CN116323161A - 夹芯板的制造方法和夹芯板 - Google Patents

夹芯板的制造方法和夹芯板 Download PDF

Info

Publication number
CN116323161A
CN116323161A CN202180062852.1A CN202180062852A CN116323161A CN 116323161 A CN116323161 A CN 116323161A CN 202180062852 A CN202180062852 A CN 202180062852A CN 116323161 A CN116323161 A CN 116323161A
Authority
CN
China
Prior art keywords
sandwich panel
panel according
manufacturing
core layer
prepreg
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202180062852.1A
Other languages
English (en)
Inventor
上坂政夫
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Bakelite Co Ltd
Original Assignee
Sumitomo Bakelite Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sumitomo Bakelite Co Ltd filed Critical Sumitomo Bakelite Co Ltd
Publication of CN116323161A publication Critical patent/CN116323161A/zh
Pending legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0067—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other
    • B29C37/0075—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other using release sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B32B5/275—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one woven fabric layer next to a non-woven fabric layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
    • B32B2037/1223—Hot-melt adhesive film-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B32B2305/188—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/737—Dimensions, e.g. volume or area
    • B32B2307/7375—Linear, e.g. length, distance or width
    • B32B2307/7376—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2377/00—Polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Abstract

夹芯板(100)的制造方法包括：准备片状的多个预浸料(211)的工序；在叠层多个预浸料(211)而成的叠层体的上下表面，隔着脱模膜(25)进行第一加热加压处理，使上述叠层体一体化而得到复合表面材料(40)的工序；和在具有蜂窝结构的片状的芯层(10)的上表面侧和下表面侧的各面上配置复合表面材料(40)，通过第二加热加压处理整体进行叠层化的工序，上述第一加热加压处理的压力在上述第二加热加压处理的同等或以上。

