JP2006007512A - Manufacturing method of honeycomb sandwich panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a honeycomb sandwich panel of extremely high quality of a composite material skin having a curved stepped part without distorting a shape and producing a gap between a honeycomb and the skin. <P>SOLUTION: A first pin 12 and a screw hole are provided to the surface plate 11 of a lower mold while a slot 22 and a pinhole are provided to a lower fairing 20, the lower fairing 20 is arranged on a surface plate 11 to insert the first pin 12 in the slot 22, a pin bolt is inserted in the pinhole to be threaded with the screw hole to locate the lower fairing 20 in the lower fairing 20, a prepreg P, a honeycomb core C and the prepreg P are arranged on the surface plate 11 and the lower fairing 20, the outer edge part of the prepreg P is held by the lower fairing 20 and the an upper fairing 30 after the pin bolt is drawn out and the whole is covered with cover materials 50 and 60 to be pressed/heated. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a honeycomb sandwich panel, and more particularly, to a method for manufacturing a honeycomb sandwich panel of a composite skin having a shape in which a step portion having a linear boundary line is provided and two curved surfaces are combined.

  Currently, a honeycomb sandwich panel composed of a honeycomb core made of a metal material or a resin material and a fiber-reinforced resin composite skin bonded to the upper and lower surfaces of the honeycomb core is used as a structural material for aircraft and satellites. (For example, refer to Patent Document 1). An example of a conventional method for manufacturing such a honeycomb sandwich panel (hereinafter referred to as “conventional method”) will be specifically described with reference to FIGS. In the following description, a method for manufacturing a honeycomb sandwich panel having a shape in which a step portion having a linear boundary line is provided and two curved surfaces are combined will be described.

  According to the conventional method, first, as shown in FIG. 6, the fairing 200 with a pin is arranged on the surface plate 110 of the lower mold 100 as a forming jig, and the fairing 200 with the pin is represented by a bolt 300. Position and fix to the face plate 110. Next, as shown in FIG. 6 and FIG. 7, the prepreg P, the honeycomb core C, and the prepreg P are laminated in this order on the surface plate 110 and the pinned fairing 200, and on the pins 210 of the pinned fairing 200. The outer edge portion of the prepreg P is locked. Then, the fairing 400 is disposed on the outer edge portion of the prepreg P.

Subsequently, as shown in FIG. 7, the prepreg P, the fairing 400, and the like disposed on the surface plate 110 are covered with the auxiliary material 500 and the bagging film 600, and the sealant 700 is disposed around the covered portion to perform bagging. The inside of the film 600 is airtight. Then, by pressing and heating in an autoclave while discharging air (evacuating) in the bagging film 600, molding of the skin S (curing of the prepreg P), adhesion between the skin S and the honeycomb core C, Are performed simultaneously to obtain a honeycomb sandwich panel H as shown in FIG.
JP-A-4-267138

  By the way, in the conventional method as described above, as shown in FIG. 6A, the pin-equipped fairing 200 is fixed to the surface plate 110 of the lower mold 100 with bolts 300. For this reason, the fairing 200 with a pin and the prepreg P are dragged by the surface plate 110 of the lower mold 100 heated and expanded by the autoclave as shown in FIG. 7B. As a result, the shape of the product is distorted, and a gap G is formed between the outer edge of the honeycomb core C and the skin S, as shown in FIG. There was a problem of being lowered.

  On the other hand, if the bolt 300 is eliminated in the conventional method as described above, the quality of the product may be deteriorated. For example, as shown in FIG. 6, when a linear stepped portion D is provided on the surface plate 110 of the lower mold 100, a prepreg P is laminated on the stepped portion D, and pressure and heating are performed. If the bolt 300 is eliminated, the relative position of the stepped portion D with respect to the prepreg P changes due to the expansion of the surface plate 110. As a result, a desired step cannot be formed on the product, and the quality of the product is reduced.

  The object of the present invention is to suppress distortion of the product shape and prevent a gap from being formed between the honeycomb core and the skin when manufacturing a honeycomb sandwich panel having a composite skin having curved and stepped portions. Another object of the present invention is to provide a method for manufacturing a honeycomb sandwich panel that can obtain a very high quality product.

