CN114439352A - Honeycomb door leaf and method of making honeycomb door leaf - Google Patents

Abstract

The present invention relates to a honeycomb door leaf and a method of manufacturing a honeycomb door leaf. The honeycomb door leaf at least comprises an inner door skin (10), a framework (20), a honeycomb core (30) and an outer door skin (40), and is characterized in that one surface of the inner door skin (10) is combined with the framework (20) through brazing, two surfaces of the framework (20) are respectively combined with the inner door skin (10) and the honeycomb core (30) through brazing, two surfaces of the honeycomb core (30) are respectively combined with the framework (20) and the outer door skin (40) through brazing, and one surface of the outer door skin (40) is combined with the honeycomb core (30) through brazing, so that the honeycomb door leaf (1, 1A) is formed. The invention adopts a brazing process to replace the traditional adhesive film bonding process in the prior art. Compared with the traditional glue film bonding process, the brazing process can reduce the cost of the manufactured honeycomb door leaf and improve the strength, so that the section size of the side beam of the medium-sized material in the framework can be reduced, and the weight of the whole honeycomb door leaf is reduced.

Description

Honeycomb door leaf and method of making honeycomb door leaf

technical field

The present invention relates to a honeycomb door leaf and a method of making the honeycomb door leaf. In particular, the present invention relates to a honeycomb door leaf manufactured by using a brazing process and a method of manufacturing a honeycomb door leaf by using a brazing process.

Background technique

Honeycomb door leaves are widely used as rail vehicle door leaves. Honeycomb door leaf is usually formed by inner door skin, outer door skin, honeycomb core, skeleton and other components. Traditionally, the inner door skin, outer door skin, honeycomb core, skeleton and other components are combined together by the adhesive film bonding process to form a complete honeycomb door leaf. However, the honeycomb door leaf manufactured by the adhesive film bonding process has disadvantages such as high cost, easy aging of the adhesive, and large total weight.

SUMMARY OF THE INVENTION

In order to overcome at least one of the disadvantages of the honeycomb door leaf formed by the glue film bonding process in the prior art, the present invention provides an improved honeycomb door leaf and an improved method of manufacturing the honeycomb door leaf.

According to a first aspect of the present invention, a honeycomb door leaf is provided, the honeycomb door leaf at least includes an inner door skin, a skeleton, a honeycomb core and an outer door skin, characterized in that one surface of the inner door skin is brazed with the The skeleton is combined, the two surfaces of the skeleton are respectively combined with the inner door skin and the honeycomb core by brazing, the two surfaces of the honeycomb core are respectively combined with the skeleton and the outer door skin by brazing, and one of the outer door skins is combined. The surface is bonded to the honeycomb core by brazing, thereby forming a honeycomb door leaf. Compared with the traditional film bonding process, the brazing process can make the honeycomb door leaf lower in cost and higher in strength, so it can also reduce the cross-sectional size of the profile edge beam in the skeleton, thereby reducing the entire honeycomb door leaf. the weight of.

According to a preferred embodiment of the first aspect, during the brazing process, the surface of the inner door skin to be joined with the skeleton is sprayed with brazing flux and dried, and is clamped to the skeleton between the inner door skin and the honeycomb core Both surfaces of the outer door skin are sprayed with brazing flux and dried, the honeycomb core sandwiched between the skeleton and the outer door skin is dipped in the brazing flux and dried, and the surface of the outer door skin to be joined with the honeycomb core is sprayed and brazed agent and dry. In this way, it can be ensured that the inner door skin, the skeleton, the honeycomb core and the outer door skin are tightly bonded together after the brazing step is completed.

According to a preferred embodiment of the first aspect, the skeleton is formed by welding together at least the front profile side beam, the rear profile side beam, the upper profile side beam and the lower profile side beam of the skeleton before brazing.

According to a preferred embodiment of the first aspect, the welding of the skeleton is completed with the aid of a welding tool. With the help of the welding tooling, the relative position changes and shape and size changes of the parts of the skeleton can be prevented during the subsequent high-temperature brazing process, or the relative position changes and shape and size changes of the parts of the skeleton can be minimized as much as possible.

According to a preferred embodiment of the first aspect, the honeycomb door leaf is a straight honeycomb door leaf obtained directly by brazing or a bent honeycomb door leaf obtained by bending the straight honeycomb door leaf in a stamping die.