Description

夹芯板的制造方法和夹芯板
技术领域
本发明涉及夹芯板的制造方法和夹芯板。
背景技术
夹芯板包括由截面为六边形的壁构成的中空状的蜂窝芯、和接合在该蜂窝芯的两面的一对预浸料等表皮材料。具有轻质且高刚性的特征的夹芯板被用于例如航空器用的结构部件等。
作为夹芯板的制造方法，公开了各种方法。作为一般的方法，例如有专利文献1中记载的技术。根据该文献，作为二次粘接形成工艺，公开了如下方法：将预浸料叠层，将其放入真空袋中，使用高压釜使预浸料中的粘合剂树脂固化后，利用膜状粘接剂将复合预浸料安装在蜂窝芯的两面，在高温下加压，使膜状粘接剂固化。
现有技术文献
专利文献
专利文献1：日本特开2020-1268公报
发明内容
发明要解决的技术课题
近年来，对夹芯板的要求越来越高。其中，若夹芯板的表面残留空隙，在之后对夹芯板实施外部装饰时就会产生针孔，存在损害外观的问题。在专利文献1中公开的技术中，在减少针孔方面也有改善的空间。
用于解决技术课题的手段
本发明的发明人为了以更高水准减少针孔而进行了深入研究，结果发现，通过隔着脱模膜进行用于预先将多个预浸料叠层一体化而得到复合表面材料的第一加热加压处理，并将该压力设为用于夹芯化的第二加热加压处理的压力的同等或以上，能够减少所得到的夹芯板表面上的空隙。即，本发明的发明人着眼于构成预浸料的纤维基材的纹理所引起的凹凸成为夹芯板上的针孔的主要原因的情况，发现控制预浸料的叠层一体化工序的加热加压条件是有效的，从而完成了本发明。详细的机理尚不清楚，但推测根据本发明，通过使用脱模膜，预浸料的表面被更均匀地加热加压，并且通过设置为更高的压力，能够有效地减少构成预浸料的纤维基材的微小凹凸。
根据本发明，提供一种夹芯板的制造方法，其包括：准备片状的多个预浸料的工序；
在叠层上述多个预浸料而成的叠层体的上下表面，隔着脱模膜进行第一加热加压处理，使上述叠层体一体化而得到复合表面材料的工序；和
在具有蜂窝结构的片状的芯层的上表面侧和下表面侧的各面上配置上述复合表面材料，通过第二加热加压处理进行一体化的工序，
上述第一加热加压处理的压力与上述第二加热加压处理的压力同等在上述第二加热加压处理以上。
并且，根据本发明，提供一种夹芯板，其包括具有蜂窝结构的芯层、和设置在上述芯层的两面、通过多个预浸料的固化物叠层并一体化而成的复合表面材料，
观察上述复合表面材料的最外表面时的针孔数密度为0～50个/cm2。
发明的效果
根据本发明，提供一种能够减少夹芯板的针孔的技术。
附图说明
图1是表示本实施方式所涉及的夹芯板的一例的示意图。
图2是表示本实施方式所涉及的夹芯板的制造方法的一例的工序截面图。
图3是表示本实施方式所涉及的夹芯板的制造方法的一例的工序截面图。
具体实施方式
以下，使用附图对本发明的实施方式进行说明。其中，在所有附图中，对相同的构成要件标注相同的附图标记，并适当地省略说明。
在本说明书中，只要没有特别说明，数值范围的说明中的“a～b”的表述表示a以上b以下。例如，“1～5质量％”是指“1质量％以上5质量％以下”。
＜夹芯板＞
图1是表示本实施方式所涉及的夹芯板的一例的示意图。
本实施方式的夹芯板100包括：具有蜂窝结构的芯层10；和设置在芯层10的两面的预浸料20(上表面为预浸料21，下表面为预浸料22)的固化物(复合表面材料40)。
并且，本实施方式的夹芯板100在芯层10与复合表面材料40之间分别具有热熔系粘接层15(未图示)。
在本实施方式中，观察复合表面材料40的最外面时的针孔数密度为0～50个/cm2。换言之，观察夹芯板100的至少一个表面时，针孔数密度为0～50个/cm2。
即，由于本实施方式的夹芯板100是通过后述的制造方法获得的，因此与现有技术相比，空隙的产生得到抑制，其结果，表面的针孔数密度减小。
针孔数密度越小越好，更优选为45个/cm2以下，进一步优选为40个/cm2以下，更进一步优选为30个/cm2以下，更进一步优选为20个/cm2以下。并且，优选在夹芯板100的两面具有上述针孔数密度。
关于针孔数密度，通过数出用放大镜(4～50倍)观察夹芯板100的表面时能够视觉辨认的孔并除以所观察的面积来求出。
[芯层]
作为芯层10，能够使用例如在具有蜂窝结构的芯层用基材中浸渗粘合剂树脂而成的片状的部件。通过蜂窝结构，芯层10能够具有高强度和轻质性。
其中，蜂窝结构是公知的结构，是指形成有多个从上表面贯穿至下表面的大致正六边形的贯穿孔的结构。
作为芯层10的具有蜂窝结构的基材，例如可以举出通过公知的方法将芳族聚酰胺纤维、纸、轻木材料、塑料、铝、钛、玻璃及其合金等成型为蜂窝状的基材。从耐热性的观点出发，作为芯层10的具有蜂窝结构的基材，优选含有芳族聚酰胺纤维。