  In order to solve the above problems, the invention according to claim 1 is characterized in that a prepreg, a honeycomb core, and a prepreg are arranged in this order on a lower surface plate provided with a stepped portion having a linear boundary line. By laminating, sandwiching the outer edge portion of the prepreg with an upper fairing and a lower fairing arranged on the side of the honeycomb core, and coating the honeycomb core and the prepreg with a coating material and pressurizing and heating. A method of manufacturing a honeycomb sandwich panel having a curved step portion, wherein the first pin is erected on the surface plate and a plurality of screw holes are provided, and the upper and lower fairings are formed on the surface plate. The lower fairing is provided with long holes in the upper and lower fairings so as to include a portion where the first pin is located when arranged, and opposed to the plurality of screw holes. A pin hole for inserting a pin bolt to be screwed into the screw hole is provided in the part, and a specific jig preparing step of standing a plurality of second pins on the lower fairing, and a top surface of the surface plate The lower fairing is disposed and the first pin is inserted into the elongated hole, and the lower fairing is disposed in the lower fairing so as to overlap the screw hole of the surface plate, and a pin bolt A pin bolt insertion step of inserting into the pin hole and screwing into the screw hole to position the lower fairing, and a lamination step of laminating a prepreg, a honeycomb core and a prepreg on the surface plate and the lower fairing And a pin bolt extracting step of extracting the pin bolt, and pressing an outer edge portion of the prepreg against the second pin of the lower fairing A material locking step for locking and an upper fairing arrangement that sandwiches the outer edge portion of the prepreg with the lower fairing and the upper fairing by arranging the upper fairing on the outer edge portion of the prepreg Coating the honeycomb core, the prepreg, the lower fairing, and the upper fairing with the coating material and applying pressure and heating to cure the prepreg and form a skin, and at the same time, And a pressing / heating step for bonding the honeycomb core.

  According to the first aspect of the present invention, the first pin and the screw hole are provided in the lower mold surface plate, the long hole and the pin hole are provided in the lower fairing, and the long hole is provided in the upper fairing. Then, the lower fairing is arranged on the surface plate, the pin bolt is inserted into the pin hole, and the lower fairing is positioned with respect to the lower mold by being screwed into the screw hole, and the first pin is inserted into the long hole. To do. Next, after the prepreg, the honeycomb core and the prepreg are laminated in this order on the surface plate and the lower fairing, the pin bolt is pulled out and the outer edge portion of the prepreg is sandwiched between the lower fairing and the upper fairing. Subsequently, the honeycomb core and the prepreg are coated with a coating material and pressurized and heated in a vacuumed state so that the prepreg is cured to form the skin, and at the same time, the honeycomb core and the skin are bonded to each other. Get a sandwich panel.

  Therefore, even when the lower surface plate is heated and expanded, the first pin of the surface plate can be moved along the long holes of the lower fairing and the upper fairing. The prepreg and upper fairing are not dragged by the face plate. As a result, distortion of the product shape can be suppressed and a gap can be prevented from being generated between the honeycomb core and the skin, so that an extremely high quality product can be obtained.

  The invention according to claim 2 is the method for manufacturing a honeycomb sandwich panel according to claim 1, wherein in the specific jig preparing step, the first pin is provided in the vicinity of a boundary line of the stepped portion, The longitudinal direction of the long hole of the lower fairing is made parallel to the boundary line of the stepped portion, and the width dimension of the long hole is made to substantially coincide with the outer diameter of the first pin.

  According to invention of Claim 2, while providing the 1st pin of a surface plate in the vicinity of the boundary line of a stepped part, the longitudinal direction of the long hole of a lower fairing is parallel to the boundary line of a stepped part To do. Therefore, in the direction parallel to the boundary line of the stepped portion, the first pin of the surface plate can be moved along the long hole of the lower fairing. Further, since the width dimension of the long hole of the lower fairing is made to substantially coincide with the outer diameter of the first pin of the face plate, in the direction perpendicular to the boundary line of the stepped portion, a table with respect to the long hole of the lower fairing is provided. The relative movement of the first pin of the face plate can be suppressed. That is, in the direction perpendicular to the boundary line of the stepped portion, the change in the relative position of the stepped portion with respect to the prepreg can be suppressed, so that a desired stepped portion can be formed on the product using the stepped portion. it can.

  According to the present invention, the first pin is provided in the lower surface plate and the long fairing is provided in the lower fairing. When the lower fairing is arranged on the surface plate and aligned, the first pin is Since it inserts in a long hole, even when a surface board expands by heating, a 1st pin can be moved along a long hole. As a result, since the prepreg is not dragged to the surface plate during pressurization / heating, distortion of the product shape can be suppressed, and a gap can be prevented from being generated between the honeycomb core and the skin. An extremely high quality product (honeycomb sandwich panel) can be obtained.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  First, a jig used in the manufacturing method according to the present embodiment will be described. In this embodiment, as shown in FIGS. 1 to 4, the lower mold 10, the lower fairing 20, the upper fairing 30, the pin bolt 40, the auxiliary material 50, the bagging film 60, the sealant 70, etc. are used as jigs. To do.

  As shown in FIGS. 1 and 2, the lower mold 10 is a jig for placing the lower fairing 20 and the prepreg P on the surface plate 11, and is disposed at a place where molding is performed. As shown in FIGS. 1, 2, and 4, the surface plate 11 of the lower mold 10 includes a cylindrical first pin 12 that is inserted into the elongated hole 22 of the lower fairing 20 and a screw that fixes the pin bolt 40. The hole 13 and the step part 14 for forming a step part in a product are provided, and it is prepared with an iron material. The stepped portion 14 has a straight boundary line.

  1 to 4, the lower fairing 20 is a plate-shaped jig that is paired with the upper fairing 30 and sandwiches the vicinity of the outer edge of the prepreg P. As shown in FIG. It is arrange | positioned on the 10 surface plates 11 in a square shape. As shown in FIGS. 1 to 3, the lower fairing 20 includes a second pin 21 that locks the vicinity of the outer edge of the prepreg P, and a first pin 12 provided on the surface plate 11 of the lower mold 10. A long hole 22 to be inserted, a pin hole 23 into which the pin bolt 40 is inserted, and a stepped portion 24 for forming a stepped portion in the product are provided.

  The long hole 22 of the lower fairing 20 is arranged in the vicinity of the stepped portion 24 as shown in FIGS. 1 and 2, and the length direction thereof is the front surface of the lower mold 10 as shown in FIG. It is set so as to be parallel to the boundary line of the stepped portion 14 provided on the face plate 11. Moreover, the width dimension of the long hole 22 is set so that it may correspond to the outer diameter of the 1st pin 12 of the surface board 11, as shown in FIG. Further, as shown in FIG. 1, in the state where the pin hole 23 of the lower fairing 20 and the screw hole 13 of the surface plate 11 of the lower mold 10 are overlapped and the pin bolt 40 is inserted into both holes, The first pin 12 is positioned near the center.

2 and 4, the upper fairing 30 is a plate-shaped jig that is paired with the lower fairing 20 and sandwiches the outer edge portion of the prepreg P, and is disposed above the lower fairing 20. The The upper fairing 30 includes a long hole (not shown) through which the first pin 12 provided on the surface plate 11 of the lower mold 10 is inserted. Further, as shown in FIG. 2, the upper fairing 30 includes a stepped portion 34 at a position facing the stepped portion 24 of the lower fairing 20.

  The pin bolt 40 positions the lower fairing 20 with respect to the surface plate 11 of the lower mold 10. The screw hole 13 provided in the surface plate 11 of the lower mold 10 and the pin hole 23 provided in the lower fairing 20 are overlapped, and the pin bolt 40 is inserted into the pin hole 23 and screwed into the screw hole 13. Thus, the lower fairing 20 can be positioned with respect to the surface plate 11.

  The auxiliary material 50 and the bagging film 60 are coating materials in the present invention, and as shown in FIG. 4, the honeycomb core C, the prepreg P, the lower fairing 20 and the upper part placed on the surface plate 11 of the lower mold 10. The fairing 30 is covered. As the auxiliary material 50, an air breather such as a glass cloth or a release film can be employed. The sealant 70 is disposed around the portion covered with the bagging film 60 (around the lower fairing 30) and seals the portion covered with the bagging film 60.

  Next, a method for manufacturing the honeycomb sandwich panel H according to the present embodiment will be described. In the present embodiment, as shown in FIG. 5, the honeycomb core C and the skin S of the fiber reinforced resin composite material bonded to the upper and lower surfaces of the honeycomb core C (the prepreg P shown in FIG. 4 is added). A method for manufacturing a honeycomb sandwich panel H having a shape formed by pressing and heating) will be described.

  First, each jig (the above-mentioned lower mold 10, lower fairing 20, etc.) used in this manufacturing method is prepared (specific jig preparing step). As shown in FIGS. 1 and 2, the lower fairing 20 is arranged on the surface plate 11 of the lower mold 10, and the first pins 12 of the surface plate 11 are formed in the long holes 22 of the lower fairing 20. Insert and overlap the screw hole 13 and the pin hole 23 (lower fairing placement step).

