JP2005212200A - Cylindrical honeycomb structure and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cylindrical honeycomb structure constituted so as to ensure rigidity by forming a part or the whole of the peripheral wall of a duct having a non-circular cross section into a honeycomb structure and capable of suppressing the distortion caused by an increase in minute mass, and its manufacturing method. <P>SOLUTION: The cylindrical body 1 of a cylindrical honeycomb structure is molded into a flat cross-sectional shape by mutually opposed plane parts X and X and mutually opposed curved surface parts Y and Y, and formed into a sandwich structure by interposing a honeycomb 4 between a surface material 2 and a back material 3. The material of a honeycomb core 4 is selected from stainless steel, an aluminum alloy, a fiber reinforced plastic obtained by impregnating or coating a reinforcing fiber with a thermoplastic resin or a thermosetting resin or the like and, as the surface material 2 and the back material 3, an intermediate material formed by applying or laminating the thermosetting resin or the thermoplastic resin to the reinforcing fiber is used. In a first embodiment, the whole periphery of the plane parts X and X and curved surface parts Y and Y of the cylindrical body 1 is formed into a honeycomb structure. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a cylindrical honeycomb structure and a manufacturing method thereof, and more particularly to a cylindrical honeycomb structure using a honeycomb sandwich structure on a cylindrical wall of a duct having a non-circular cross section and a manufacturing method thereof.

  Conventionally, a honeycomb sandwich panel with a honeycomb core interposed between the front and back surfaces is a flat surface such as a floor or wall for the purpose of reducing weight, improving rigidity against vertical loads, preventing deformation, and heat-curing. It is used in various fields such as a panel, a curved panel, a circular cross section, and a cylindrical body having a rectangular cross section (for example, Patent Document 1).

  By the way, as a reinforcing material of a cylindrical body formed in a circular cross section, for example, a material using a reinforcing fiber filament is known (for example, see Patent Document 2).

On the other hand, when manufacturing non-circular cross-section ducts (cylindrical bodies) made of stainless steel, aluminum alloys, fiber reinforced plastics, etc., in places that cannot be used with circular cross-section ducts, Or in the place similar to it, bending generate | occur | produces compared with a duct with a circular cross section, and big bending generate | occur | produces. In order to suppress this, it is necessary to increase the wall thickness of the peripheral wall of the duct. As a result, there is a problem that the weight is remarkably increased.
Japanese Patent Laid-Open No. 10-85314 Japanese Patent Laid-Open No. 2001-21067

  The present invention has been devised by paying attention to such conventional problems, and by making a part or all of the peripheral wall of the duct having a non-circular cross section into a honeycomb structure, rigidity is ensured and a minute mass increase is made. An object of the present invention is to provide a cylindrical honeycomb structure capable of suppressing bending and a manufacturing method thereof.

  In order to achieve the above object, the present invention provides a tubular honeycomb structure of the present invention having a sandwich structure with a honeycomb core interposed between a front surface material and a back surface material. This is a tubular honeycomb structure provided with a flat portion at at least one of the above, wherein the entire circumference of the tubular body has a honeycomb sandwich structure.

  Here, at least the plane part or only the plane part of the cylindrical body has a honeycomb sandwich structure, and 70% to 100% of the total area of the plane part of the cylindrical body has a honeycomb sandwich structure.

  Further, the honeycomb core is made of one material selected from stainless steel, aluminum alloy, and fiber reinforced plastic, and the surface material and the back material are coated or laminated with a thermosetting resin or a thermoplastic resin on a reinforcing fiber. An intermediate material is used.

  Further, in the manufacturing method of the tubular honeycomb structure of the present invention, a fiber reinforced resin sheet made of reinforcing fibers and a thermosetting resin is wound around a mandrel, and a honeycomb core is disposed at a predetermined position on the fiber reinforced resin sheet. Further, a fiber reinforced resin sheet similar to the above is wound thereon, and then the outer peripheral surface is pressurized with a pressurizing means, or heat-cured without using a pressurizing means, and the mandrel is removed from the cured cylindrical body. The gist is to pull it out.