作为芯层10的基材的形状，优选织物状的纤维布。由此，加工成蜂窝结构的加工性变得良好，并且能够使夹芯板100轻质化。
在芯层10含有织物状的纤维布的情况下，纤维与纤维交叉的部位在制造工序中不易被加压，容易残留空隙，但在本实施方式的夹芯板100中，通过后述的制造方法，能够有效地抑制空隙的产生。
作为芯层10的层厚，没有特别限定，例如可以为1mm以上50mm以下，也可以为3mm以上40mm以下，还可以为5mm以上30mm以下。
芯层10中的各芯材小室尺寸没有特别限定，例如可以设定1边为1mm以上10mm以下。
芯层10的表面(上表面、下表面)的面积没有限定，例如可以具有一个夹芯板100的表面积，也可以具有将多个夹芯板合计的表面积。由此，能够将1片夹芯板100单片化，切出多个板而获得，能够提高生产率。例如，芯层10的表面(上表面、下表面)的面积可以是大面积，例如可以为1m2以上。
并且，从提高耐腐蚀性和耐热性的观点出发，芯层10也可以是对内部和/或外部进行了各种表面处理的材料。
[预浸料]
作为预浸料20，例如可以使用将粘合剂树脂浸渗于预浸料用基材中而成的B阶状态的片部件。
在本实施方式中，预浸料20由预浸料211和预浸料212叠层而成(参考图2)。
另外，预浸料20也可以由3片以上的预浸料叠层而成。
B阶状态是指，对于浸渗于预浸料用基材中的粘合剂树脂，根据DSC(差示扫描量热计)的测定结果计算出的反应率超过0％且为60％以下、优选为0.5％以上55％以下、更优选为1％以上50％以下的状态。
作为预浸料20的上述预浸料用基材，例如可以举出纤维基材。
作为上述纤维基材，可以使用芳族聚酰胺纤维、聚酯纤维、聚苯硫醚纤维、碳纤维、石墨纤维、玻璃纤维和碳化硅纤维等。从高耐热性的观点出发，上述纤维基材优选含有玻璃纤维。
通过含有纤维基材，能够进一步提高夹芯板100的耐热性。并且，能够缩小复合表面材料40与芯层10的线膨胀系数差，因此能够抑制夹芯板100的翘曲。
作为预浸料20的固化物(复合表面材料40)的玻璃化转变温度(Tg)的上限值，例如为250℃以下，优选为220℃以下，进一步优选为200℃以下。由此，能够在低温条件下实施加热加压处理。另一方面，作为上述玻璃化转变温度(Tg)的下限值，例如可以为110℃以上，也可以为120℃以上。由此，能够提高热特性。
在本实施方式中，芯层10、预浸料20中所使用的粘合剂树脂可以彼此相同，也可以不同，从有效地提高密合性、提高耐燃烧性的观点出发，优选为彼此相同的粘合剂树脂。关于粘合剂树脂，将在后面说明。
[复合表面材料]
本实施方式的复合表面材料40是通过将预浸料211和预浸料212叠层一体化，通过后述的第一加热加压处理使粘合剂树脂固化而得到的。换言之，复合表面材料40是预浸料211和预浸料212的固化物叠层并一体化而成的材料。
[粘接层]
在本实施方式中，在芯层10与复合表面材料40之间存在热熔系粘接层15(参考图3)。由此，能够提高密合性并抑制空隙的产生。
在本实施方式中，热熔系粘接层15可以使用公知的材料，优选由热熔粘接剂构成。由此，在固化后容易减少内部应力和应变的产生，能够有效地抑制空隙的产生。
热熔粘接剂含有非固化性树脂作为主成分，该非固化性树脂在高温时能够流动，通过冷却恢复到不能流动的状态。即，在某特定的温度以上熔融，表现出粘接性。
作为上述非固化性树脂，可以举出选自聚氨酯系、丙烯腈系、二烯系、丙烯酸系、丁二烯系、聚酰胺系、聚乙烯醇缩丁醛系、烯烃系、异戊二烯系、氯丁二烯系、聚酯系、聚氯乙烯系、苯乙烯系、乙烯-乙酸乙烯酯系、氟系、硅酮系以及含有它们的共聚物的热塑性树脂等中的1种以上或2种以上。
其中，热熔粘接剂更优选含有聚酰胺作为主成分。
热熔粘接剂的粘度优选在163℃时为约30,000厘泊(cP)以下，更优选为20,000厘泊(cP)以下，进一步优选为10,000厘泊(cP)以下。
另外，在本实施方式中，热熔粘接剂是指含有20～65重量％的在利用ASTM的D412-06A进行试验时在300％的伸长率下显示0.5～3.5MPa的拉伸应力的聚合物成分的粘接剂。
并且，作为热熔系粘接层15的形状，没有特别限定，从有效地抑制空隙的产生的观点出发，优选无纺布状或膜状。
[用途]
本实施方式的夹芯板100能够适用于航空器用板。例如，夹芯板100能够用于洗手间或隔板等航空器的内部装饰、或手推车的框体等航空器内的配件等。
＜夹芯板的制造方法＞
接着，对本实施方式的夹芯板100的制造方法进行说明。
(工序1)芯层10和预浸料211、212的制作
准备芯层用基材。芯层用基材具有蜂窝结构，优选由芳族聚酰胺纤维形成。
