direction in which the recesses or protrusions of the corrugated portions 20a extend, i.e., in the direction perpendicular to the direction in which the recesses and protrusions of the corrugated portions 20a are repeatedly formed. Furthermore, by arranging the corrugated sheets 21, the two basic panels 10 can be easily and accurately positioned relative to each other.

[0022] FIG. 5A is an exploded perspective view showing an example of a panel structure. FIG. 5B is a cross-sectional view showing an example of a panel structure. The panel structure 102 shown in FIGS. 5A and 5B is configured such that a double-sided pyramidal member 22 is sandwiched between two basic panels 10. In the panel structure 102, the two basic panels 10 and the double-sided pyramidal member 22 are positioned so that the chamfered portions on the ridges of the pyramidal portions 12a on the two basic panels 10 contact the chamfered portions on the ridges of the pyramidal portions 12a on the double-sided pyramidal member 22. By arranging the double-sided pyramidal member 22 in this manner, the spacing between the two basic panels 10 can be increased compared to the corrugated sheet 21. This allows the panel thickness of the panel structure 102 to be increased.

[0023] FIG. 6A is an exploded perspective view showing an example of a panel structure. FIG. 6B is a cross-sectional view showing an example of a panel structure. The panel structure 103 shown in FIGS. 6A and 6B is configured by sandwiching a plurality of double-sided quadrangular pyramidal members 22 stacked between two basic panels 10. The two basic panels 10 and the plurality of double-sided quadrangular pyramidal members 22 are positioned so that the chamfered portions on the ridges of the quadrangular pyramidal portions 12a are in contact with each other. By stacking a plurality of double-sided quadrangular pyramidal members 22 in this way, the panel thickness of the panel structure 102 can be increased.

[0024] FIG. 7A is an exploded perspective view showing an example of a panel structure. FIG. 7B is a cross-sectional view showing an example of a panel structure. The panel structure 104 shown in FIGS. 7A and 7B is configured by sandwiching a corrugated sheet 21 and a double-sided square pyramidal member 22 between two stacked basic panels 10. The corrugated sheet 21 is disposed between the square pyramidal portion 12a of the opposing basic panel 10 and the square pyramidal portion 12a of the double-sided square pyramidal member 22, and also between the square pyramidal portions 12a of the opposing double-sided square pyramidal members 22. By disposing the corrugated sheet 21 in this manner, strength can be increased in the direction in which the concave or convex portions of the corrugated portion 20a extend. Furthermore, by disposing the double-sided square pyramidal member 22, the panel thickness of the panel structure 102 can be increased. The number of corrugated sheets 21 and the double-sided square pyramidal members 22 may be one each, or at least one of them may be two or more.

[0025] FIG. 8A is an exploded perspective view showing an example of a panel structure. FIG. 8B is a cross-sectional view showing an example of a panel structure. The panel structure 105 shown in FIGS. 8A and 8B is configured such that a corrugated sheet 21 and a double-sided quadrangular pyramidal member 22 are sandwiched between two basic panels 10. In addition, in this panel structure 105, a double-sided corrugated sheet member 23, which is formed by joining two corrugated sheets 21, is sandwiched between the opposing quadrangular pyramidal portions 12a. The double-sided corrugated sheet member 23 is configured such that the convex portions are joined together. By arranging the double-sided corrugated sheet member 23, it is possible to further increase the strength in the direction in which the concave or convex portions extend.

[0026] The panel structure 106 shown in Figure 9 is configured such that a corrugated sheet 21 and a double-sided quadrangular pyramidal member 22 are sandwiched between two basic panels 10. In this panel structure 106, the protruding height of the quadrangular pyramidal portion 12a of the double-sided quadrangular pyramidal member 22 is formed so as to gradually increase in one direction. With this configuration, the panel thickness of the panel structure 106 can be changed in one direction.

[0027] The panel structure 107 shown in FIG. 10 is configured by sandwiching a corrugated plate 21 and a double-sided square pyramidal member 22 between two stacked basic panels 10. In each basic panel 10, the base plate 11 has a curved shape. The base plate 11 may be curved in one direction to maintain a constant spacing between the two base plates 11, thereby maintaining a constant panel thickness (panel structure 107A), or curved to vary the panel thickness (panel structure 107B). Alternatively, the panel structure 107 may be curved in one direction to maintain a constant spacing between the two base plates 11, thereby forming a ring-shaped cross section (panel structure 107C). ​​Furthermore, the conical plate 12, the corrugated plate 21, and the double-sided square pyramidal member 22 have shapes that conform to the base plate 11. That is, the conical plate 12 and the double-sided square pyramidal member 22 have their square pyramidal portions 12a arranged to conform to the curved base plate 11. Furthermore, the corrugated plate 21 has wave-like portions 20a formed to correspond to the pyramidal portions 12a of the pyramidal plate 12 and the double-sided pyramidal member 22. With this configuration, the panel structure 107 can be used for a variety of purposes depending on its shape.