According to a preferred embodiment of the first aspect, the straight honeycomb door leaf or the bent honeycomb door leaf is heat-treated. Through appropriate heat treatment, the surface strength, hardness, wear resistance, etc. of the obtained finished honeycomb door leaf can be further improved. For example, the heat treatment may be aging treatment, solution treatment, or other heat treatment processes currently known in the art or developed in the future as technology advances.

According to a second aspect of the present invention, a method for manufacturing a honeycomb door leaf is provided, the honeycomb door leaf at least includes an inner door skin, a skeleton, a honeycomb core and an outer door skin, characterized in that the method comprises: Brazing one surface to the skeleton, brazing the two surfaces of the skeleton to the inner door skin and honeycomb core, respectively, brazing the two surfaces of the honeycomb core to the skeleton and the outer door skin, respectively, and brazing one surface of the outer door skin The brazing step of forming the honeycomb door leaf to the honeycomb core. Similarly, compared with the traditional adhesive film bonding process, the brazing process can reduce the cost and increase the strength of the honeycomb door leaf, so it can also reduce the cross-sectional size of the profile edge beam in the skeleton, thereby reducing the overall The weight of the honeycomb door leaf.

According to a preferred embodiment of the second aspect, the brazing step includes spraying and drying the surface of the inner door skin to be joined with the skeleton, and drying the surface to be sandwiched between the inner door skin and the honeycomb core Both surfaces of the skeleton are sprayed with brazing flux and dried, the honeycomb core sandwiched between the skeleton and the outer door skin is dipped in the brazing flux and dried, and the surface of the outer door skin to be joined with the honeycomb core is sprayed and brazed agent and dry. In this way, it can be ensured that the inner door skin, the skeleton, the honeycomb core and the outer door skin are tightly bonded together after the brazing step is completed.

According to a preferred embodiment of the second aspect, the method includes welding together at least the front profile edge beam, the rear profile edge beam, the upper profile edge beam and the lower profile edge beam of the skeleton to form the skeleton prior to the brazing step skeleton welding steps.

According to a preferred embodiment of the second aspect, the method comprises a heat treatment step of heat treating the honeycomb door leaf obtained by brazing. Through appropriate heat treatment, the surface strength, hardness, wear resistance, etc. of the obtained finished honeycomb door leaf can be further improved. As needed, the desired heat treatment (eg, aging treatment, solution treatment, etc.) can be performed before or after stamping the straight honeycomb door leaf.

Other features of the present invention will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings.

Description of drawings

Figure 1 schematically shows a honeycomb door leaf 1 in an exploded perspective view;

Figure 2 schematically shows the skeleton 20 of the honeycomb door leaf 1 in an exploded perspective view;

Figure 3 schematically shows a welding tool 50 used to assist in welding together the components of the skeleton 20;

Figure 4 schematically shows a straight honeycomb door leaf 1 obtained by brazing;

FIG. 5 schematically shows the bending and forming process of the straight honeycomb door leaf 1 by using a stamping die 60;

Fig. 6 schematically shows the bent honeycomb door leaf 1A obtained by the stamping shown in Fig. 5;

Figure 7 schematically shows the attachment of the door catch handle 70 to the straight honeycomb door leaf 1 to obtain a finished door leaf;

Figure 8 schematically shows the attachment of the door catch handle 70 to the bent honeycomb door leaf 1A to obtain the finished door leaf.

Detailed ways

Compared with ordinary doors, honeycomb doors have the advantages of light weight, high strength, strong temperature resistance, good weather resistance, and strong fire resistance, so they are widely used as rail vehicle doors. As shown in the exploded perspective view of FIG. 1 , the honeycomb door leaf 1 according to the present invention mainly includes an inner door skin 10 , a frame 20 , a honeycomb core 30 and an outer door skin 40 as a whole from the inside to the outside.