准备具有蜂窝结构的基材，使粘合剂溶液浸渗于该基材中。然后，使基材干燥，得到芯层10。
另一方面，准备预浸料用基材。作为预浸料用基材，可以举出纤维基材。将粘合剂树脂浸渗于该预浸料用基材中。然后，使基材干燥，得到B阶状态的各预浸料211、212。
作为粘合剂树脂的浸渗方法，例如可以举出：将粘合剂树脂溶解在溶剂中，使用喷嘴等喷射装置将所得到的溶液喷射到基材上进行涂布的方法；将基材浸渍在该溶液中的方法；利用刮刀式涂布机、逗点式涂布机等各种涂布机将该溶液涂布到基材上的方法；或利用转印辊将该溶液转印到基材上的方法等。其中，优选将预浸料用基材浸渍在该溶液中的方法。
并且，作为进行加热干燥的条件，没有特别限定，通常在100～220℃、优选120～190℃进行2～10分钟。
[粘合剂溶液]
粘合剂溶液是将粘合剂树脂等溶解在公知的有机溶剂中的溶液，能够使用公知的溶液。粘合剂树脂优选热固性树脂，例如可以举出酚醛树脂、不饱和聚酯树脂或环氧树脂等热固性树脂。作为酚醛树脂，包括在分子内具有1个以上酚羟基的化合物，例如可以举出酚醛清漆型苯酚、酚醛清漆型甲酚、酚醛清漆型萘酚等酚醛清漆树脂；双酚F、双酚A等双酚树脂；对二甲苯改性酚醛树脂等苯酚芳烷基树脂；二亚甲基醚型甲酚、羟甲基型苯酚等甲阶型酚醛树脂；使上述树脂等进一步羟甲基化而成的化合物等。
其中，从在叠层一体化工序中得到对于压板等的脱模性的观点出发，粘合剂树脂优选含有酚醛树脂。
并且，在粘合剂溶液中，除了上述热固性树脂以外，还可以含有其他添加剂。作为添加剂，没有特别限定，例如可以举出无机填充材料等填充材料、橡胶、热塑性树脂等。
(工序2)预浸料的一体化
接着，如图2(a)所示，准备片状的预浸料211和212。预浸料211和212处于B阶状态。预浸料211和212可以具有相同的材料和厚度，也可以具有彼此不同的材料和厚度。
接着，如图2(b)所示，对预浸料211和212叠层而成的叠层体隔着脱模膜实施第一加热加压处理，使粘合剂树脂固化，从而使预浸料211和212一体化，得到预浸料20的固化物，即复合表面材料40。此时，从叠层的片状的预浸料211和212的上下表面隔着脱模膜配置平坦的压板，从上下方向均匀地加热加压。
第一加热加压处理的条件优选为110～150℃、0.5～3.0MPa，更优选为120～140℃、1.5～2.5MPa。
通过将第一加热加压处理的温度和压力设为上述下限值以上，能够使预浸料211和212彼此牢固地一体化。
另一方面，通过将第一加热加压处理的温度和压力设为上述上限值以下，能够抑制预浸料211和212的破损并适当地一体化。
在本实施方式中，该第一加热加压处理的压力与后述的第二加热加压处理相比在同等或以上。由此，能够减少复合表面材料40中的空隙，并良好地保持复合表面材料40与芯层10的密合性，能够有效地减少在夹芯板100内产生空隙。
并且，优选第一加热加压处理的压力高于后述的第二加热加压处理的压力。由此，能够进一步有效地减少在夹芯板100内产生空隙。
并且，在本实施方式中，在预浸料211和212的一体化工序中，隔着脱模膜25将压板的平滑面按压在叠层的上述预浸料的上下表面，同时进行第一加热加压处理。
由此，能够对预浸料211和212的整个面更均匀地施加压力，能够有效地抑制夹芯板100中的空隙。
作为上述压板，能够使用公知的压板，可以举出与后述的金属板30相同的压板。
[脱模膜]
本实施方式的脱模膜25优选含有例如选自聚对苯二甲酸乙二醇酯树脂(PET)、聚对苯二甲酸丁二醇酯树脂(PBT)、聚对苯二甲酸丙二醇酯树脂(PTT)、聚对苯二甲酸己二醇酯树脂(PHT)等聚对苯二甲酸亚烷基酯树脂、聚4-甲基-1-戊烯树脂(TPX)、间规聚苯乙烯树脂(SPS)和聚丙烯树脂(PP)中的1种或2种以上。其中，优选聚4-甲基-1-戊烯树脂(TPX)、聚丙烯树脂(PP)。
并且，脱模膜25优选满足在180℃进行120秒的加热处理后测得的储能模量(频率100Hz、100℃)为0.05GPa以上10GPa以下，进一步优选为0.1GPa以上5GPa以下。
由此，能够提高在脱模膜使用后(热压后)脱模膜从凸凹剥离的剥离性。即，通过将施加热历程后的储能模量的值控制在上述数值范围内，能够增大脱模膜使用前后(热压前后)脱模膜的结晶度的变动，结果，能够保持追随性并提高脱模性。并且，在预浸料的一体化时能够获得适度的弹性，能够更进一步均匀地施加压力，从而能够有效地减少在夹芯板100中产生空隙。
脱模膜25的厚度优选为50μm以上150μm以下，进一步优选为75μm以上140μm以下，最优选为90μm以上130μm以下。由此，能够在制作成型品时对脱模膜25更进一步均匀地施加冲压，能够更进一步高度地抑制产生空隙。
(工序3)整体叠层化
