JP2007062181A - Manufacturing method of gas permeable sandwich panel and sandwich panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To propose, in order to manufacture a gas permeable sandwich panel to function as a sound absorbing material using a honeycomb material filled with a gas permeable foam material as a core material and a gas permeable porous material as a surface material, a way of using an adhesive wherein the gas permeabilities of the foam material and the surface material are not damaged. <P>SOLUTION: The manufacturing method of the gas permeable sandwich panel comprises the following steps: the liquid adhesive (2) having a predetermined viscosity is attached, in a narrow strip, only to the tip of the cell wall verging on one face of the honeycomb material (3); the gas permeable surface material (5) is pressed against the face of the honeycomb material (3) to which the adhesive (2) has been attached; before the adhesive (2) hardens, the water-absorptive foam material (10) is thrust in from the other face of the honeycomb material (3) until it contacts the attached adhesive (2) thus to fill the cell spaces (7); and the hardening is accelerated by letting the foam material (10) brought into contact with the adhesive (2) absorb the moisture contained in the adhesive (2), and the adhesion of the surface material (5) to the honeycomb material (3) is swiftly completed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a breathable sandwich panel using a honeycomb material filled with a foam material having a breathing structure using a porous material having a breathability as a surface material, and the sandwich panel.

  Structures using a honeycomb material as a core material are often used for the walls and floor surfaces of aircraft, railway vehicles, and building materials. As the intended use of the honeycomb structure, the use as a sound absorbing material is important as well as the use as a sound insulating material.

  In this specification, the sound insulating material is a structure that blocks the propagation of sound by attaching non-breathable face materials on both surfaces while filling or unfilling cells of the honeycomb material, and the sound absorbing material is a honeycomb material. The porous body is filled with a porous body, a surface material having air permeability is attached to at least one surface of the honeycomb material, sound is incident through the air-permeable surface material, and sound is absorbed into the porous body. Think of it as a damped structure. However, whether a certain honeycomb structure is viewed as a sound insulating material or a sound absorbing material differs depending on the person who is thinking, and is not necessarily clear.

  In Patent Document 1, the name of the invention is “a manufacturing method of a sound absorbing panel”. This sound-absorbing panel is obtained by attaching a face material in which a net-like and perforated metal plate is superimposed on both surfaces of a cell-unfilled honeycomb material with an extremely thin film adhesive made of a thermosetting resin. The point that the cell is not filled is not as defined in the sound absorbing material. Regarding the method of using the adhesive, the film material is bonded to the surface of the honeycomb material with another adhesive and then heated and melted with hot air to form a plurality of holes communicating with the honeycomb core. A special film adhesive and a method of using the same are disclosed.

  In Patent Document 2, the name of the invention is “a manufacturing method of a panel-shaped core material”. It has been disclosed to press-fit a foamed foam material into the honeycomb material, and to provide an adhesive on the inner surface of the cell by dipping or spraying, etc. It seems that no specific usage is disclosed. In the attached drawing (FIG. 6) illustrating the embodiment, the adhesive is drawn in a planar shape (one horizontal line) between the outer covering material and the honeycomb material.

  Patent Document 3 relates to a sandwich panel in which the name of the device is “sandwich panel”, and a synthetic resin foam having a thickness smaller than that of the honeycomb core is filled in a substantially central portion in the thickness direction of the honeycomb core. The specification states that the honeycomb core and the cover plate are bonded only at the end face of the honeycomb core, and the end face of the press-fitted polyurethane foam is the same as the end face of the honeycomb core. It describes that the foam may be melted by an adhesive that bonds the core and the cover plate, and that the cover plate is uneven. In addition, it seems that the presence or absence of the air permeability of the jacket plate, a special method of using an adhesive for not impairing the breathability of the jacket plate, and the like are not disclosed.

JP-A-9-156010 JP-A-1-198951 Japanese Utility Model Publication No. 61-30844

  An object of the present invention is to produce a breathable sandwich panel that functions as a sound absorbing material by using a honeycomb material filled with a foam material having a breathable structure as a core material and a breathable porous material as a surface material. And a sandwich panel manufacturing method including the use of an adhesive that does not impair the breathability of the porous material.