The frame 20 is an important component of the honeycomb door leaf 1 . As shown in the exploded perspective view of FIG. 2 , the frame of the frame 20 is mainly composed of a front profile side beam 21 , a rear profile side beam 22 opposite to the front profile side beam 21 , an upper profile side beam 23 and a side beam opposite to the upper profile side beam 23 . The lower profile side beam 24 is composed of these parts. The front profile side beam 21 can be provided with a groove structure (not shown), and the finger guard strip (not shown) can be embedded in the groove structure; the rear profile side beam 22, the upper profile side beam 23 and the lower profile side beam 24 It is also possible to both provide a groove structure in which a sealant strip (not shown) is embedded. The finger-protecting rubber strips and the sealing rubber strips are respectively embedded in the corresponding groove structures of the front profile side beam 21, the rear profile side beam 22, the upper profile side beam 23 and the lower profile side beam 24 to form the front, rear, upper and lower sides. All sealed structure. The finger-protecting tape can be any finger-protecting tape known in the art, and the sealing tape can also be any sealing tape known in the art. When a honeycomb door leaf used for example as a rail car door is closed, the door frame or sealing frame of the rail car will squeeze the finger guard strips and sealing strips around the frame of the honeycomb door leaf, thereby forming an effective seal for the car door.

In the frame formed by the front profile side beam 21 , the rear profile side beam 22 , the upper profile side beam 23 and the lower profile side beam 24 , various door frame parts can also be provided according to actual needs. For example, as shown in FIG. 2, the frame may be provided with a window frame 25, a window frame positioning member 26 for positioning the window frame 25 relative to the front profile side beam 21, a door carrier connection reinforcement block for connecting the door carrier 27. The isolation lock connecting insert 28 for connecting the isolation lock, the supporting roller support 29 for connecting to the rear profile side beam 22, and the like. Here, window frames, door carriers, isolation locks, etc. are all common parts in the field of rail vehicle door leaves.

In order to prevent the relative position changes and shape and size changes of the parts of the skeleton 20 during the subsequent high-temperature brazing process or try to minimize the relative position changes and shape and size changes of the parts of the skeleton Preliminary welding positioning of each part. In an exemplary embodiment, as shown in FIG. 3 , the various parts of the skeleton 20 may be welded and positioned with the aid of a welding tool 50 . The welding tool 50 may be an operating table designed according to the specific structure and size of the honeycomb door leaf to be manufactured, and positioning structures corresponding to each part of the frame 20 may be provided on the table top of the operating table. After the welding of each part of the skeleton is completed, it is necessary to check the size and shape tolerance of the skeleton and its parts. When necessary, the skeleton or its parts whose size and shape tolerances do not meet the requirements can be further polished and corrected. In this way, each part of the frame 20 (for example, the front profile side beam 21, the rear profile side beam 22, the upper profile side beam 23 and the lower profile side beam 24, the window frame 25, the window frame positioning member 26, the door carrier frame is connected and strengthened) The positioning accuracy and dimensional accuracy of the block 27, the isolation lock connecting block 28, the supporting roller support 29 used to connect to the rear profile side beam 22, etc.) are high, and the dimensional stability of the finished honeycomb door leaf during mass production can also be guaranteed. good. In a preferred embodiment, the welding of the parts of the skeleton can be performed using conventional welding techniques.

After the frame 20 has been welded, the brazing step of the honeycomb door leaf 1 will be carried out as described below. Here, "brazing" refers to the simultaneous heating of the brazing flux and the weldment below the melting point of the weldment (which in this embodiment refers to the inner door skin 10 , the skeleton 20 , the honeycomb core 30 and the outer door skin 40 ) After the flux reaches the melting temperature, the liquid flux is used to fill the gap of the solid workpiece to connect the weldments.

First, before brazing the inner door skin 10 , the skeleton 20 , the honeycomb core 30 and the outer door skin 40 of the honeycomb door leaf 1 , the components of the honeycomb door leaf 1 need to be prepared with flux spraying, dipping, drying, etc. Specifically, the surface of the inner door skin 10 to be joined with the frame 20 is preferably sprayed with brazing flux and then dried, while the surface of the inner door skin 10 as the inner side of the finished honeycomb door leaf does not need to be sprayed with brazing flux. The inner surface and the outer surface of the welded frame 20 sandwiched between the inner door skin 10 and the honeycomb core 30 are preferably sprayed with brazing flux, and then dried. The honeycomb core 30 sandwiched between the welded frame 20 and the outer door skin 40 is preferably impregnated with a brazing flux as a whole, and then dried. The inner surface of the outer door skin 40 to be joined with the honeycomb core 30 is preferably sprayed with a brazing flux and then dried, while the surface of the outer door skin 40 as the outer side of the finished honeycomb door leaf does not need to be sprayed with a brazing flux. In this way, it can be ensured that the inner door skin, the skeleton, the honeycomb core and the outer door skin are tightly bonded together after the brazing step is completed later.

