JP2003236953A - Manufacturing method for heat insulating panel, and heat insulating panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat insulating panel having uniform heat insulating properties in the whole thereof and a simple manufacturing method thereof. <P>SOLUTION: The heat insulating panel is formed by a manufacturing process comprising a process of forming a stacked layer wherein a foamed sheet body 10 constituted of a synthetic resin foam and a honeycomb core material 20 are stacked and provided, a heat insulating layer forming process wherein the stacked layer of the foamed sheet body 10 and the honeycomb core material 20 are so pressed that the foamed sheet body 10 is pressed into cell spaces of the honeycomb core material 10 so as to form a heat insulating layer, and a panel forming process wherein the heat insulating layer thus formed is held by surface layers between and the layers are contact-bonded together. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb panel suitable for general construction structural members and aircraft structural members, which has a heat insulating property utilizing the lightweight and rigidity of the honeycomb core.

[0002]

2. Description of the Related Art Honeycomb cores are filled with a foaming resin such as a phenolic resin for the purpose of improving the heat insulating property without impairing the lightness and rigidity of the honeycomb core, by reacting and foaming the foamed resin in the cells of the honeycomb panel. We manufacture an adiabatic honeycomb core in which the honeycomb cell space of a panel is filled with a foam material. However, in reality, it is extremely difficult to uniformly fill and react the foam material in each cell of the honeycomb panel, and excessive filling and insufficient filling of the foamable resin occurred. The heat-insulating properties of the cells filled with the foaming resin are high, and the heat-insulating properties of the cells with insufficient filling are low, providing a heat-insulating honeycomb panel in which the heat-insulating properties of the entire honeycomb panel are sufficiently satisfied. I couldn't do it.
For example, the thermal conductivity of the structural material of the honeycomb panel manufactured in this manner is about 0.045 W / m · K, and further high heat insulating properties are required due to the increasing demand for heat insulating properties in recent years.

[0003]

Therefore, the present invention provides a heat insulating honeycomb panel having a uniform heat insulating property over the entire panel,
And a simple manufacturing method of the panel.

[0004]

In order to solve the above problems, a method for manufacturing a heat insulating panel according to the present invention comprises a step of forming a polymer layer of a synthetic resin foam and a polymer layer forming step of polymerizing a honeycomb core material. A heat insulation layer forming step of forming a heat insulation layer by pressing the foamed plate body and the polymerized layer of the honeycomb core material into the cell space of the honeycomb core material, and a panel in which the heat insulation layer is sandwiched between the surface layers and pressure-bonded. And a forming step.

Further, the heat insulating panel of the present invention has a structure in which the heat insulating material sandwiched between the surface materials is a foamed honeycomb core in which foamed pillar portions made of a foamed plate material are pressed into the cell spaces of the honeycomb core material.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION A method for manufacturing a heat insulating honeycomb panel of the present invention will be described. A foam board material is provided. Foam board material 10
Is a urethane resin-based or phenolic resin-based foamed plate body having a thickness dimension h pre-foamed and molded. This plate material 10 has a specific gravity of 9 to 50 Kg / m ³ ) and a thermal conductivity of 0.010 to 0.03.
It has 0 W / m · K. The foam plate material 10 is pressed into the honeycomb core material 20. Here, the honeycomb core material 20 has a height dimension h and a cell size of 1/8 to 1/2 inch (compression pressure 1
(38 N / cm ² or less) cells 21 are connected in series. The foam plate material 10 and the honeycomb core material 20 are polymerized and sandwiched by the pressure plates 30. Then, a predetermined pressure is applied to the pressure plate 30 to press the foamed columnar parts cut out from the foam plate material 10 into the spaces of the cells 21 of the honeycomb core material 20 to form the heat insulating honeycomb core material 50 which is a heat insulating material. .

The heat-insulating honeycomb core material 5 thus prepared
A heat insulating panel (heat insulating honeycomb panel) 100 is formed by thermocompressing a prepreg layer 60 made of at least one of glass fiber, carbon fiber, aramid fiber, or a combination thereof on the front and back surfaces of No. 0. Since the heat-insulating honeycomb panel 100 configured as described above uses the heat-insulating foam plate material 10 having a uniform thickness dimension h having the same cell height dimension h of the honeycomb core material 20, each cell of the honeycomb core material 20 is used. The heat-insulating foam plate material is surely and uniformly pressed into the space 21 to form a heat-insulating panel having no variation in heat-insulating property.

In addition to obtaining excellent heat insulating properties peculiar to the heat insulating foam plate material, the reaction step can be omitted as compared with the conventional manufacturing method, and the manufacturing step can be simplified very simply. Also,
The heat insulating honeycomb core 50 of this heat insulating honeycomb panel 100
In each cell 21 of the honeycomb core material 20, a columnar portion 15 made of a foam material, which is punched out from the heat insulating foam plate 10 at the time of press fitting and is inserted into the cell 21, is press-fitted. This column 1
The width dimension W of 5 is larger than the cell width dimension W of the cell 21 by the member thickness of the core material 20, and the columnar portion 15 in the cell 21 is compressed and inserted into the cell 21.
For this reason, the columnar portion 15 tries to expand (restore) in the cell 21, is pressed against the cell 21 in a pressed state, is stable, and does not fall out. An adiabatic honeycomb core 5 in which the columnar portion 15 made of an adiabatic foam material is securely press-fitted into all the cells 21 space.
0 has uniform heat insulation over the entire surface. The heat insulating (honeycomb) panel 100 in which the prepreg material is laminated on both surfaces of the heat insulating honeycomb core 50 having uniform heat insulating property has uniform heat insulating property.

Next, an example of the heat insulating panel will be shown. Example 10mm thick honeycomb core with 3/16 cell size
And a specific gravity of 27 Kg / m^Three, Thermal conductivity 0.026 W / m
10mm thick phenol resin foam board with K
2.5 kgf / cm^TwoApply the power of. Press fit here
FIG. 7 shows the change in pressure applied at the time. As this drawing shows,
Maximum pressure 2.5 Kgf / cm^TwoAnd the passage of time
The pressure drops together. The characteristics of the materials used are       Foam material density 27 Kg / m^Three                   Thermal conductivity 0.026W / m ・ K                   Compressive strength 15 ± 3N / cm^Two(1.5 ± 0.35 Kgf                               / Cm^Two)       Honeycomb core material Compressive strength                   3/16 inch 114N / cm^Two(11.7 Kgf / cm                   ^Two) Has become.

Next, a glass prepreg having a weight of 500 g / m ² was thermocompression-bonded to both surfaces of the heat-insulating honeycomb core press-fitted by a press to manufacture a heat-insulating panel using a honeycomb panel. The heat insulating honeycomb panel produced in this manner exhibited a heat transfer rate of 0.032 W / m · K.

As a comparative example, a heat insulating honeycomb panel was manufactured in the following manner. Non-woven fabric with foamable phenolic resin pre-sprayed and adhered, and thickness with 3/16 cell size 1
0mm honeycomb cores are stacked, 160 ℃, 5 minutes,
The phenol resin was foamed by heating and reacting at 1 Kgf / cm ^{2 with} a heating press to fill the honeycomb cells. 500 g / m on both sides of the obtained foamed honeycomb core
A glass prepreg having a weight of ² was thermocompression bonded to manufacture a heat insulating honeycomb panel. The heat insulating honeycomb panel produced by this production method exhibited a thermal conductivity of 0.045 W / m · K.

As shown in the above examples, the heat insulating honeycomb panel formed by the manufacturing method of the present invention has improved heat insulating efficiency as compared with the heat insulating honeycomb panel shown in the comparative example. Further, the process of heating and reacting the foamable resin is not required, and the labor of the manufacturing process can be saved.

[0013]

Industrial Applicability According to the present invention, it is possible to obtain a heat-insulating panel having excellent heat-insulating characteristics peculiar to a heat-insulating foam plate material, in which the manufacturing process can be saved and the heat-insulating property does not vary.

[Brief description of drawings]

FIG. 1 is a perspective view of a heat insulating foam plate and a honeycomb core material.

FIG. 2 is an explanatory view of a heat insulating layer forming step of pressurizing a polymerized layer.

FIG. 3 is an explanatory view of a heat insulating layer forming step of pressurizing a polymerized layer.

FIG. 4 is a perspective view of a heat insulating honeycomb core.

FIG. 5 is an enlarged explanatory view of cells of a heat insulating honeycomb core.

FIG. 6 is a cross-sectional view of a heat insulation panel.

FIG. 7 is a graph showing changes in pressure during press fitting.

[Explanation of symbols]

10 Thermal insulation foam board 15 Column 20 Honeycomb core material 21 cells 50 Insulated honeycomb core 60 Surface layer (prepreg layer) 100 heat insulation panel (heat insulation honeycomb panel)

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) F16L 59/04 F16L 59/04 F term (reference) 2E001 DD01 GA42 HD01 HF11 2E162 CD01 CD19 DA09 3H036 AA09 AB18 AB25 AC01 4F100 AD11 AG00 AK01A AK33 AK47 AK51 AT00B AT00C BA03 BA10B BA10C DC07A DH01 DJ01A EJ201 EJ202 EJ422 GB08 GB31 JJ02A

Claims (3)

[Claims] 1. A method of manufacturing a heat insulating panel in which a heat insulating layer is sandwiched between surface layers, a polymer layer forming step of polymerizing and disposing a foam plate made of a synthetic resin foam and a honeycomb core material, and the foam plate and the honeycomb core. There is a heat insulating layer forming step of pressurizing the polymerized layer of the material, and a panel forming step of sandwiching the heat insulating layer between the surface layers and crimping the heat insulating layer. A method of manufacturing a heat insulating panel, which comprises forming a heat insulating layer. 2. A heat insulation panel in which a heat insulation material is sandwiched and pressure-bonded between surface materials, wherein the heat insulation material comprises a foamed honeycomb core in which foamed pillar portions made of foamed plate material are press-fitted into the cell spaces of the honeycomb core material. panel. 3. The heat insulation panel according to claim 2, wherein the foam pillar portion is pressed against the honeycomb core material.