  Further, in the second method for manufacturing a tubular honeycomb structure according to the present invention, a preheated mandrel is wrapped with an intermediate sheet material composed of reinforcing fibers and a thermoplastic resin, and the intermediate sheet material is kept at a predetermined position in a state of being kept warm. The honeycomb core is disposed on the intermediate sheet material, and the intermediate sheet material similar to the above is wound while being heated and pressurized to form a cylindrical body, and after the cylindrical body cools, the mandrel is pulled out. To do.

  Here, the thermoplastic resin of the intermediate sheet material is a thermoplastic resin that can be dissolved in a thermoplastic film or a solvent.

  In this way, a part or all of the peripheral wall of the duct with a non-circular cross section is made into a honeycomb structure, so that rigidity can be secured, bending can be suppressed by a small increase in mass, and the duct itself has high heat insulation characteristics. It is possible to make the insulation unnecessary.

Since the present invention is configured as described above, the following excellent effects can be obtained. (a) By making a part or all of the peripheral wall of the duct having a non-circular cross section into a honeycomb structure, rigidity can be ensured and bending can be suppressed by a small increase in mass.
(b). When the honeycomb structure is applied to the entire peripheral wall of the duct, each honeycomb is finely divided by the cell wall, and the convection of trapped air can be prevented, so that a high heat insulating effect can be obtained.
(c) Since the heat insulation effect can be imparted to the duct body having a non-circular cross section, the heat insulating material wound around the outside of the normal duct can be dispensed with, which is economical.
(d) Since it can be manufactured by various methods and can be easily manufactured, it can be manufactured at low cost and cost reduction can be achieved.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  FIG. 1 is a perspective view of a tubular honeycomb structure having a non-circular cross section showing a first embodiment of the present invention, and FIG. 2 is a cross sectional view taken along line AA of FIG. The shaped body 1 is formed into a flat cross section with opposing flat surface portions X and X and opposing curved surface portions Y and Y, and the configuration thereof is a honeycomb core 4 between the surface material 2 and the back surface material 3. The structure is sandwiched between

  The cylindrical body 1 is not limited to a flat shape with a non-circular cross section, and can be applied to a cylindrical body with a rectangular cross section. In addition, the shape of the honeycomb of the tubular honeycomb structure according to the present invention may be a shape that can be reinforced, such as a hexagonal shape, a 3-12 square shape, a circle, a star shape, or a combination thereof. If it does not specifically limit. In this case, the size of each honeycomb shape is preferably a size (cell size) included in a 5-30 mm square, and more preferably included in a 10-30 mm square. Good size.

  Moreover, it is preferable that the plane portions X and X facing each other of the cylindrical body 1 of the present invention have a honeycomb sandwich structure of 70 to 100% of the total area of the plane portion, but considering rigidity, strength, and the like. In such a case, it is more preferable to use 80 to 100% of the total area of the plane part.

  The material of the honeycomb core 4 was selected from stainless steel, aluminum alloy, a reinforcing fiber (for example, Nomex fiber: a registered trademark of DuPont), a thermoplastic resin, or a fiber reinforced plastic impregnated or coated with a thermosetting resin. One or a combination thereof is used, and the surface material 2 and the back material 3 are made of an intermediate material in which a reinforcing fiber is coated or laminated with a thermosetting resin or a thermoplastic resin.

  In the first embodiment of the present invention, the entire circumference of the flat surface portions X and X and the curved surface portions Y and Y of the cylindrical body 1 has a honeycomb structure.

  Further, in the second embodiment of the present invention shown in FIGS. 3 and 4, only the flat portions X and X of the tubular body 1 have a honeycomb structure, and the curved portions Y and Y have thermosetting resin or thermoplastic resin as reinforcing fibers. The surface material 2 and the back material 3 are made of an intermediate material coated or laminated with a resin.

  As described above, a part or all of the peripheral wall of the duct having a non-circular cross section has a honeycomb structure, so that rigidity can be ensured and bending can be suppressed by a minute increase in mass.

In the embodiment of the present invention shown in FIG. 1, when used in a duct having a width D of 300 mm, a height H of 100 mm, and a length L of 1000 mm, when the internal pressure of 100 kPa is applied, the deformation can be suppressed to 1 mm. The weight per 1 m of the duct is as follows.
[Material of honeycomb core]
Stainless steel 16.8kg
Aluminum alloy 8.5kg
Carbon fiber reinforced plastic (CFRP) 5.3 kg (* 1)
Honeycomb duct 2.8kg (* 2)
* 1: Reference weight when using medium elastic canvas grade carbon fiber woven cloth * 2: Example of cloth GFRP with inner and outer skins of 1 mm and honeycomb core all around

  In the embodiment of the present invention, when the honeycomb structure is applied to the entire peripheral wall of the duct as described above, the individual honeycombs are finely divided by the cell walls, and the convection of trapped air can be prevented. Can be obtained.

  Moreover, since the heat insulation effect can be given to the duct main body of a non-circular cross section, the heat insulating material currently wound around the normal duct outer side can be made unnecessary.

  Next, a method for manufacturing a cylindrical honeycomb structure having a non-circular cross section as described above will be described.

  The method for manufacturing the tubular honeycomb structure according to the embodiment of the present invention is roughly divided into a case where a thermosetting fiber reinforced plastic (FRP) is used and a case where a thermoplastic fiber reinforced plastic (FRP) is used.

(A) [When using thermosetting fiber reinforced plastic (FRP)]
First, a fiber reinforced resin sheet made of reinforcing fiber and thermosetting resin is wound around a mandrel (core metal) having a predetermined size (flat shape), and a honeycomb core is disposed at a predetermined position on the fiber reinforced resin sheet. To do. Further, after winding a fiber reinforced resin sheet similar to the above on it, bagging (backing) or applying a tightening force by winding a shrink tape, etc., the outer peripheral surface is placed in an oven, an autoclave, A tubular honeycomb structure is manufactured by pressurizing with a pressurizing means such as a heater or heat-curing without using a pressurizing means, and pulling out the mandrel from the cured tubular body.
Whether or not the pressurizing means is used is arbitrary.

(B1) [When using thermoplastic fiber reinforced plastic (FRP)]
This manufacturing method uses an intermediate material obtained by coating a reinforcing fiber such as a glass cloth with a thermoplastic material such as polyamide, polyetherimide, or PES (polyethersulfone) (hereinafter referred to as a laminate sheet).

  First, an intermediate sheet material (laminate sheet) made of reinforcing fibers and a thermoplastic resin is wound around a preheated mandrel, and a honeycomb core is disposed at a predetermined position of the laminate sheet while maintaining the temperature. Further, a cylindrical sheet is formed by winding a laminate sheet similar to the above while heating and pressurizing (applying force with a roller or the like), and after the cylindrical body cools, the cylindrical body is pulled out. A honeycomb structure is manufactured.

(B2) [When using thermoplastic fiber reinforced plastic (FRP)]
First, after reinforcing fibers such as a thermoplastic film and glass cloth are alternately wound around a mandrel, a honeycomb core is disposed at a predetermined position on the mandrel. Further, a thermoplastic film and a reinforcing fiber such as a glass cloth are alternately wound on the honeycomb core, bagged (packed) with a film having higher heat resistance, and evacuated. And while maintaining a vacuum, a thermoplastic film is heated to melting | fusing point by heating means, such as oven and an autoclave, and after cooling, a mandrel is drawn out and a cylindrical honeycomb structure is manufactured.

(B3) [When using thermoplastic fiber reinforced plastic (FRP)]
When applied only to thermoplastic resins that are soluble in solvents.
First, a thermoplastic resin is dissolved in a solvent (hereinafter referred to as varnish), and wound around a mandrel while impregnating the varnish into a reinforcing fiber such as a glass cloth. Using a heating means such as an oven or a dryer, semi-dry under conditions that match the characteristics of the solvent used. In this state, a honeycomb core is disposed at a predetermined position, and wound around a mandrel while impregnating a varnish into a reinforcing fiber such as a glass cloth on the honeycomb core. And after drying completely, a mandrel is pulled out and a cylindrical honeycomb structure is manufactured.

  In this way, by manufacturing a part or all of the peripheral wall of the duct having a non-circular cross section with a honeycomb structure, it is possible to secure rigidity and suppress bending by a small increase in mass, and the duct itself has high heat insulation. It is possible to provide properties and eliminate the need for a heat insulating material.

  Furthermore, since the heat insulation effect can be given to the duct body having a non-circular cross section, the heat insulating material wound around the outside of the normal duct can be dispensed with, which is economical. Since the tubular honeycomb structure can be manufactured by various methods, it can be manufactured easily and inexpensively, and the cost can be reduced.

1 is a partially cutaway perspective view of a tubular honeycomb structure having a non-circular cross section showing a first embodiment of the present invention. It is AA arrow sectional drawing of FIG. FIG. 5 is a partially cutaway perspective view of a tubular honeycomb structure having a non-circular cross section showing a second embodiment of the present invention. It is a BB arrow sectional view of Drawing 3.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Cylindrical body 2 Surface material 3 Back surface material 4 Honeycomb core X Plane part Y Curved part

Claims (9)

A tubular structure having a sandwich structure with a honeycomb core interposed between a front surface material and a back surface material, and having a planar portion at least at one location of the tubular body,
A tubular honeycomb structure characterized in that the entire circumference of the tubular body has a honeycomb sandwich structure. The cylindrical honeycomb structure according to claim 1, wherein at least a planar portion of the cylindrical body has a honeycomb sandwich structure. The tubular honeycomb structure according to claim 1 or 2, wherein only a flat portion of the tubular body has a honeycomb sandwich structure. The tubular honeycomb structure according to claim 1, 2, or 3, wherein 70% to 100% of the total area of the planar portion of the tubular body is a honeycomb sandwich structure. The cylindrical honeycomb structure according to claim 1, 2, 3, or 4, wherein the honeycomb core uses one material selected from stainless steel, aluminum alloy, and fiber reinforced plastic. The tubular honeycomb structure according to claim 1, 2, 3, 4 or 5, wherein an intermediate material obtained by coating or laminating a reinforcing fiber with a thermosetting resin or a thermoplastic resin is used for the front surface material and the back surface material. A fiber reinforced resin sheet comprising reinforcing fibers and a thermosetting resin is wound around a mandrel, a honeycomb core is disposed at a predetermined position on the fiber reinforced resin sheet, and a fiber reinforced resin sheet similar to the above is wound thereon. Thereafter, the outer peripheral surface is pressurized with a pressurizing means, or is heat-cured without using a pressurizing means, and a mandrel is pulled out from the cured tubular body. An intermediate sheet material composed of reinforcing fibers and thermoplastic resin is wound around a preheated mandrel, and a honeycomb core is disposed at a predetermined position of the intermediate sheet material while being kept warm, and an intermediate sheet similar to the above is further disposed thereon A method for manufacturing a tubular honeycomb structure in which a material is wound while being heated and pressurized to form a tubular body, and after the tubular body cools, a mandrel is pulled out. The method for manufacturing a tubular honeycomb structure according to claim 7, wherein the thermoplastic resin of the intermediate sheet material is a thermoplastic resin that can be dissolved in a thermoplastic film or a solvent.

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