[0028] The panel structure 108 shown in FIG. 11 is configured by sandwiching a corrugated sheet 21 and a double-sided square pyramidal member 22 between two stacked basic panels 10. In each basic panel 10, the pyramidal plate 12, the corrugated sheet 21, and the double-sided square pyramidal member 22 have a thickness-changing portion 24 where the thickness varies. For example, in portion A of the panel structure 108, the thickness-changing portion 24 is formed so that the quadrangular pyramidal portion 12a of the double-sided square pyramidal member 22 gradually becomes thicker toward the tip in the protruding direction. In this configuration, the thickness of the quadrangular pyramidal portion 12a is increased toward the base, thereby increasing rigidity. In addition, in portion B of the panel structure 108, the thickness-changing portion 24 is formed so that the thickness of the quadrangular pyramidal portion 12a of the pyramidal plate 12 gradually becomes thinner toward the tip in the protruding direction. In this configuration, the thickness is increased toward the tip in the protruding direction, thereby increasing rigidity. Furthermore, the corrugated sheet 21 of the panel structure 108 may have a thickness-varying portion 24 formed so that the thickness of one portion is greater than the other portion in one direction. This configuration allows the rigidity to be appropriately increased in one direction as needed.

[0029] The panel structure 109 shown in Figure 12 has a configuration in which resin (or foamed resin) 25 is sandwiched between the conical plates 12 of two basic panels 10. The resin 25 has recesses and protrusions repeatedly formed in one direction along the entire slopes of the multiple quadrangular pyramidal portions 12a of the conical plate 12. When foamed resin is used as the resin 25, it is possible to reduce weight and improve thermal insulation, sound insulation, and impact absorption.

[0030] The panel structure 110 shown in Figure 13 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 110, the corrugated sheet 21 is formed using an adhesive that can be bonded to the basic panels 10. This configuration significantly simplifies the work of applying the adhesive. Furthermore, by using the corrugated sheet 21 as an adhesive as well, the number of parts can be reduced.

[0031] The panel structure 111 shown in Fig. 14 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 111, an adhesive 25 that can adhere to the basic panel 10 is applied to the surface of the corrugated sheet 21. Specifically, the adhesive 25 is applied to the surface of the corrugated sheet 21 that faces the basic panel 10. With this configuration, there is no need to apply an adhesive separately to the location where the corrugated sheet 21 will be placed between the two basic panels 10.

[0032] The panel structure 112 shown in FIG. 15 has a configuration in which a corrugated plate 21 is sandwiched between two basic panels 10. In the panel structure 112, the conical plate 12 and the corrugated plate 21 are formed using a composite material 50 in which thermoplastic resin fibers 51 having a lower melting point or glass transition temperature than the base plate 11 are woven. With this configuration, bonding using the thermoplastic resin fibers 51 requires a higher temperature than adhesives such as resins. If the thermoplastic resin fibers 51 are made of a material having a melting point or glass transition temperature similar to that of the base plate 11, the base plate 11 would also soften and lose its shape when heated to soften the thermoplastic resin fibers 51. In contrast, in this embodiment, the conical plate 12 and the corrugated plate 21 are formed using a composite material 50 in which thermoplastic resin fibers 51 having a lower melting point or glass transition temperature than the base plate 11 are woven. This prevents the base plate 11 from softening when the thermoplastic resin fibers 51 are heated. Here, "thermoplastic resin fibers" refers to the aforementioned thermoplastic resin stretched into fibers and woven into a fabric.

[0033] The panel structure 113 shown in FIG. 16 has a configuration in which a corrugated sheet 21 is sandwiched between two basic panels 10. In the panel structure 113, the corrugated sheet 21 is formed using a conductive material. In this configuration, the basic panel 10 and the corrugated sheet 21 are joined together by an adhesive 25 that softens when heated by passing an electric current through the corrugated sheet 21. If heat is applied to the outer surface of the basic panel 10 to soften the adhesive 25, the basic panel 10 also softens and loses its shape. In this embodiment, by passing an electric current through the corrugated sheet 21 to generate heat, the adhesive 25 can be heated from the inside of the portion sandwiched between the basic panels 10. This prevents the basic panel 10 from softening.

[0034] The panel structure 114 shown in FIG. 17 is configured by connecting a laminate 30, each of which sandwiches a corrugated sheet 21 or a corrugated member 20 made of a double-sided square pyramidal member 22, between two basic panels 10 in the planar direction D. In this panel structure 114, the laminates 30 are joined at their connecting portions 31 via a splice plate 52. The panel structure 114A is configured such that two basic panels 10 protrude from each other in the connecting direction D, and the laminates 30 are connected by facing the protruding portions. The panel structure 114B is configured such that the panel structures 114A are stacked in the stacking direction, so that the opposing connecting portions 31 of the panel structures 114A are closed. By connecting the laminates 30 in the planar direction D in this way, a large panel structure 114 can be obtained.

[0035] The panel structure 115 shown in FIG. 18 is a laminated body 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided pyramidal member 22 is sandwiched between two basic panels 10. The panel structure 115 is in a state in which the end 32 of the laminated body 30 in the planar direction D is deformed so that the inside is closed off from the outside of the laminated body 30. The panel structure 115A is configured by bonding the base plates 11 of two basic panels 10 together at the end 32. The panel structure 115B is configured by bonding the base plates 11 of two basic panels 10 together at the end 32 and then folding them back. The panel structure 115C is configured by bonding the base plates 11 of two basic panels 10 together at the end 32 and then folding them back. The panel structure 115D is configured by blocking the end 32 with a blocking member 33. The blocking member 33 is arranged to cover the end 32 of the base plates 10 of the two basic panels 10. The closing member 33 may be used in the panel structures 115A, 115B, and 115C. Closing the end 32 of the panel structure 115 can prevent foreign matter from entering the interior.

