JP2006247867A - Frp honeycomb structure and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an FRP honeycomb structure which is a structure for a foundation structure material having rigidity and compression strength while achieving weight reduction. <P>SOLUTION: The FRP honeycomb structure is constituted by gathering a plurality of FRP core units CU, of which the cross sections have the same shape, in a state that the respective outside surfaces 11 of the FRP core units CU are butted to each other and subjecting them to curing treatment using a resin material. The manufacturing method of this FRP honeycomb structure comprises a core unit molding process for forming an FRP composition layer to the periphery of a core member having a polygonal cross-sectional shape to impregnate the same with the resin material and curing the impregnated layer to mold the core unit, and a honeycomb structure molding process for gathering the core units so that the outside surfaces of them a butted to each other to impregnate them with the resin material and curing the impregnated core units to mold the honeycomb structure. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

The present invention relates to a honeycomb structure made of fiber reinforced plastics (hereinafter referred to as FRP) obtained by braiding a fiber material for FRP such as carbon fiber and a method for manufacturing the same.

As is well known, a honeycomb structure having a honeycomb structure is used in order to obtain rigidity and compression strength while reducing the weight when adapting a composite material. As a conventional honeycomb structure, for example, a structure in which an FRP plate is configured in a sandwich structure, as disclosed in Patent Document 1, is known.

FRP in such a structure is a composite material in which a fiber material such as carbon fiber or glass fiber is molded with a matrix of various plastics, and is a lightweight FRP composition structure material having characteristics of high strength And has been used in many industrial fields. This FRP composition is composed as a multi-layered structure around a mandrel by setting a fiber material such as carbon fiber or glass fiber in a braider device and braiding. When a preform is formed using the FRP structure formed in a plurality of layers, a resin material is impregnated or adhered to the FRP structure, and then cured and formed by heat and pressure treatment. Thereafter, the mandrel is extracted to obtain a molded product.

In the conventional FRP honeycomb structure, as shown in FIG. 1 and FIG. 2 in Patent Document 1, an FRP base material sheet 9 is introduced into a corrugated molding apparatus 10 including a gear 12 and a rack 13. The corrugated sheet 11 is formed, and the corrugated sheet 11 and the flat plate 14 are alternately joined in a superposed manner to finish the honeycomb structure.

In the manufacturing method of the honeycomb structure by lap bonding, there is a design limitation on the height dimension T in the honeycomb structure defined by the width dimension of the base material sheet 9, and the core material is uniform. However, there are many problems such as that the optimum design in the plane cannot be achieved, and that many of the honeycomb cores have a regular hexagonal cross section and are not diverse.

JP 2000-52459 A (summary, FIGS. 1 to 3)

Therefore, the present invention is a structure for various substructures, and provides an FRP honeycomb structure as a substructure having rigidity and compressive strength while achieving weight reduction. An FRP honeycomb which can be adapted to various designs by selectively combining core units of different constituent elements in the cross-sectional surface of the honeycomb structure without the limitation of the height direction T in the honeycomb structure. It is an object of the present invention to provide a structure and a manufacturing method thereof.

In order to achieve the above-described object, the present invention specifically includes a plurality of FRP core units having the same cross-sectional shape, and the outer surfaces of the respective FRP core units are assembled in a butted shape to form a resin. The FRP honeycomb structure is characterized by being hardened with a material.

Further, in this invention, the invention according to claim 2 is the FRP honeycomb structure according to claim 1, wherein each of the FRP core units includes different constituent elements, and each of the FRP core units. Each of the outer surfaces is assembled into a butted shape and cured with a resin material to form a hybrid structure in the cross-sectional plane.

Further, in the present invention, the invention according to claim 3 is the FRP honeycomb structure according to claim 1 or 2, wherein the cross-sectional shape of each FRP core unit is triangular, quadrangular, hexagonal or It is a polygonal shape such as an octagon.