  The above-described problem is that the liquid adhesive 2 having a predetermined viscosity is attached in a narrow band shape only at the tip of the cell wall facing one side of the honeycomb material 3, and the surface material 5 having air permeability is attached to the honeycomb material 3. The one adhesive surface is pressed against the one surface, and before the adhesive 2 is cured, the foam material 10 having water absorption is brought into contact with the adhered adhesive 2 from the other surface of the honeycomb material 3. The foam material 10 that has been pushed in to fill the cell space 7 and absorbs the moisture contained in the adhesive 2 by the foam material 10 in contact with the adhesive 2 promotes curing, so that the surface material 5 adheres quickly to the honeycomb material 3. This method is solved by a method for manufacturing a breathable sandwich panel including the steps achieved in (1).

  In this problem, it is necessary to avoid applying a solid adhesive to the foam material or the air-permeable surface material because the air-permeable surface is blocked and its function is impaired. An alternative problem-solving means is to limit the location and amount of adhesive used so as not to impair air permeability. Adhesion between the honeycomb material and the surface material is performed at the tip of the cell wall of the honeycomb material and a localized portion in the surface material with which the tip contacts. Therefore, it is sufficient to supply the minimum amount of adhesive that can bond these points only to those points. Specifically, the adhesive may be attached only to the tip of the cell wall in the form of a narrow strip having a width of 1 to 2 mm and pressed against the surface material as it is to cure the adhesive.

  In order to cure the adhesive, it is necessary to take away the moisture of the adhesive, but the inside of the sandwich panel that is being manufactured is a closed space, although it is breathable, the moisture evaporation rate is slow, and the adhesive is cured. It takes time. Therefore, in the present invention, attention is paid to the water absorption of the foam material, and this is utilized as a means for promoting the curing of the adhesive. That is, the adhesive is attached to the tip of the cell wall of the honeycomb material, and the foam material having water absorption from the other surface of the honeycomb material is pressed against the surface material, and the tip of the foam material is attached to the adhesive attachment portion. Push in until it reaches to bring a portion of the foam material into contact with the adhesive. If it does so, the moisture content of an adhesive agent will be rapidly absorbed by a foam material, and hardening of an adhesive agent will be accelerated | stimulated. The moisture once absorbed in the foam material is gradually released into the outside air by the air permeability of the sandwich panel.

  According to the invention of claim 1 of the present application, since the adhesive adhesion area in the surface material is severely restricted, obstruction of air permeability can be minimized. For example, in the case of a honeycomb material in which hexagonal cells are connected, the location where the adhesive is present is limited to the tip of the cell wall and the hexagonal outline in the surface material with which the tip abuts. Since the cell wall is made thin, the area where the adhesive is present is limited even if a slight spread is added thereto.

  According to the invention of claim 1, since the adhesive is rapidly cured by absorbing the moisture content of the adhesive into the foam material, accurate positioning is possible without shifting from the bonding position where the surface material is pressed. Is realized. The adhesive is hardened in such a way that the concave corners formed by the tips of the orthogonal cell walls and the surface material are buried in a solid fillet shape.

  The first embodiment of the invention of claim 1 is the emulsion system having a predetermined viscosity as the adhesive 2 in the state described in claim 1 in which the adhesive is attached in a narrow band shape only at the tip of the cell wall. This is realized by each step of selecting an adhesive, pouring the adhesive 2 to a flat shallow container 1 held horizontally to a predetermined depth, and immersing and pulling only the tip of the cell wall of the honeycomb material 3 shallowly. (Claim 2).

  When attaching an adhesive to the tip of the cell wall, the low-viscosity adhesive that flows smoothly flows and a sufficient amount of adhesion cannot be obtained, so it is desirable that the adhesive has an appropriate viscosity (and surface tension). . In the present invention, an emulsion adhesive was selected from such a viewpoint. As described in claim 1, in order to attach the adhesive in a narrow band shape only at the tip of the cell wall, a method of immersing the honeycomb material to a predetermined depth in a flat shallow container (bat) poured with the adhesive is available. The simplest.

  The second embodiment of the invention of claim 1 is to select a phenol foam material having an open cell structure as the foam material 10 (claim 3). As described above, in order to absorb the moisture content of the adhesive into the foam material, it is desirable that the foam material has a strong water absorption, but it can be understood from the fact that the open cell phenolic foam is used for water supply of fresh flowers. In addition, it has strong water absorption.