Then, position and stack the inner door skin 10 , the frame 20 , the honeycomb core 30 and the outer door skin 40 , which have been prepared for corresponding brazing flux spraying, dipping, drying, etc. The door skin 10, the frame 20, the honeycomb core 30 and the outer door skin 40 are preliminarily assembled into a blank door leaf. Preferably, the positioning of the components making up the honeycomb door leaf 1 can be carried out by means of a positioning tool (not shown). As a result, the positioning accuracy and dimensional accuracy of the components of the honeycomb door leaf 1 (eg, the inner door skin 10, the frame 20, the honeycomb core 30 and the outer door skin 40, etc.) can be ensured, and at the same time, the finished honeycomb can also be guaranteed during mass production. The dimensional stability of the door leaf is good.

Finally, the preliminarily assembled blank door leaf is entirely sent to a brazing furnace (not shown) for brazing treatment. The whole blank door leaf is brazed at one time in the brazing furnace so that the blank door leaf is heated evenly, so the deformation of the blank door leaf can be minimized and the dimensional accuracy of the honeycomb door leaf to be formed can be ensured. After the brazing is completed, the inner door skin 10 , the frame 20 , the honeycomb core 30 and the outer door skin 40 will be closely combined with each other, thereby obtaining the straight honeycomb door leaf 1 as shown in FIG. 4 .

In some cases, the honeycomb door leaf often needs to have a certain curvature or bending for specific functional or aesthetic requirements. Theoretically, the bending of the door leaf can be achieved by various methods, such as stamping and roll forming of the straight honeycomb door leaf after brazing, or pre-bending the various components of the door leaf before brazing. For example, as shown in FIG. 5 , the straight-shaped honeycomb door leaf 1 obtained after brazing can be transferred to a stamping and forming station, and the straight-shaped honeycomb door leaf 1 can be placed between the upper stamping die 61 and the lower stamping die 62 of the stamping die 60 . A bending forming process is performed to obtain a bent honeycomb door leaf 1A, as shown in FIG. 6 . Experiments show that by adopting the stamping forming method, the radian and angle of the stamping die can be flexibly adjusted, so honeycomb door leaves with different radians and bends can be easily manufactured. At the same time, the formed bent honeycomb door leaf also has a uniform thickness and a flat surface. In contrast, using the rolling method to bend the straight honeycomb door leaf will cause local deformation of the obtained bent honeycomb door leaf, resulting in uneven thickness, uneven surface, and pits. In addition, if the components of the honeycomb door leaf (eg, the inner door skin 10, the skeleton 20, the honeycomb core 30 and the outer door skin 40) are pre-bent before brazing, due to the high temperature of the brazing process, the door leaf The preset curvature or bend of the part is changed so that the desired curvature or bend cannot be obtained. Therefore, for the bending of the honeycomb door leaf, the method of stamping and forming the straight honeycomb door leaf after brazing is preferable.

In order to further improve the surface strength, hardness, wear resistance, etc. of the obtained finished honeycomb door leaf, the honeycomb door leaf obtained by brazing can be subjected to heat treatment. According to actual needs, the heat treatment can be solution treatment, aging treatment, or other heat treatment processes currently known in the art or developed in the future with technological progress. Generally, the surface hardness of the honeycomb door leaf obtained after brazing is low and deformation is relatively easy to occur. As a non-limiting example, for example, for a honeycomb door leaf whose material itself is not easy to be stamped and formed, the straight honeycomb door leaf obtained after brazing can be stamped and formed, and then the obtained bent honeycomb door leaf can be subjected to required heat treatment. For example, for the honeycomb door leaf that the material itself is easy to deform, the surface curvature accuracy is high, or it is hoped to try to avoid subsequent shaping, the straight honeycomb door leaf obtained after brazing can be subjected to heat treatment and then stamping and forming to obtain a bent honeycomb door leaf. However, the sequence of heat treatment process and stamping forming is not limited to this, but can be flexibly adjusted according to actual needs.

Finally, after the necessary heat treatment, bending, etc. are performed on the honeycomb door leaf 1, the required components can be attached to the honeycomb door leaf according to the specific application. For example, as shown in FIGS. 7 and 8 , the door handle 70 can be bonded or welded to the straight honeycomb door leaf 1 or the bent honeycomb door leaf 1A, thereby obtaining a finished honeycomb door leaf.