[0036] The panel structure 116 (116A, 116B) shown in FIG. 19 is a laminated structure 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided square pyramidal member 22 is sandwiched between two basic panels 10. In the panel structure 116A shown in FIG. 19, a filler 34 is filled between the two basic panels 10. The panel structure 116A (laminate 30) has through-holes 35 formed in the stacking direction in the areas filled with the filler 34. By forming the through-holes 35 in the panel structure 116A, the panel structure 116A can be used for a wider range of applications, such as for mounting. Furthermore, since the strength of the areas where the holes are formed is reduced, reinforcement can be achieved by partially increasing the thickness of the basic panel 10. The panel structure 116B shown in FIG. 19 is configured such that the thickness of the basic panel 10 (e.g., base plate 11) at predetermined portions 11f and 11g where the through-holes 35 are located is increased compared to other portions. 19B shows a configuration in which the thickness of the base plate 11 is thicker on the inside at a predetermined portion 11f, and a configuration in which the thickness of the base plate 11 is thicker on the outside at a predetermined portion 11g. Note that the thickness of the base plate 11 may be thicker on both the inside and outside. This configuration can reinforce the strength around the through hole 35.

[0037] The panel structure 117 shown in Figure 20 is configured as a laminate 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided square pyramidal member 22 is sandwiched between two basic panels 10. The panel structure 117 has an insert member 36 disposed at an end in the surface direction D, which is inserted between the base plates 11 of the two basic panels 10 and covers the end 32. A through hole 37 penetrating the panel structure 117 in the stacking direction may be provided in the portion where the insert member 36 is disposed. With this configuration, the end 32 of the panel structure 117 can be blocked and protected by covering the end 32.

[0038] The panel structure 118 shown in FIG. 21 is a laminated body 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided pyramidal member 22 is sandwiched between two basic panels 10. The panel structure 118 has an interface member 38 connected to the end of the laminated body 30 in the planar direction D. The interface member 38 is inserted between the two basic panels 10. In the panel structure 118A, the interface member 38A has through-holes 39 that penetrate the panel in a direction perpendicular to the paper surface in a cross-sectional view, and any number of through-holes may be provided in any direction. By inserting a rod-shaped member or fastener (not shown) into the through-holes 39, the panel structure 118A can be fixed to other members or rotated or turned. In the panel structure 118B, the interface member 38B connects the laminated bodies 30 to each other in the planar direction D. The interface member 38B has through-holes 40 that run along the planar direction D, and any number of through-holes may be provided in any direction. The panel structure 118B can be fixed to another member or can be rotated or turned by inserting a rod-shaped member or fastening member (not shown) into the through-hole 40. In this way, the provision of the interface member 38 can widen the range of uses of the panel structure 118.

[0039] The panel structure 119 shown in Figure 22 is a laminated body 30 configured with two basic panels 10 sandwiching a double-sided quadrangular pyramidal member 22. In the panel structure 119, an interface member 41 is connected to the end of the laminated body 30 in the planar direction D. The interface member 41 is inserted and joined so as to partially replace the double-sided quadrangular pyramidal member. This configuration allows the interface member 41 to be firmly attached. The interface member 41 may be provided with a through hole 41a similar to the through hole 39 described above.

[0040] The panel structure 120 shown in FIG. 23 is a laminated body 30 in which a corrugated sheet 21 or a corrugated member 20 made of a double-sided pyramidal member 22 is sandwiched between two basic panels 10. The panel structure 120 has a first communication portion 42 that communicates the space sandwiched between the base plates 11 in the planar direction. In the panel structure 120A, the first communication portion 42A is formed by removing a portion of the double-sided pyramidal member in the communication direction. In the panel structure 120B, the first communication portion 42B is formed by disposing a tubular portion 43 in the first communication portion 42A of the panel structure 120A. In a plan view, the first communication portion 42 and the tubular portion 43 may be arranged in a linear direction or in a curved or bent direction. The provision of the first communication portion 42 and the tubular portion 43 allows piping, wiring, liquids, and gases to pass through the interior of the panel structure 120. This broadens the range of uses of the panel structure 120.

[0041] The panel structure 121 shown in Figure 24 is configured as a laminated body 30 in which a corrugated plate 21 or a corrugated member 20 made of a double-sided square pyramidal member 22 is sandwiched between two basic panels 10. The panel structure 121 has a second communication portion 44 that communicates between the inside and outside of the laminated body 30. The second communication portion 44 is provided, for example, by penetrating a part of the base plate 11 or a part of the pyramidal plate 12, and also communicates with the internal communication portion. The provision of the second communication portion 44 makes it possible to pass piping, wiring, liquids, and gases between the inside and outside of the panel structure 121. This allows the panel structure 121 to have a wider range of uses.

[0042] Next, a method for manufacturing the panel structure 100 configured as described above will be described. Fig. 25 is a flowchart showing an example of a method for manufacturing the panel structure 100. As shown in Fig. 25, the method for manufacturing the panel structure 100 includes a basic panel arrangement step S10, a corrugated member arrangement step S20, and a joining step S30.

[0043] In the basic panel arrangement step S10, two basic panels 10 are arranged with the quadrangular pyramidal portions 12a facing each other.

[0044] In the corrugated member arrangement step S20, a double-sided pyramidal member 22 is arranged between two basic panels 10.