接着，使用准备好的复合表面材料40，将其与芯层10一体化。
如图3(a)所示，在芯层10的上表面侧和下表面侧各自的开口面上配置复合表面材料40，通过第二加热加压处理，整体进行叠层化。并且，配置用于对复合表面材料40实施加压加热处理的金属板30(上侧为金属板31，下侧为金属板32)。
接着，如图3(b)所示，一边使金属板30与复合表面材料40抵接，一边通过第二加热加压处理将芯层10和复合表面材料40整体叠层化。由此，能够将芯层10与复合表面材料40一体化。
第二加热加压处理能够采用例如优选110℃～140℃、30分钟～90分钟、0.35MPa～2.0MPa，更优选120℃～130℃、30分钟～90分钟、0.5MPa～1.0MPa的条件。
并且，第二加热加压处理能够在大气中进行。因此，能够提高生产率。
并且，如图3(a)所示，在本实施方式中，在复合表面材料40与芯层10之间分别夹入热熔系粘接层15进行叠层。由此，芯层10和复合表面材料40内所存在的空隙被热熔系粘接层15填埋，能够抑制在夹芯板100的表面产生空隙。
金属板30可以使用公知的金属板，例如可以举出SUS板、白铁板、铝板、镁板等金属板。
并且，金属板30的膜厚没有特别限定，例如可以为0.5mm以上10mm以下，也可以为0.8mm以上5mm以下，还可以为1.0mm以上2.0mm以下。通过设定在这样的范围内，能够实现刚性与导热性的平衡。
然后，如图3(c)所示，将金属板30从复合表面材料40分离，从而得到夹芯板100。
以上，参考附图对本发明的实施方式进行了说明，但是这些仅为本发明的示例，也能够采用上述以外的各种结构。
在上述实施方式中，对使用了脱模膜的例子进行了说明，但也可以不使用脱模膜。
实施例
以下，参考实施例对本发明进行详细说明，但本发明并不限定于这些实施例的任何记载。
＜夹芯板的制作＞
[实施例1]
(复合表面材料的制造)
配合酚醛树脂(甲阶型酚醛树脂，Durez公司制造的“34370”)，使其浸渗于玻璃纤维(#7781，Hexcel Corporation制造)中，得到了片状的预浸料(厚度250μm)。该预浸料处于B阶状态。
将所得到的预浸料叠层2片，将SUS板(厚度：1.5mm、Rz：1.0μm)按压在两面，使用机械压力机在2.0MPa、130℃、60分钟的条件下进行加热加压(第一加热加压处理)，使该预浸料中的酚醛树脂固化，形成了复合表面材料。此时，在SUS板与预浸料之间配置有脱模膜(聚甲基戊烯：TPX(注册商标)膜，厚度120μm)。
(夹芯板的制造)
在蜂窝芯(芳族聚酰胺纤维，厚度：10mm，HRH-10-1/8-3.0(Hexcel Corporation制造)，面积：1m×3m)的两面配置热熔系粘接剂(主成分聚酰胺)，再在其上配置所得到的复合表面材料，得到了叠层体。
接着，将SUS板(厚度：1.5mm，Rz：1.0μm)按压在所得到的叠层体的两面，使用机械压力机在0.7MPa、127℃、60分钟的条件下进行加热加压(第二加热加压处理)，使该预浸料固化，形成了树脂板。然后，从树脂板分离SUS板，得到了由树脂板、蜂窝芯、树脂板构成的夹芯板。
[实施例2]
作为脱模膜，将“聚甲基戊烯：TPX(注册商标)膜”变更为“聚丙烯膜：TORAYFAN(注册商标)，厚度100μm”，除此以外，以与实施例1相同的方式得到了夹芯板。
[实施例3]
将第一加热处理的2.0MPa变更为0.7MPa，除此以外，以与实施例1相同的方式得到了夹芯板。
[比较例1]
除了在SUS板与预浸料之间不配置脱模膜以外，以与实施例1相同的方式得到了夹芯板。
[参考例]
配合酚醛树脂，使其浸渗于玻璃纤维(#7781，Hexcel Corporation制造)中，得到了片状的预浸料(250μm)。该预浸料处于B阶状态。
在上述蜂窝芯的两面配置所得到的B阶状态的预浸料，制成叠层体，将该叠层体放入真空袋中，将其在高压釜内在0.7MPa、127℃、60分钟的条件下整体加热固化，得到了夹芯板。
(评价项目)
对上述的夹芯板进行以下评价。将评价结果示于表1。
·针孔的测定
使用放大镜(4倍)观察所得到的夹芯板的成为表面侧的表面，测定针孔的数量，计算出密度。
[表1]
Figure BDA0004123820850000111
本申请基于2020年9月14日申请的日本申请特愿2020-153525号主张优先权，其公开的全部内容援用于本说明书中。
附图标记说明
10：芯层，15：热熔系粘接层，20：预浸料，21：预浸料，22：预浸料，25：脱模膜，30：金属板，31：金属板，32：金属板，40：复合表面材料，100：夹芯板，211：预浸料，212：预浸料。