In general, for the honeycomb door leaf 1 (for example, the door leaf for rail vehicles) including the inner door skin 10, the frame 20, the honeycomb core 30 and the outer door skin 40, the present invention adopts the brazing process to replace the prior art traditional film bonding process. Compared with the traditional adhesive film bonding process, the use of the brazing process can reduce the cost of the manufactured honeycomb door leaf and have higher strength, so the profile side beams in the frame 20 (ie, the front profile side beams 21, 21, The cross-sectional dimensions of the rear profile side beam 22 , the upper profile side beam 23 and the lower profile side beam 24 ) can further reduce the weight of the entire honeycomb door leaf 1 .

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims (10)

1. A honeycomb door leaf (1, 1A) at least comprises an inner door skin (10), a framework (20), a honeycomb core (30) and an outer door skin (40), and is characterized in that one surface of the inner door skin (10) is combined with the framework (20) through brazing, two surfaces of the framework (20) are respectively combined with the inner door skin (10) and the honeycomb core (30) through brazing, two surfaces of the honeycomb core (30) are respectively combined with the framework (20) and the outer door skin (40) through brazing, and one surface of the outer door skin (40) is combined with the honeycomb core (30) through brazing, so that the honeycomb door leaf (1, 1A) is formed.

2. The honeycomb door leaf (1, 1A) according to claim 1, characterized in that, during brazing, the surface of the inner doorskin (10) to be joined with the frame (20) is sprayed with a brazing flux and dried, both surfaces of the frame (20) sandwiched between the inner doorskin (10) and the honeycomb core (30) are sprayed with a brazing flux and dried, the honeycomb core (30) sandwiched between the frame (20) and the outer doorskin (40) is impregnated with a brazing flux and dried, and the surface of the outer doorskin (40) to be joined with the honeycomb core (30) is sprayed with a brazing flux and dried.

3. Cellular door leaf (1, 1A) according to claim 1, characterized in that the frame is formed by welding together at least the front profile border beam (21), the rear profile border beam (22), the upper profile border beam (23) and the lower profile border beam (24) of the frame (20) before brazing.

4. Cellular door leaf (1, 1A) according to claim 2, characterized in that the welding of the skeleton (20) is done with the aid of a welding tool (50).

5. Honeycomb door leaf (1, 1A) according to any of claims 1-4, characterised in that it is a straight honeycomb door leaf (1) obtained directly by brazing or a folded honeycomb door leaf (1A) obtained by bending a straight honeycomb door leaf (1) in a stamping die (60).

6. Honeycomb door leaf (1, 1A) according to claim 5, characterised in that the straight honeycomb door leaf (1) or the folded honeycomb door leaf (1A) is heat treated.

7. A method of manufacturing a cellular door leaf (1, 1A) comprising at least an inner door skin (10), a carcass (20), a cellular core (30) and an outer door skin (40), characterized in that the method comprises a brazing step of brazing one surface of the inner door skin (10) to the carcass (20), brazing both surfaces of the carcass (20) to the inner door skin (10) and the cellular core (30), respectively, brazing both surfaces of the cellular core (30) to the carcass (20) and the outer door skin (40), respectively, and brazing one surface of the outer door skin (40) to the cellular core (30) to form the cellular door leaf (1, 1A).

8. Method for manufacturing a cellular door leaf (1, 1A) according to claim 7, characterized in that the brazing step comprises spraying and drying a surface of the inner door skin (10) to be joined with the carcass (20), spraying and drying a brazing agent on both surfaces of the carcass (20) clamped between the inner door skin (10) and the cellular core (30), dipping and drying the cellular core (30) clamped between the carcass (20) and the outer door skin (40) with a brazing agent, and spraying and drying a surface of the outer door skin (40) to be joined with the cellular core (30) with a brazing agent.

9. Method for manufacturing a cellular door leaf (1, 1A) according to claim 7 or 8, characterized in that the method comprises a frame welding step for welding together at least the front profile border beam (21), the rear profile border beam (22), the upper profile border beam (23) and the lower profile border beam (24) of the frame (20) to form the frame (20) before the brazing step.

10. Method for manufacturing a cellular door leaf (1, 1A) according to claim 7 or 8, characterized in that it comprises a heat treatment step of heat treating the cellular door leaf (1, 1A) obtained by brazing.

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