Further, in the present invention, the invention according to claim 4 relates to a method for manufacturing an FRP honeycomb structure, wherein an FRP assembly layer is organized around a core member having a polygonal cross section, and a resin material. A core unit forming step of forming a core unit by impregnating and hardening the resin, and a honeycomb structure forming step of forming the honeycomb structure by impregnating and hardening the resin material by gathering the outer surfaces of the core unit in a butted manner It is characterized by.

Further, in this invention, the invention according to claim 5 is the method for manufacturing the FRP honeycomb structure according to claim 4, wherein the cross-sectional shape of the core member is triangular, quadrangular, hexagonal or It is made of an octagonal shape.

Furthermore, in the present invention, the invention according to claim 6 is the method for manufacturing the FRP honeycomb structure according to claim 4 or 5, wherein the core unit forming step has a set angle of ± θ °. A braided device and a 0 ° center yarn are selectively combined, and a braided device is used to form a braided layer on a mandrel serving as a core member of the composition.

Furthermore, in this invention, the invention according to claim 7 is the method for manufacturing the FRP honeycomb structure according to claim 4 or 5, wherein the core unit forming step is a sheet-like fiber unidirectional material. (UD sheet) or a cloth material is wound around a core member and impregnated and cured to form a resin material.

Furthermore, in this invention, the invention according to claim 8 is the method for manufacturing the FRP honeycomb structure according to claim 4 or claim 5, wherein the core unit forming step is a sheet-like fiber unidirectional material. (UD sheet) or cloth material is slit into a desired width and formed into a band-like body, and this band-like body is overlaid on each outer surface of the core member and impregnated and cured to form a resin material. It is characterized by this.

Furthermore, in the present invention, the invention according to claim 9 is the method for manufacturing the FRP honeycomb structure according to claims 4 to 8, wherein the type of braiding yarn, the amount of yarn, the thickness of the yarn In addition, a plurality of types of core units having different structures such as the structure of the assembly layer, the type of resin, and the amount of the resin were prepared in advance, and the honeycomb structure was formed by collecting these and processing the resin material. It is characterized by.

Furthermore, in this invention, the invention according to claim 10 is the method for manufacturing the FRP honeycomb structure according to claims 4 to 9, wherein the honeycomb structure forming step is formed by a set of core units. It is characterized by comprising a step of forming a honeycomb composite by bonding the honeycomb structures to each other in a face-to-face manner.

In the FRP honeycomb structure according to the present invention, a plurality of FRP core units having the same cross-sectional shape are formed in advance, and the FRP core units are assembled in a shape of abutting each outer surface. The FRP honeycomb structure is cured to remove the design restrictions on the height dimension T in the honeycomb structure, and can provide a honeycomb structure having a large height dimension T. It can be said that it works effectively.

Furthermore, in the FRP honeycomb structure according to the present invention, each FRP core unit is composed of a structure including different constituent elements, and the outer surfaces of the FRP core units are gathered together in a butted shape and cured with a resin material. Thus, it can be said that the FRP honeycomb structure works extremely effectively in that it can be a hybrid structure in the cross-sectional plane of the FRP honeycomb structure.

Hereinafter, the FRP honeycomb structure and the manufacturing method thereof according to the present invention will be described in detail based on specific examples shown in the drawings. FIG. 1 is a schematic perspective view for explaining a basic configuration of a braiding composition base material by braiding treatment. On the other hand, FIG. 2 is a schematic perspective view showing the basic structure of the FRP honeycomb structure according to the present invention. FIG. 3 is a view for explaining the manufacturing process of the FRP honeycomb structure according to the present invention. FIG. 3A is a schematic perspective view showing an example of a core unit, and FIG. 3B is n core units. FIG. 2 is a schematic perspective view of a honeycomb structure formed by collective molding. FIG. 4 is a schematic perspective view of a honeycomb composite body formed by collectively forming N honeycomb structures.

On the other hand, FIG. 5 is a flowchart showing the sequence of forming the core unit and the sequence of assembling the core unit and forming the honeycomb structure in the order of steps. FIG. 6 is a schematic front view showing an example of the basic configuration of the braider apparatus, and FIG. 7 is a schematic side sectional view of the braider apparatus shown in FIG.

The present invention provides a FRP honeycomb structure as a foundation structure material having rigidity and compression strength while reducing the weight when constructing structures for various foundation structures. For manufacturing, a braiding technique is applied. This braiding technique is to make a braiding composition base as shown in FIG. 1 using a braider apparatus as shown in FIG. 5 and FIG. 6, for example, using a carbon fiber or the like, the axis of a mandrel A pair of yarns Y, Y (4, 4) with a set angle of ± θ ° (where the set angle θ is 0 ° <θ ° <90 °) and a center yarn y (0 ° with respect to the axis) According to 5), each is set in a braider device, and a tubular FRP tissue body is formed around the mandrel by braiding.

First, a configuration example of a braider will be described with reference to FIG. 5 and 6, the braider BR is composed of a braider body Bb and a mandrel device Bm.

The braider body Bb in the braider BR has a curved upper plate U with a radius of curvature R disposed in a substantially cylindrical machine base Fb having a horizontal axis and an opening e on one side, and a circumferential direction of the upper plate U. It has a bobbin carrier C that travels along the perforated track, a driving device D that causes the bobbin carrier C to travel along the track, and a yarn guide device G.

Then, the yarn Y drawn out in the axial direction of the bobbin from the bobbin placed on the bobbin carrier C is gathered at substantially the center of the upper plate U, and the position of the mandrel m attached to the mandrel device Bm is the mandrel m The assembly point P of the assembly formed above is positioned at the center of the upper plate U. The mandrel device Bm can control the position of the mandrel m in one, two, or three dimensions.

Thus, the bobbin carrier C is caused to travel along the track by the driving device D, and the position of the mandrel m is controlled by the mandrel device Bm. As a result, a large number of yarns Y are interlaced, and if necessary, By interlacing the yarn y for medium thread from the bobbin carrier C arranged almost horizontally on the frame Fb ′ of the machine base Fb with the yarn Y that is unwound from the bobbin carrier C running along the track and assembled. Braiding is performed to assemble a braid layer on mandrels m of various shapes. According to the present invention, a plurality of the assembly layers can be formed in a laminated form.

Next, the composition structure of the FRP composition which is the basis of the FRP honeycomb structure according to the present invention will be described in detail based on the basic configuration example shown in FIG. A laminated structure 1 of the FRP composition shown in FIG. 1 shows a typical example in which a cylindrical (pipe-like) composition is composed of, for example, an inner braid layer 2 and an outer braid layer 3. Thus, the assembly layer may be a single layer or may be structured and structured in a multilayered manner.

In the example shown in FIG. 1, the inner braid layer 2 is composed of braids 4 and 4 whose braid angle with respect to the axis is ± θ °, and a central yarn 5 whose angle with respect to the axis is 0 °, A composition layer having a layer structure with a high elastic modulus in the axial direction is formed. On the other hand, the outer braid layer 3 is composed of only the braids 6 and 6 whose braiding angle with respect to the axis is ± θ °, and does not have a central yarn whose angle with respect to the axis is 0 °. A composition layer having a layer structure having a low elastic modulus in the direction and a large strain at break is formed.

Next, the basic configuration of the FRP honeycomb structure and the method for manufacturing the FRP honeycomb structure according to the present invention will be described in detail based on one specific embodiment shown in FIGS. The manufacturing method of the FRP honeycomb structure according to the present invention basically includes a core in which an FRP assembly layer is formed around a core member having a polygonal cross section, and a core unit CU is formed by impregnating and curing a resin material. The unit forming step includes a honeycomb structure forming step in which the outer side surfaces 11 of the core unit CU are gathered in abutting manner and impregnated and cured with a resin material to form the honeycomb structure HA.

First, in this invention, the core unit CU shown in FIG. 3A is manufactured and prepared in accordance with the core unit molding procedure shown in FIG. 5A. In this invention, the core unit CU can be formed by (1) a composition method using a braider device, (2) a fiber unidirectional material (UD sheet) or a cloth material wrapping method, and (3) a fiber unidirectional material (UD). Sheet) or a method of pasting and joining a band formed of a cloth material in a band shape.

(1) In the composition method using a braider device, a mandrel m having a hexagonal cross section is prepared, the mandrel m is set on the braider device, and a braid having an assembly angle of ± θ ° around the mandrel m; A braided layer is composed by selectively combining with a central thread of 0 °, and the resin is impregnated and cured to form the FRP core unit CU.

(2) In the method of winding a fiber unidirectional material or cloth material, for example, a braiding sheet prepared by cutting a cylindrical braiding material composed by a braider device along one generatrix into a sheet shape is prepared. The braiding sheet is wound around a core member having a hexagonal cross section, and resin is impregnated and cured to form an FRP core unit CU.

(3) In the method of pasting and joining the strip formed of a unidirectional fiber material or cloth material, for example, a cylindrical braiding material composed by a braider device is cut along a generatrix to form a sheet. Then, a braided strip having a strip shape is prepared by slitting the braiding sheet into a desired width dimension, and this braided strip is axially attached to each outer side surface of the hexagonal cross-section core member. Then, the FRP core unit CU is molded by impregnating and curing the resin.

The core unit CU is composition molded and prepared by any of these methods. This core unit CU has a plurality of types of cores having different mechanical characteristics and physical characteristics depending on the type of braiding yarn, the amount of yarn, the thickness of the yarn, the structure of the braided layer, the type of resin and the amount of resin, etc. A unit CU can be prepared.

In the present invention, the FRP core unit CU molded as described above is assembled such that the outer surfaces 11 thereof are butted together, and the resin material is impregnated and cured to form the honeycomb structure HA. In this case, if each of the FRP core units CU includes different components, the honeycomb structure HA can have a hybrid structure in the cross-sectional plane.

Furthermore, in the present invention, as shown in FIG. 3B, a honeycomb structure HA is formed by a set of n (19 in the embodiment schematically shown in FIG. 3B) FRP core units CU, and the honeycomb structure N bodies HA (three in the embodiment schematically shown in FIG. 4) are prepared, and the honeycomb structures are bonded to each other at their outer side surfaces 12 and impregnated and cured with a resin material. Thus, the honeycomb composite body HB can be formed. In the honeycomb composite body HB formed in this way, the hybrid structure in the cross-sectional plane can be further enhanced.

In the present invention, n FRP core units CU are assembled and resin-treated to form an FRP honeycomb structure HA, and N FRP honeycomb structures HA are assembled and resin-treated to form an FRP honeycomb composite. When HB is formed, the honeycomb structure can be surely formed by heating and pressurizing and sucking with the core member set in each core unit CU.

In this invention, after forming into the honeycomb structure HA or the honeycomb composite body HB as described above, the honeycomb structure HA or the honeycomb composite body HB is finished through the core member extracting step of extracting the core member.

The FRP honeycomb structure HA according to the present invention can provide a honeycomb structure having a large height dimension T by removing the design restrictions on the height dimension T of the honeycomb structure HA, The FRP core unit CU is composed of assembled objects including different constituent elements, and can provide a high hybrid structure in the cross-sectional plane of the FRP honeycomb structure.

The FRP honeycomb structure HA or the FRP honeycomb composite body HB having such a structure is a three-dimensional structure of a precision surface plate, a robot hand, a floor material such as an airplane, a body material such as an automobile, and further, the FRP honeycomb structure HA. A three-dimensional structure such as a golf club head can be formed by processing.

FIG. 1 is a schematic perspective view for explaining a basic configuration of a braiding composition base material by braiding treatment. FIG. 2 is a schematic perspective view showing the basic configuration of the FRP honeycomb structure HA according to the present invention. FIG. 3 is a view for explaining the manufacturing process of the FRP honeycomb structure HA according to the present invention. FIG. 3A is a schematic perspective view showing an example of the core unit CU, and FIG. FIG. 3 is a schematic perspective view of a honeycomb structure formed by collectively forming core units. FIG. 4 is a schematic perspective view of a honeycomb composite body formed by collectively forming N honeycomb structures. FIG. 5 is a flowchart showing a procedure for forming the core unit and a procedure for forming the honeycomb structure by assembling the core units in the order of steps. FIG. 6 is a schematic front view showing an example of the basic configuration of the braider device. FIG. 7 is a schematic sectional side view of the braider device shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Laminated structure of FRP composition 2 Inner braid layer 3 Outer braid layer 4, 4 Braid with an angle of ± θ ° with respect to the axis 5 Center yarns 6 with an angle with respect to the axis 6 and 6 Outer set Material layer braid CU FRP core unit HA FRP honeycomb structure HB FRP honeycomb composite 11 Each outer surface 12 of FRP core unit Each outer surface of FRP honeycomb structure BR Braider Bb Braider body Y Braid y Central yarn m Mandrel

Claims (10)

An FRP honeycomb structure comprising a plurality of FRP core units having the same cross-sectional shape, each outer surface of each FRP core unit being assembled in a butting manner and cured by a resin material. Each of the FRP core units includes a different component, and the outer surfaces of the FRP core units are gathered together in abutting manner and cured with a resin material, so that the hybrid in the transverse plane is obtained. The FRP honeycomb structure according to claim 1, wherein the FRP honeycomb structure has a structure. The FRP honeycomb structure according to claim 1 or 2, wherein a cross-sectional shape of each FRP core unit is a polygonal shape such as a triangle, a quadrangle, a hexagon, or an octagon. A core unit forming step of forming an FRP assembly layer around a core member having a polygonal cross section, impregnating and curing a resin material to form a core unit, and collecting each outer surface of the core unit in a butted manner And a honeycomb structure forming step of forming a honeycomb structure by impregnating and curing a resin material. The method for manufacturing an FRP honeycomb structure according to claim 4, wherein the cross-sectional shape of the core member is triangular, quadrangular, hexagonal or octagonal. In the core unit molding step, a braid device is used to selectively combine a braid having a braid angle of ± θ ° and a central yarn having 0 °, and a braid device forms a braid layer on a mandrel that is a core member of the composition. 6. The method for manufacturing an FRP honeycomb structure according to claim 4, wherein the FRP honeycomb structure is formed. 5. The core unit molding step comprises a sheet-shaped fiber unidirectional material (UD sheet) or cloth material wound around a core member and impregnated and cured to form a resin material. Or the manufacturing method of the FRP honeycomb structure of Claim 5. In the core unit forming step, a sheet-like fiber unidirectional material (UD sheet) or cloth material is slit into a desired width to form a belt-like body, and the belt-like body is overlapped on each outer surface of the core member. 6. The method for manufacturing an FRP honeycomb structure according to claim 4, wherein the resin material is formed by impregnating and curing a resin material. Plural types of different core units such as braiding yarn type, yarn amount, yarn thickness, braided layer structure, resin type and resin amount are prepared in advance, and these are assembled into a resin material The method for manufacturing an FRP honeycomb structure according to any one of claims 4 to 8, wherein the honeycomb structure is formed by treatment. 5. The honeycomb structure forming step includes a step of forming a honeycomb composite body by bonding honeycomb structures formed by an assembly of core units to each other in a side-by-side manner. A method for manufacturing an FRP honeycomb structure according to any one of claims 9 to 9.

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