  Next, as shown in FIGS. 1 and 2, the pin bolt 40 is inserted into the pin hole 23 and screwed into the screw hole 13 to position the lower fairing 20 with respect to the surface plate 11 of the lower mold 10 (pin bolt insertion process). ). In a state where the pin bolt 40 is inserted into the screw hole 13 and the pin hole 23, the first pin 12 of the surface plate 11 is positioned near the center of the long hole 22 of the lower fairing 20 as shown in FIG. It has become.

  Next, as shown in FIG. 4, a plurality of prepregs P are laminated on the surface plate 11 and the lower fairing 20, and a honeycomb core C is disposed on the prepreg P, and the prepreg P and the honeycomb core C A plurality of prepregs P are laminated on top (lamination process). Then, the outer edge portion of each prepreg P is pressed and locked to the second pin 21 of the lower fairing 20 (material locking step). In addition, the pin bolt 40 is extracted from the screw hole 13 and the pin hole 23 immediately before the outer edge portion of the prepreg P is pressed and locked to the second pin 21 (pin bolt extraction process).

  Next, as shown in FIG. 2 and FIG. 4, the upper fairing 30 is disposed on the outer edge portion of the prepreg P disposed above, so that the outer edge portion of the prepreg P is moved by the lower fairing 20 and the upper fairing 30. Clamp (upper fairing placement step). Next, as shown in FIG. 4, the honeycomb core C, the prepreg P, the lower fairing 20 and the upper fairing 30 placed on the surface plate 11 of the lower mold 10 are covered with the auxiliary material 50 and the bagging film 60. Then, by disposing the sealant 70 around the covered portion, the space in the film surrounded by the surface plate 11 and the bagging film 60 is made airtight (covering step).

  Next, using a suction device (not shown), air is exhausted (evacuated) from the space in the film, and the pressure in the bagging film 6 is set to a vacuum pressure, thereby lowering the prepreg P and the lower fairing 20. The surface plate 11 of the mold 10 is fixed in close contact (vacuum drawing step). Thereafter, the lower mold 10 is carried into an autoclave (not shown), and the prepreg P placed on the surface plate 11 of the lower mold 10 is heated while applying a predetermined pressure, thereby forming the skin S. And the adhesion between the skin S and the honeycomb core C are simultaneously realized (pressure / heating step). Through the above process group, a honeycomb sandwich panel H as shown in FIG. 5 is obtained.

  In the manufacturing method according to the present embodiment described above, as shown in FIG. 1, the first pin 12 and the screw hole 13 are provided in the surface plate 11 of the lower mold 10, and the long hole 22 is provided in the lower fairing 20. In addition, the lower fairing 20 is disposed on the surface plate 11 and the pin bolt 40 is inserted into the screw hole 13 and the pin hole 23 to position the lower fairing 20 with respect to the lower mold 10. One pin 12 is inserted into the long hole 22 and positioned near the center of the long hole 22. 4A, after the prepreg P, the honeycomb core C, and the prepreg P are arranged in this order on the surface plate 11 and the lower fairing 20, the pin bolt 40 is connected to the screw hole 13 and the pin hole 23. And the outer edge portion of the prepreg P is sandwiched between the lower fairing 20 and the upper fairing 30. Thereafter, as shown in FIG. 4 (a), the honeycomb core C and the prepreg P are covered with the auxiliary material 50 and the bagging film 60, and are pressurized and heated in a vacuumed state, thereby forming the skin S. Adhesion between the skin S and the honeycomb core C is realized at the same time to obtain a honeycomb sandwich panel H.

  Therefore, even when the surface plate 11 of the lower mold 10 is heated and expanded, the first pin 12 of the surface plate 11 is moved along the long hole 22 of the lower fairing 20 as shown in FIG. Since it can be moved, the lower fairing 20 and the prepreg P are not dragged by the surface plate 11. As a result, the distortion of the product shape can be suppressed and a gap can be prevented from being generated between the honeycomb core C and the skin 4, so that an extremely high quality product as shown in FIG. 5 is obtained. be able to.

  In the manufacturing method according to the present embodiment described above, as shown in FIG. 1, the first pins 12 of the surface plate 11 of the lower mold 10 are provided in the vicinity of the boundary line of the stepped portion 14, The length direction of the long hole 22 of the lower fairing 20 is parallel to the boundary line of the stepped portion 14. Therefore, in the direction parallel to the boundary line of the stepped portion 14, the first pin 12 of the surface plate 11 is moved along the long hole 22 of the lower fairing 20 as shown in FIG. Can do.