  The third embodiment of the invention of claim 1 is a breathable sandwich panel itself manufactured by the above manufacturing method. That is, the honeycomb material 3, the air-permeable surface material 5 bonded to the tip of the cell wall facing at least one surface of the honeycomb material, and the water-absorbing foam material filled in the cell space 7 of the honeycomb material 3 10 (Claim 4).

  The above sandwich panel has a structure in which cells of honeycomb material are filled with a porous material, and the porous material absorbs and attenuates sound incident through the air-permeable surface material attached to the surface of the honeycomb material. Therefore, it functions as a sound absorbing material intended by the present invention.

  1 to 4 are conceptual diagrams or cross-sectional views illustrating a process of manufacturing a breathable sandwich panel according to this embodiment in the order of steps.

  FIG. 1 (A) is a view showing a state in which the adhesive 2 is uniformly poured to a depth of 2 to 3 mm into a container 1 having a flat bottom and an open top, and the honeycomb material 3 is lifted thereon. The honeycomb material 3 is made of paper, metal, synthetic resin, inorganic material, and the like, and among them, paper is preferable from the viewpoint of weight. In this example, a paper honeycomb material impregnated with magnesium silicate was used. The shape of the cell is not limited to a hexagon, but may be a triangle, square, pentagon, circle, waveform, or the like. In this embodiment, an aluminum fiber material is used as the breathable face material 5, but a glass cloth fiber material, a cloth fiber material, a synthetic fiber material, or the like may be used.

  The container 1 has a size capable of accommodating a honeycomb material up to a length of 1000 × width of 1000 × height of 30 mm, and the emulsion-based adhesive 2 put therein has a viscosity of 45,000 to 85,000 MPa · s and a nonvolatile content of 42 to 46 wt%, moisture is 54 to 58 wt%. The honeycomb material 3 having a length of 980 × width of 980 × height of 30 mm is immersed in this, and the adhesive 2 is adhered to a height of 1 to 2 mm at the tip of the hexagonal cell wall.

  FIG. 1B shows a state in which the cell walls of the honeycomb material 3 are immersed in the adhesive 2 in the container 1, and FIG. 1C shows a state in which the honeycomb material 3 is pulled up from the container 1. FIG. 1C shows a state in which the adhesive 2 adheres in a strip shape to a predetermined height at the tip of the cell wall, and the cross section swells in a drop shape (reference numeral 4).

  FIG. 2 (A) shows a state in which the tips of the cells of the honeycomb material 3 to which the adhesive 2 is adhered are pressed against a breathable face material 5 made of aluminum fibers. The size of the face material 5 is length 1000 × width 1000 × thickness 1.6 mm. In the figure, reference numeral 6 denotes an adhesive adhered so as to fill a concave corner formed by the cell wall tip and the face material 5, and 7 indicates a cell space of the honeycomb material 3.

  FIG. 2B shows a state in which the face material 5 once bonded is forcibly peeled from the honeycomb material 3 for the test after the adhesive is cured. The cell wall of the honeycomb material 3 at a position outside the adhesion point is broken and remains in a hexagonal shape on the face material side (reference numeral 8). The ventilation surface 9 important for sound absorption / absorption / moisture release is not blocked by an adhesive.

  FIG. 3 shows a state where the cell space 7 is filled with the phenol foam material 10. A foam material is placed on the honeycomb material 3 and is pressed by a press until it reaches the adhesive adhesion position. In this state, since the foam material 10 contacts the adhesive and absorbs the moisture, the adhesive is rapidly cured.

  In FIG. 3, the dimensions of the foam material 10 are 1000 × 1000 × 28 mm in thickness. Compared with the dimensions of the honeycomb material 3 described above, the foam material 10 is larger by 20 mm in both length and width, and when the honeycomb material 3 is press-fitted into the center of the foam material 10, the foam 10 mm in width around the honeycomb material 3. It can be seen that an “edge-wrapping portion” (reference numeral 12) made of only the material is formed. This edge turning portion can prevent the honeycomb material from being cut at the end portion of the panel to open the cell and the foam material from dropping off from that portion when adjusting the dimensions of the panel material.