Claims (15)

1.一种夹芯板的制造方法，其特征在于，包括：
准备片状的多个预浸料的工序；
在叠层所述多个预浸料而成的叠层体的上下表面，隔着脱模膜进行第一加热加压处理，使所述叠层体一体化而得到复合表面材料的工序；和
在具有蜂窝结构的片状的芯层的上表面侧和下表面侧的各面上配置所述复合表面材料，通过第二加热加压处理进行一体化的工序，
所述第一加热加压处理的压力与所述第二加热加压处理的压力同等或为所述第二加热加压处理的压力以上。
2.根据权利要求1所述的夹芯板的制造方法，其特征在于，
所述第一加热加压处理的条件为110～140℃、0.5～3.0MPa。
3.根据权利要求1或2所述的夹芯板的制造方法，其特征在于，
所述芯层含有织物状的纤维布。
4.根据权利要求1至3中任一项所述的夹芯板的制造方法，其特征在于，
在进行所述叠层化的所述工序中，在所述芯层与所述复合表面材料之间存在热熔系粘接剂。
5.根据权利要求4所述的夹芯板的制造方法，其特征在于，
所述热熔系粘接剂含有聚酰胺作为主成分。
6.根据权利要求4或5所述的夹芯板的制造方法，其特征在于，
所述热熔系粘接剂为无纺布状或膜状。
7.根据权利要求1至6中任一项所述的夹芯板的制造方法，其特征在于，
所述脱模膜在180℃进行120秒加热处理后测得的储能模量为0.05GPa以上10GPa以下，所述储能模量是在频率1Hz、100℃的条件下测得的。
8.根据权利要求1至7中任一项所述的夹芯板的制造方法，其特征在于，
所述脱模膜含有选自聚对苯二甲酸乙二醇酯树脂(PET)、聚对苯二甲酸丁二醇酯树脂(PBT)、聚对苯二甲酸丙二醇酯树脂(PTT)、聚对苯二甲酸己二醇酯树脂(PHT)等聚对苯二甲酸亚烷基酯树脂、聚4-甲基-1-戊烯树脂(TPX)、间规聚苯乙烯树脂(SPS)和聚丙烯树脂(PP)中的1种或2种以上。
9.根据权利要求1至8中任一项所述的夹芯板的制造方法，其特征在于，
所述预浸料是将粘合剂树脂浸渗于预浸料用基材而成的B阶状态的片部件。
10.根据权利要求1至9中任一项所述的夹芯板的制造方法，其特征在于，
所述脱模膜的厚度为50μm以上150μm以下。
11.一种夹芯板，其特征在于，
包括具有蜂窝结构的芯层、和设置在所述芯层的两面的通过多个预浸料的固化物叠层并一体化而成的复合表面材料，
观察所述复合表面材料的最外表面时的针孔数密度为0～50个/cm2。
12.根据权利要求11所述的夹芯板，其特征在于，
所述芯层含有织物状的纤维布。
13.根据权利要求11或12所述的夹芯板，其特征在于，
在所述复合表面材料与所述芯层之间分别具有粘接层。
14.根据权利要求11至13中任一项所述的夹芯板，其特征在于，
所述预浸料的固化物的玻璃化转变温度为110℃以上250℃以下。
15.根据权利要求11至14中任一项所述的夹芯板，其特征在于，
用于航空器用板。
CN202180062852.1A 2020-09-14 2021-07-09 夹芯板的制造方法和夹芯板 Pending CN116323161A (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2020153525 2020-09-14
JP2020-153525 2020-09-14
PCT/JP2021/025960 WO2022054388A1 (ja) 2020-09-14 2021-07-09 サンドイッチパネルの製造方法およびサンドイッチパネル