  Further, in the manufacturing method according to the present embodiment described above, as shown in FIG. 1, the width dimension of the long hole 22 of the lower fairing 20 is approximately equal to the outer diameter of the first pin 12 of the surface plate 11. Therefore, in the direction perpendicular to the boundary line of the stepped portion 14, the relative movement of the first pin 12 of the surface plate 11 with respect to the long hole 22 of the lower fairing 20 can be suppressed. That is, in the direction perpendicular to the boundary line of the stepped portion 14, the change in the relative position of the stepped portion 14 with respect to the prepreg P can be reduced, so that a desired stepped portion can be added to the product using the stepped portion 14. Can be formed.

It is a top view of the lower mold | type used with the manufacturing method which concerns on embodiment of this invention. FIG. 2 is a side view of the lower mold shown in FIG. 1 (viewed from the direction of arrow II). It is a top view of the lower fairing used with the manufacturing method which concerns on embodiment of this invention. FIG. 4 is a cross-sectional view of the IV-IV portion in a state in which a lower fairing, a prepreg, a honeycomb core, and an upper fairing are arranged on the lower mold surface plate shown in FIG. 1 and are covered with a covering material. It is a fragmentary sectional view of the honeycomb sandwich panel manufactured with the manufacturing method concerning an embodiment of the invention. The lower mold | type used with the conventional manufacturing method is shown, (a) is a top view, (b) is a side view (figure seen from the arrow B direction). FIG. 7 is a cross-sectional view of a VII-VII portion in a state in which a lower fairing, a prepreg, a honeycomb core, and an upper fairing are arranged on the lower mold surface plate shown in FIG. The honeycomb sandwich panel manufactured with the conventional manufacturing method is shown, (a) is a fragmentary sectional view, (b) is a partial top view.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Lower mold | type 11 Surface board 12 1st pin 13 Screw hole 14 Step part 20 Lower fairing 21 2nd pin 22 Long hole 23 Pin hole 30 Upper fairing 40 Pin bolt 50 Secondary material (covering material)
60 Bagging film (coating material)
C Honeycomb core H Honeycomb sandwich panel P Prepreg S Skin

Claims (2)

A prepreg, a honeycomb core, and a prepreg are laminated in this order on a lower die surface plate provided with a stepped portion having a linear boundary line, and an upper fairing and a lower portion disposed on the side of the honeycomb core. A method of manufacturing a honeycomb sandwich panel having a curved step portion by sandwiching an outer edge portion of the prepreg with fairing, coating the honeycomb core and the prepreg with a covering material, and applying pressure and heating,
A first pin is erected on the surface plate and a plurality of screw holes are provided so as to include a portion where the first pin is located when the upper and lower fairings are arranged on the surface plate. A long hole is provided in the upper and lower fairings, a pin hole for inserting a pin bolt to be screwed into the screw hole is provided in a portion of the lower fairing facing the plurality of screw holes, and the lower fairing A specific jig preparation step of standing a plurality of second pins on the fairing;
A lower fairing arrangement in which the lower fairing is disposed on the surface plate and the first pin is inserted into the elongated hole, and the pin hole of the lower fairing is overlapped with the screw hole of the surface plate. Process,
A pin bolt insertion step of inserting a pin bolt into the pin hole and screwing into the screw hole to position the lower fairing;
A laminating step of laminating a prepreg, a honeycomb core and a prepreg on the surface plate and the lower fairing;
A pin bolt extraction step of extracting the pin bolt;
A material locking step of pressing and locking the outer edge portion of the prepreg to the second pin of the lower fairing;
An upper fairing arrangement step of sandwiching the outer edge portion of the prepreg between the lower fairing and the upper fairing by arranging the upper fairing on the outer edge portion of the prepreg;
The honeycomb core, the prepreg, the lower fairing, and the upper fairing are coated with the coating material and pressurized and heated to cure the prepreg and form a skin. At the same time, the skin and the honeycomb core A pressure and heating process for bonding
A method for manufacturing a honeycomb sandwich panel. In the specific jig preparation step,
The first pin is provided in the vicinity of the boundary line of the stepped portion, the longitudinal direction of the long hole of the lower fairing is parallel to the boundary line of the stepped portion, and the width dimension of the long hole 2. The method for manufacturing a honeycomb sandwich panel according to claim 1, wherein is substantially matched with an outer diameter of the first pin.

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