[0045] In the joining step S30, the double-sided pyramidal member 22 is joined to the pyramidal plates 12 of the two basic panels 10 so that the double-sided pyramidal member 22 is sandwiched between the pyramidal plates 12 of the two basic panels 10.

[0046] Fig. 26 is a diagram schematically illustrating an example of the bonding process. As shown in Fig. 26, in the bonding process S30, vibrations are generated by a vibration generator 60 on the two basic panels 10, thereby generating heat at the bonding surfaces. The heat softens the bonding surfaces, and the two basic panels 10 can be bonded by applying pressure to them in the softened state. This process allows the interiors of the two basic panels 10 to be selectively heated, thereby suppressing softening of the basic panels 10. The vibrations include ultrasonic vibrations.

[0047] In the bonding step S30, the two basic panels 10 may be heated by a separate heat source such as a heating device so as not to reach their melting points or glass transition temperatures, and vibrations may be generated between the two basic panels 10 by the vibration generator 60. By heating the two basic panels 10 so as not to reach their melting points or glass transition temperatures, softening of the basic panels 10 can be suppressed, and the amount of heat generated by the vibration generator 60 can also be reduced.

[0048] Fig. 27 is a diagram schematically illustrating an example of the joining step. As shown in Fig. 27, in the joining step S30, two basic panels 10 are heated by a high-frequency induction heating device 70. The joining surfaces are softened by the heating, and the two basic panels 10 can be joined by applying pressure to the softened joining surfaces.

[0049] In the bonding step S30, the two basic panels 10 may be heated by another heating device so as not to reach their melting points or glass transition temperatures, and then the two basic panels 10 may be heated by the high-frequency induction heating device 70. By heating the two basic panels 10 so as not to reach their melting points or glass transition temperatures, softening of the basic panels can be suppressed and the amount of heat applied by the high-frequency induction heating device 70 can be reduced.

[0050] FIG. 28 is a diagram schematically illustrating an example of the bonding process. As shown in FIG. 28 , in the bonding process S30, the bonding surfaces are heated by a heating device 80 having a heating surface 81 corresponding to the shape of the bonding surfaces of the basic panel 10 and the corrugated member 20. The heat from the heating softens the bonding surfaces. When the bonding surfaces are softened, the heating device is removed, and the two basic panels 10 are pressed together, thereby bonding the corrugated member 20 and the two basic panels 10. Since the bonding surfaces have unevenness, the shape of the heating device 80 can be adapted to the bonding surfaces to efficiently and uniformly heat them. Various devices can be used as the heating device 80, such as a hot plate, an infrared irradiation device, a far-infrared irradiation device, or a laser irradiation device.

[0051] As described above, according to the first aspect of the present disclosure, a panel structure is provided, comprising: a base plate 11; a conical plate 12 having a shape in which a plurality of hollow quadrangular pyramidal portions 12a of the same shape and the same dimensions are connected in a planar direction D along the base plate 11 with their bases aligned or spaced apart and adjacent to each other, and the quadrangular pyramidal portions 12a protrude; two basic panels 10 arranged with the quadrangular pyramidal portions 12a facing each other; and a corrugated member 20 sandwiched between the conical plates 12 of the two basic panels 10, the corrugated member 20 having a corrugated portion 20a in which recesses and protrusions are repeatedly formed in one direction along the entire slope of the plurality of quadrangular pyramidal portions 12a of the conical plate 12.

[0052] With this configuration, the corrugated member 20 is sandwiched between the conical plates 12 of the two basic panels 10, ensuring rigidity with the corrugated member 20 and allowing the thickness of the panel structure to be freely set. This makes it possible to provide a panel structure that is highly rigid and offers a high degree of freedom in design.

[0053] According to the second aspect of the present disclosure, in the panel structure relating to the first aspect, the corrugated member 20 is at least one of a corrugated plate 21 having a corrugated portion 20a, and a double-sided quadrangular pyramidal member 22 having two pyramidal plates 12 of the same shape and size, each having a quadrangular pyramidal portion 12a of the same shape and size, joined together so that the quadrangular pyramidal portions 12a protrude in opposite directions.

[0054] According to this configuration, by providing the corrugated plate 21 as the corrugated member 20, rigidity can be ensured in the direction perpendicular to the direction in which the corrugated portion 20a is formed, i.e., in the direction in which the recesses and protrusions that make up the corrugated portion 20a extend. In addition, by providing the double-sided pyramidal member 22 as the corrugated member 20, the distance between the two basic panels 10 can be increased.

[0055] According to a third aspect of the present disclosure, in the panel structure according to the second aspect, a plurality of corrugated members 20 are arranged in a stacked state.

[0056] According to this configuration, the distance between the two basic panels 10 can be set with a high degree of freedom.

[0057] According to the fourth aspect of the present disclosure, in the panel structure relating to the second aspect, the double-sided pyramidal member 22 is formed so that the protruding height of the pyramidal portions 12a of the two pyramidal plates 12 gradually increases in one direction.

[0058] This configuration makes it possible to form a panel structure in which the panel thickness gradually increases in one direction.

[0059] According to the fifth aspect of the present disclosure, in a panel structure relating to any of the first to third aspects, each base plate 11 has a shape curved in one direction so that the distance between the two base plates 11 is constant, and the conical plate 12 and the corrugated member 20 have a shape that follows the base plate 11.

[0060] According to this configuration, a curved panel structure can be formed, which widens the range of uses for the panel structure.

[0061] According to the sixth aspect of the present disclosure, in a panel structure relating to any of the first to fifth aspects, the conical plate 12 and the corrugated member 20 have a thickness-changing portion 24 in which the thickness changes so that the thickness becomes thicker or thinner toward the tip in the protruding direction.

[0062] According to this configuration, the provision of the thickness-changing portion 24 can increase the strength of a portion of the interior of the panel structure.

[0063] According to the seventh aspect of the present disclosure, in a panel structure relating to any of the first to sixth aspects, the base plate 11 is joined to a mesh-like portion along the boundary between multiple quadrangular pyramidal portions 12a of the pyramidal plate 12.

[0064] According to this configuration, the base plate 11 and the conical plate 12 can be firmly joined together.

[0065] According to the eighth aspect of the present disclosure, in the panel structure relating to the second aspect, the double-sided pyramidal member 22 has mesh-like portions joined together along the boundaries between multiple pyramidal portions 12a of the pyramidal plate 12.

[0066] This configuration makes it possible to obtain a double-sided pyramidal member 22 having high strength.

[0067] According to the ninth aspect of the present disclosure, there is provided a base plate 11, and a conical plate 12 having a shape in which a plurality of hollow quadrangular pyramidal portions 12a of the same shape and the same dimensions are connected in a surface direction D along the base plate 11 with their bases aligned or spaced apart and adjacent to each other, and the quadrangular pyramidal portions 12a protrude, and the base plate 11 is joined to the base plate 11, and two basic panels 10 are arranged with the quadrangular pyramidal portions 12a facing each other, and between the two basic panels 10, recesses and protrusions are repeatedly formed in one direction along the entire slope of the plurality of quadrangular pyramidal portions 12a of the conical plate 12, and resin or foamed resin sandwiched between the conical plates 12 of the two basic panels 10 is filled in.

[0068] This configuration allows the base panel 10 and the corrugated member 20 to be firmly joined together.

[0069] According to a tenth aspect of the present disclosure, in the panel structure according to any one of the first to ninth aspects, the corrugated member 20 is formed using an adhesive 25 that can be bonded to the basic panel 10 .

[0070] According to this configuration, the corrugated member 20 itself is made of the adhesive material 25, so the number of parts can be reduced.

[0071] According to an eleventh aspect of the present disclosure, in the panel structure according to any one of the first to tenth aspects, the corrugated member 20 has an adhesive 25 applied to the surface facing the basic panel 10 .

[0072] According to this configuration, there is no need to separately apply the adhesive 25, and therefore the number of steps required to manufacture the panel structure can be reduced.

[0073] According to the twelfth aspect of the present disclosure, in a panel structure relating to any of the first to eleventh aspects, at least one of the conical plate 12 and the corrugated member 20 is formed using a composite material 50 woven with thermoplastic resin fibers 51 having a melting point or glass transition temperature lower than that of the base plate 11.

[0074] According to this configuration, there is no need to separately apply the adhesive 25, and therefore the number of steps required to manufacture the panel structure can be reduced.

[0075] According to the thirteenth aspect of the present disclosure, in a panel structure relating to any of the first to twelfth aspects, the corrugated member 20 is formed using a conductive material, and when an electric current is passed through the corrugated member 20, the basic panel 10 softens due to the heat generated, thereby joining the basic panel 10 and the corrugated member 20.

[0076] According to this configuration, the base material between the basic panels 10 can be heated from the inside, so there is no need to heat the basic panels 10 from the outer surface, and thermal deformation of the basic panels 10 can be prevented.

[0077] According to the fourteenth aspect of the present disclosure, in a panel structure relating to any of the first to thirteenth aspects, a laminate 30 having a corrugated member 20 sandwiched between two basic panels 10 is connected in the surface direction D, the connecting portions of the laminate 30 are joined via a splice plate 52, the two basic panels 10 are stacked so that they protrude from each other in the connecting direction, and the laminates 30 are connected to each other by facing the protruding portions.

[0078] According to this configuration, by connecting the laminates 30 together in the planar direction, the dimension of the panel structure in the planar direction D can be increased.

[0079] According to the 15th aspect of the present disclosure, in a panel structure relating to any of the 1st to 14th aspects, the surface-wise ends of the laminate 30, in which the corrugated member is sandwiched between two basic panels 10, are bonded together by bonding the base plates 11 of the two basic panels 10 together so as to close the inside of the laminate 30 from the outside.

[0080] According to the 16th aspect of the present disclosure, in a panel structure relating to any of the 1st to 14th aspects, the surface-wise end of the laminate 30, in which two basic panels 10 sandwich a corrugated member, is arranged in a folded state, with the base plates 11 of the two basic panels 10 bonded together so as to close the inside of the laminate 30 from the outside.

[0081] According to the 17th aspect of the present disclosure, in a panel structure relating to any of the 1st to 14th aspects, a blocking member 33 is arranged at the surface-direction end of the laminate 30, in which two basic panels 10 sandwich a corrugated member, to cover the end 32 of the base plate 11 of the two basic panels 10 so as to close the inside of the laminate 30 from the outside.

[0082] According to these configurations, by closing the end portion of the laminate 30 in the plane direction D, it is possible to prevent foreign matter from entering through the end portion 32 .