Publications (1)

Publication Number Publication Date
CN116323161A true CN116323161A (zh) 2023-06-23

Family

ID=80632191

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202180062852.1A Pending CN116323161A (zh) 2020-09-14 2021-07-09 夹芯板的制造方法和夹芯板

Country Status (5)

Country Link
US (1) US20230256724A1 (zh)
EP (1) EP4212326A1 (zh)
JP (1) JP7074266B1 (zh)
CN (1) CN116323161A (zh)
WO (1) WO2022054388A1 (zh)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023132270A1 (ja) * 2022-01-07 2023-07-13 住友ベークライト株式会社 サンドイッチパネル、サンドイッチパネルの製造方法、およびサンドウィッチパネル製造用離型フィルム
WO2024075684A1 (ja) * 2022-10-06 2024-04-11 住友ベークライト株式会社 サンドイッチパネル、およびサンドイッチパネルの製造方法

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5773121A (en) * 1994-07-29 1998-06-30 Isorca Inc. Syntactic foam core incorporating honeycomb structure for composites
US20080182067A1 (en) * 2007-01-31 2008-07-31 Hongbin Shen Composite panel having in-situ thermoset foamed core
JP2011240524A (ja) * 2010-05-14 2011-12-01 Kubo Seisakusho:Kk サンドイッチパネル
US20150151524A1 (en) * 2012-12-19 2015-06-04 Embraer S.A. Methods for fabricating stabilized honeycomb core composite laminate structures
CN104837622A (zh) * 2012-12-06 2015-08-12 三菱瓦斯化学株式会社 覆金属箔层叠板的制造方法
US20180186134A1 (en) * 2015-07-06 2018-07-05 Toray Industries, Inc. Method for manufacturing fiber-reinforced composite material
US20190283345A1 (en) * 2016-07-22 2019-09-19 Sumitomo Bakelite Co., Ltd. Method for manufacturing sandwhich panel, sandwhich panel, composite material sheet, and curved panel member
CN110545975A (zh) * 2017-03-23 2019-12-06 帝人株式会社 自粘性预浸料及其制造方法

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4482659A (en) * 1983-10-21 1984-11-13 Westinghouse Electric Corp. Toughened thermosetting compositions for composites
US5455096A (en) * 1993-09-20 1995-10-03 United Technologies Corporation Complex composite sandwich structure having a laminate and a foaming ashesive therein and a method for making the same
US6005184A (en) * 1997-07-11 1999-12-21 Space Systems/Loral, Inc. Solar panels having improved heat dissipation properties
US6153721A (en) * 1998-02-26 2000-11-28 Honeywell International Inc. Preparation of polyindanebisphenols and polymers derived therefrom
US20050025929A1 (en) * 2003-07-28 2005-02-03 Smith Lance D. Sandwich panel with interior barrier
US20160060281A1 (en) * 2013-05-31 2016-03-03 Scott Edward Angell Butadien2,3-diyl linked di-dopo derivatives as flame retardants
JP6464602B2 (ja) * 2013-08-06 2019-02-06 三菱ケミカル株式会社 積層基材の製造方法、及び積層基材
US10793690B2 (en) * 2016-03-24 2020-10-06 Dic Corporation Prepreg and molded article
JP2019065111A (ja) * 2017-09-29 2019-04-25 東レ株式会社 エポキシ樹脂組成物、プリプレグおよび炭素繊維強化複合材料
JP7114367B2 (ja) * 2018-06-28 2022-08-08 三菱重工業株式会社 複合材構造体の成形方法
KR102092818B1 (ko) * 2018-07-18 2020-03-24 주식회사 티엘비 이형필름을 이용한 인쇄회로기판의 캐비티 형성 방법
JP2020153525A (ja) 2019-03-18 2020-09-24 リンナイ株式会社 給湯システム