  When the foam material 10 is 28 mm and the height of the honeycomb material 3 is 30 mm, when the foam material 10 is fully pressed into the honeycomb material 3, as shown in FIG. It can be seen that there is a margin of 2 mm close to the surface on the pushing side, and a part of the cell wall protrudes from the upper surface of the foam material 10. In the figure, reference numeral 11 is given to this protrusion. The protrusion 11 is an adhesive applied to the face material when the other non-breathable surface material 14 is attached to the surface opposite to the surface on which the air-permeable surface material 5 is attached (see FIG. 4). The layer 13 is supported from below so as not to be in close contact with the foam material 10, thereby preventing the communication bubbles of the foam material 10 from being blocked.

  The non-breathable surface material 14 is preferably an aluminum material from the viewpoint of the effect of a backup material for obtaining lightness, workability, and self-supporting strength. As the adhesive layer 13, a room temperature curing type epoxy adhesive (urethane or acrylic is also acceptable) is selected, and this is solidly applied to the surface of the adhesive surface of the surface material 14. Immerse and adhere. Thus, the anti-corrosion effect with respect to a water | moisture content can be anticipated by apply | coating an adhesive agent to a metal surface.

  On the other hand, the phenol foam has a strong water absorption as described above. As described above, the foam material 10 filled in the cell space 7 and in contact with the portion where the adhesive 2 is present rapidly absorbs moisture contained in the adhesive and promotes its initial curing. Thereby, the shift | offset | difference (sliding) in the middle of the adhesion | attachment of the face material 5 pressed on the honeycomb material is prevented. Moisture once absorbed by the foam material 10 is gradually dissipated out of the panel with the help of the open cell structure of the foam material 10 and the air permeability of the surface material 5. At that time, the panel may be lightly heated to help dissipate moisture.

  With the breathable sandwich panel of the present invention, as a soundproofing material in which sound absorption and sound insulation are integrated into the soundproofing material field where sound insulation was the main, or as a humidity control / condensation prevention material in a residential field where high airtightness is required New proposals can be made as thermal insulation and energy-saving materials filled with foam in the environmental field.

It is a figure which shows a mode that it spreads the adhesive agent shallowly in a container, it is going to immerse a honeycomb material there (A), a mode that it immersed (B), and a mode that it pulled up (C). It is a figure which shows a mode (A) which pressed the honeycomb material which adhered the adhesive agent to the surface material, and a mode (B) of the surface material forcedly peeled off from the honeycomb material after hardening of the adhesive agent. It is a figure which shows a mode that the foam material was filled into cell space. It is a figure which shows the sandwich panel completed by attaching another surface material to the upper surface of the honeycomb material in a previous figure.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Container 2 Liquid adhesive agent 3 Honeycomb material 4, 6 Adhesive adhering to a cell wall 5 Breathable surface material 7 Cell space 8 Cell wall fractured | ruptured at the position of an adhesive 9 Surface ventilation surface 10 Foam material 11 Cell wall Protruding part 12 Edge part 13 Epoxy adhesive 14 Non-breathable surface material

Claims (4)

A liquid adhesive (2) having a predetermined viscosity is attached in a narrow band shape only at the tip of the cell wall facing one side of the honeycomb material (3),
A breathable surface material (5) is pressed against the one surface of the honeycomb material (3) to which the adhesive (2) is adhered;
Before the adhesive (2) is cured, the foam material (10) having water absorption is pushed in from the other surface of the honeycomb material (3) until it comes into contact with the adhered adhesive (2), and the cell space (7 )
The foam material (10) in contact with the adhesive (2) absorbs moisture contained in the adhesive to accelerate the curing, and the surface material (5) can be quickly bonded to the honeycomb material (3). A method for producing a breathable sandwich panel comprising the steps of:   The step of adhering the adhesive in a narrow band shape only at the tip of the cell wall selects an emulsion-based adhesive as the liquid adhesive (2) and puts the adhesive into a flat shallow container (1) held horizontally. The manufacturing method according to claim 1, which is carried out by each step of pouring (2) and dipping only the tip of the cell wall of the honeycomb material (3) shallowly into it.   The manufacturing method of Claim 2 including the process of selecting the phenol foam material which has an open cell structure as said foam material (10). The honeycomb material (3), the air-permeable surface material (5) bonded to the tip of the cell wall facing at least one surface of the honeycomb material, and the cell space (7) of the honeycomb material (3) were filled. A sandwich panel produced by the production method according to claim 1, comprising a foam material having water absorption.

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