[0083] According to the 18th aspect of the present disclosure, in a panel structure relating to any of the 1st to 17th aspects, in a laminate 30 in which two basic panels 10 sandwich a corrugated member 20, a filler 34 is filled between the conical plates 12 and the base plate 11 of the two basic panels 10, and a through hole 35 penetrating the laminate 30 in the stacking direction is formed in the portion filled with the filler 34.

[0084] According to this configuration, by forming through holes 35 in the portion of panel structure 116 filled with filler 34, the range of uses such as mounting of panel structure 116 is expanded.

[0085] According to the 19th aspect of the present disclosure, in a panel structure relating to any of the 1st to 17th aspects, in a laminate 30 in which two basic panels 10 sandwich a corrugated member 20, an insertion member 36 is arranged at the end in the surface direction D, inserted between the base plates 11 of the two basic panels 10 and covering the end.

[0086] According to this configuration, the end portion 32 of the panel structure 117 can be closed, and the end portion 32 can be protected by being covered.

[0087] According to the 20th aspect of the present disclosure, in a panel structure relating to any of the first to 19th aspects, an interface member 38 is connected to the end in the surface direction D of the laminate 30, in which the corrugated member 20 is sandwiched between two basic panels 10, while being inserted between the base plates 11 of the two basic panels 10.

[0088] According to this configuration, the provision of the interface member 38 can widen the range of uses of the panel structure 118 .

[0089] According to the 21st aspect of the present disclosure, in a panel structure relating to any of the 1st to 20th aspects, the corrugated member 20 is a double-sided square pyramidal member 22 having a shape formed by joining two pyramidal plates 12 of the same shape and size, each having a square pyramidal portion 12a of the same shape and size, so that the square pyramidal portions 12a protrude in opposite directions, and the interface member 38 is inserted and joined between the square pyramidal portions 12a of the opposing pyramidal plates 12 so as to partially replace the double-sided square pyramidal member 22.

[0090] This configuration allows the interface member 41 to be attached firmly.

[0091] According to the 22nd aspect of the present disclosure, in a panel structure relating to any of the 1st to 21st aspects, the corrugated member 20 is a double-sided quadrangular pyramidal member 22 having a shape in which two pyramidal plates 12 of the same shape and size, each having a quadrangular pyramidal portion 12a of the same shape and size, are joined together so that the quadrangular pyramidal portions 12a protrude in opposite directions, and has a first communicating portion 42 that is formed by removing a portion of the double-sided quadrangular pyramidal member 22 and communicates in a direction along the concave or convex portion.

[0092] This configuration allows piping, wiring, liquids, and gases to pass through the interior of the panel structure 120. This allows the panel structure 120 to be used in a wider range of applications.

[0093] According to the 23rd aspect of the present disclosure, in the panel structure relating to the 22nd aspect, the laminate 30 in which the corrugated member 20 is sandwiched between two basic panels 10 has a second communicating portion 44 that communicates the first communicating portion 42 with the outside in the surface direction D.

[0094] This configuration allows piping, wiring, liquids, and gases to pass between the inside and outside of the panel structure 121. This allows the panel structure 121 to be used in a wider range of applications.

[0095] According to a 24th aspect of the present disclosure, there is provided a method for manufacturing a panel structure, including the steps of: arranging two basic panels (10) each having a base plate (11) and a conical plate (12) joined to the base plate (11) so that the quadrangular pyramidal portions (12a) protrude, the basic panels (10) each having a base plate (11) and a plurality of hollow quadrangular pyramidal portions (12a) of the same shape and dimensions connected in a plane direction D along the base plate (11) with their bases aligned or spaced apart and adjacent to each other; arranging a corrugated member (20) between the two basic panels (10) and having a corrugated portion (20a) in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the plurality of quadrangular pyramidal portions (12a) of the conical plate (12); and joining the corrugated member (20) to the conical plate (12) of each of the two basic panels (10) so that the corrugated member (20) is sandwiched between the conical plate (12) of each of the two basic panels (10).

[0096] This configuration allows efficient manufacturing of a panel structure that is highly rigid and has a high degree of freedom in design.

[0097] According to the 25th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 24th aspect, vibrations are generated in two basic panels 10 by a vibration generating device 60, thereby generating heat at the joining surface, which softens the joining surface, and the two basic panels 10 are joined by applying pressure to the softened joining surface.

[0098] According to this configuration, the insides of the two basic panels 10 can be selectively heated, and therefore softening of the basic panels 10 can be suppressed.

[0099] According to the 26th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 25th aspect, two basic panels 10 are heated by a heating device so that the basic panels do not reach their melting point or glass transition temperature, and vibrations are generated between the two basic panels 10 by a vibration generating device 60.

[0100] According to this configuration, by heating the two basic panels 10 so that they do not reach their melting point or glass transition temperature, softening of the basic panels 10 can be suppressed and at the same time the amount of heat generated by the vibration generating device 60 can be reduced.

[0101] According to the 27th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 24th aspect, the corrugated member 20 is formed using a conductive material, heated by a high-frequency induction heating device 70 to soften the joining surface, and then two basic panels 10 are joined by applying pressure to the softened joining surfaces.

[0102] According to this configuration, the insides of the two basic panels 10 can be selectively heated, and therefore softening of the basic panels 10 can be suppressed.

[0103] According to the 28th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 27th aspect, the corrugated member 20 is heated by the high-frequency induction heating device 70 while two basic panels 10 are heated by another heating device so that the basic panels do not reach their melting point or glass transition temperature.

[0104] According to this configuration, by heating the two basic panels 10 so that they do not reach their melting point or glass transition temperature, softening of the basic panels 10 can be suppressed and the amount of heat applied by the high-frequency induction heating device 70 can be reduced.

[0105] According to the 29th aspect of the present disclosure, in the manufacturing method of the panel structure relating to the 24th aspect, the joining surfaces are heated by a heating device 80 having a heating surface 81 corresponding to the shape of the joining surfaces between the basic panel 10 and the corrugated member 20, the joining surfaces are softened by the heat generated by the heating, and the two basic panels 10 are joined by applying pressure to the softened joining surfaces.

[0106] According to this configuration, the shape of the heating device 80 can be adapted to the joining surface having the uneven portions, thereby enabling efficient and uniform heating.

[0107] The technical scope of the present invention is not limited to the above-described embodiment, and appropriate modifications can be made without departing from the spirit of the present invention. For example, in the above-described embodiment, the base plate 11, the conical plate 12, and the corrugated member 20 can be formed using various materials such as thermoplastic resin, thermosetting resin, metal, and composite material.

[0108] In the above embodiment, the base plate 11, the conical plate 12, and the corrugated member 20 can be joined together by adhesion, welding, or the like.

[0109] In the above embodiment, the thickness of the base plate 11 can be set appropriately depending on the application, location, and the like.

[0110] In the above embodiment, the conical plate 12 or the double-sided quadrangular pyramidal member 22 may have a flat portion between adjacent quadrangular pyramidal portions 12 a. Similarly, the corrugated plate 21 may have a flat portion between adjacent concave-convex portions.

[0111] In the above embodiment, the tip of the conical plate 12 or the double-sided pyramidal member 22 in the protruding direction or the ridge of the pyramidal portion 12 a may be chamfered. Similarly, the tip of the corrugated plate 21 in the protruding direction may be chamfered.

[0112] In the above embodiment, the quadrangular pyramid portion 12a is not limited to a quadrangular pyramid, and may be another polygonal pyramid.

[0113] DESCRIPTION OF SYMBOLS 10 Basic panel 11 Base plate 11a, 21a First surface 12 Pyramidal plate 12a Square pyramidal portion 20 Corrugated member 20a Corrugated portion 21 Corrugated plate 21b Second surface 22 Double-sided square pyramidal member 23 Double-sided corrugated plate member 24 Plate thickness changing portion 25 Adhesive 30 Laminate 31 Connecting portion 32 End portion 33 Closing member 34 Filler 35, 37, 39, 40, 41a Through hole 36 Insertion member 38, 38A, 38B, 41 Interface member 42, 42A, 42B, 44 Connecting portion 43 Tubular portion 50 Composite material 51 Thermoplastic resin fiber 52 Splice plate 60 Vibration generator 70 High-frequency induction heating device 80 Heating device 81 Heating surface 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 114A, 114B, 115, 115A, 115B, 115C, 115D, 116, 117, 118, 118A, 118B, 119, 120, 120A, 120B, 121 Panel structure D Planar direction, connecting direction S10 Basic panel arrangement process S20 Wave-shaped member arrangement process S30 Joining process

Claims

1. A panel structure comprising: a base plate; a conical plate joined to the base plate so that the square pyramidal sections protrude and having a shape connected in a planar direction along the base plate so that multiple hollow square pyramidal sections of the same shape and dimensions share a base or are spaced apart in a direction perpendicular to the base, and two basic panels arranged with the square pyramidal sections facing each other; and a corrugated member sandwiched between the conical plates of the two basic panels, the corrugated member having a corrugated section in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the multiple square pyramidal sections of the conical plate.

2. The panel structure according to claim 1, wherein the corrugated member is at least one of a corrugated plate having the corrugated portion, and a double-sided quadrangular pyramidal member having two quadrangular pyramidal plates of the same shape and dimensions, each having quadrangular pyramidal portions of the same shape and dimensions, joined together so that the quadrangular pyramidal portions protrude in opposite directions.

3. The panel structure according to claim 2, wherein the corrugated members are arranged in a stacked state.

4. The panel structure according to claim 2, wherein the double-sided pyramidal member is formed so that the protruding height of the pyramidal portions of the two pyramidal plates gradually increases in one direction.

5. A panel structure as described in claim 1, wherein each of the base plates has a shape curved in one direction so that the distance between the two base plates is constant, and the conical plate and the corrugated member have shapes that follow the shape of the base plates.

6. The panel structure according to claim 1, wherein the tapered plate and the corrugated member have a thickness varying portion where the thickness changes so that the thickness becomes thicker or thinner towards the tip in the protruding direction.

7. The panel structure according to claim 1, wherein the base plate is joined to a mesh-like portion of the pyramidal plate along the boundary between the plurality of quadrangular pyramidal portions.

8. The panel structure according to claim 2, wherein the double-sided pyramidal member is formed by joining mesh-like portions along the boundaries between the plurality of pyramidal portions of the pyramidal plate.

9. A panel structure comprising: a base plate; a conical plate joined to the base plate so that the square pyramidal sections protrude and having a shape connected in a planar direction along the base plate so that a plurality of hollow quadrangular pyramidal sections of the same shape and dimensions share a base or are spaced apart in a direction perpendicular to the base, and two basic panels arranged with the quadrangular pyramidal sections facing each other; and a resin or foamed resin sandwiched between the conical plates of the two basic panels, in which recesses and protrusions are repeatedly formed in one direction along the entire slopes of the plurality of quadrangular pyramidal sections of the conical plate.

10. The panel structure according to claim 1, wherein the corrugated member is formed using an adhesive that can be bonded to the basic panel.

11. The panel structure according to claim 1, wherein the corrugated member has an adhesive applied to the surface facing the base panel.

12. The panel structure according to claim 1, wherein at least one of the tapered plate and the corrugated member is formed using a composite material in which thermoplastic resin fibers having a melting point or glass transition temperature lower than that of the base plate are woven.

13. The panel structure according to claim 1, wherein the corrugated member is formed using a conductive material, and the basic panel is softened by heat generated when an electric current is passed through the corrugated member, thereby joining the basic panel and the corrugated member.

14. A panel structure as described in claim 1, wherein a laminate in which two of the basic panels sandwich the corrugated member is connected in the planar direction, the connecting portion of the laminate is joined via a splice plate, the two basic panels are stacked so that they protrude from each other in the connecting direction, and the laminates are connected to each other by facing the protruding portions.

15. A panel structure as described in claim 1, wherein the surface-direction ends of the laminate, in which the corrugated member is sandwiched between two of the basic panels, are bonded together by bonding the base plates of the two basic panels together so as to close the inside of the laminate from the outside.

16. A panel structure as described in claim 1, wherein the surface-direction end of the laminate, in which the corrugated member is sandwiched between two of the basic panels, is provided with the base plates of the two basic panels bonded together and the bonded portion folded so as to close the inside of the laminate from the outside.

17. A panel structure as described in claim 1, wherein the surface-direction ends of the laminate, in which the corrugated member is sandwiched between two of the basic panels, are provided with closing members that cover the ends of the base plates of the two basic panels so as to close the inside of the laminate from the outside.

18. A panel structure as described in claim 1, wherein in a laminate in which two of the basic panels sandwich the corrugated member, a filler is filled between the conical plate and the base plate of the two basic panels, and a through hole penetrating the laminate in the stacking direction is formed in the portion filled with the filler.

19. A panel structure as described in claim 1, wherein in a laminate in which two of the basic panels sandwich the corrugated member, an insert member is disposed at the end in the surface direction, inserted between the base plates of the two basic panels to cover the end.

20. A panel structure as described in claim 1, in which an interface member is connected to the end of the surface direction of the laminate in which the corrugated member is sandwiched between two of the basic panels, while being inserted between the base plates of the two basic panels.

21. The panel structure described in claim 20, wherein the corrugated member is a double-sided quadrangular pyramidal member formed by joining two pyramidal plates of the same shape and size, each having quadrangular pyramidal portions of the same shape and size, so that the quadrangular pyramidal portions protrude in opposite directions, and the interface member is inserted and joined between the quadrangular pyramidal portions of the opposing pyramidal plates so as to partially replace the double-sided quadrangular pyramidal member.

22. The panel structure described in claim 1, wherein the corrugated member is a double-sided quadrangular pyramidal member formed by joining two pyramidal plates of the same shape and size, each having quadrangular pyramidal portions of the same shape and size, so that the quadrangular pyramidal portions protrude in opposite directions, and has a first communicating portion that is formed by removing a portion of the double-sided quadrangular pyramidal member and communicates in a direction along the concave or convex portion.

23. A panel structure according to claim 22, further comprising a second communication portion that connects the first communication portion with the outside in the planar direction.

24. A method for manufacturing a panel structure, comprising the steps of: arranging two basic panels, each having a base plate and a conical plate joined to the base plate so that the square pyramidal portions protrude and having a shape connected in a plane direction along the base plate so that a plurality of hollow square pyramidal portions of the same shape and size share a base or are spaced apart in a direction perpendicular to the base, with the square pyramidal portions facing each other; arranging a corrugated member between the two basic panels, the corrugated member having a corrugated portion in which recesses and protrusions are formed repeatedly in one direction along the entire slope of the plurality of square pyramidal portions of the conical plate; and joining the corrugated member to each of the conical plates of the two basic panels so that the corrugated member is sandwiched between the conical plates of each of the two basic panels.

25. A method for manufacturing a panel structure as described in claim 24, in which vibrations are generated in the two basic panels using a vibration generating device, heat is generated, the joining surfaces are softened by the heat, and the two basic panels are joined by applying pressure to the softened joining surfaces.

26. A method for manufacturing a panel structure according to claim 25, wherein the vibration is generated between the two basic panels by a vibration generating device while the two basic panels are heated by a heating device so that the basic panels do not reach their melting point or glass transition temperature.

27. A method for manufacturing a panel structure as set forth in claim 24, wherein the corrugated member is formed using a conductive material, and the joining surfaces are softened by heating with a high-frequency induction heating device, and the two basic panels are joined by applying pressure to the softened joining surfaces.

28. A method for manufacturing a panel structure according to claim 27, wherein the corrugated member is heated by a high-frequency induction heating device while the two basic panels are heated by another heating device so that the basic panels do not reach their melting point or glass transition temperature.

29. A method for manufacturing a panel structure as described in claim 24, wherein the joining surfaces are heated by a heating device having a heating surface corresponding to the shape of the joining surfaces of the basic panel and the corrugated member, the joining surfaces are softened by the heat generated by the heating, and the two basic panels are joined by applying pressure to the softened joining surfaces.

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