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5773121A (en) * 1994-07-29 1998-06-30 Isorca Inc. Syntactic foam core incorporating honeycomb structure for composites
US20080182067A1 (en) * 2007-01-31 2008-07-31 Hongbin Shen Composite panel having in-situ thermoset foamed core
JP2011240524A (ja) * 2010-05-14 2011-12-01 Kubo Seisakusho:Kk サンドイッチパネル
CN104837622A (zh) * 2012-12-06 2015-08-12 三菱瓦斯化学株式会社 覆金属箔层叠板的制造方法
US20150151524A1 (en) * 2012-12-19 2015-06-04 Embraer S.A. Methods for fabricating stabilized honeycomb core composite laminate structures
US20180186134A1 (en) * 2015-07-06 2018-07-05 Toray Industries, Inc. Method for manufacturing fiber-reinforced composite material
US20190283345A1 (en) * 2016-07-22 2019-09-19 Sumitomo Bakelite Co., Ltd. Method for manufacturing sandwhich panel, sandwhich panel, composite material sheet, and curved panel member
CN110545975A (zh) * 2017-03-23 2019-12-06 帝人株式会社 自粘性预浸料及其制造方法

Also Published As

Publication number Publication date
WO2022054388A1 (ja) 2022-03-17
JPWO2022054388A1 (zh) 2022-03-17
EP4212326A1 (en) 2023-07-19
JP7074266B1 (ja) 2022-05-24
US20230256724A1 (en) 2023-08-17

Similar Documents

Publication Publication Date Title
JP6604396B2 (ja) 複合材料シート、サンドイッチパネル、湾曲状のパネル部材、複合材料シートの製造方法、およびサンドイッチパネルの製造方法
EP2495099B1 (en) Fiber-reinforced molded product and method for producing same
EP2268475B1 (en) Method of tape laying of thermoplastic composite materials
CN116323161A (zh) 夹芯板的制造方法和夹芯板
JP2009113369A (ja) 熱可塑性樹脂複合材料成形品の成形方法
JP2006219078A (ja) 航空機用複合体及び航空機の複合体構造部の製造方法
TW200413166A (en) Cushion material for hot pressing and method for producing the same
US10442143B2 (en) Manufacturing method for fibre-reinforced resin substrate or resin molded article
JP2015051629A (ja) 積層基材の製造方法、及び積層基材
WO2022260186A1 (ja) プレス用積層体及びプレス済積層体
JP3154908B2 (ja) 耐熱クッション材及びその製造方法
TW201618962A (zh) 由聚（甲基）丙烯酸酯系發泡體及可逆性可交聯複合物所構成之夾層組件
WO2023132270A1 (ja) サンドイッチパネル、サンドイッチパネルの製造方法、およびサンドウィッチパネル製造用離型フィルム
WO2023062870A1 (ja) 金属－プリプレグ複合体
JP2012210807A (ja) 真空成形方法および成形体
CN210415764U (zh) 防静电复合膜
JP7218043B2 (ja) ハニカム積層体
JP2023101115A (ja) サンドイッチパネルの製造方法およびサンドイッチパネル
JPH06210754A (ja) 片面銅張り積層板の製造方法
JP2023120619A (ja) サンドイッチパネル製造用離型フィルム
JPH07214713A (ja) 微細凹凸を有する複合材積層板の製造方法
JPH11320593A (ja) 積層板の製造法およびその製造に用いる成形用プレート
TW201514004A (zh) 纖維強化板材的製造方法
TW201513995A (zh) 纖維強化板材的製造方法

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination