JP2007301888A - Lightweight composite board material, method for manufacturing the same, and speaker using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a light weight and high rigidity board material taking the place of a conventional honeycomb structure material. <P>SOLUTION: The light weight composite board material 10 comprises a plurality of tube materials 11 having hollow insides and a pair of surface materials 12 provided so as to close each of the hollow parts of a plurality of the tubes at both ends of these tube materials. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a lightweight composite plate, a manufacturing method thereof, and a speaker using the same.

  Conventionally, honeycomb structural materials have been applied to plane speakers and the like in addition to moving devices such as airplanes and bullet trains, taking advantage of their light weight and high rigidity.

  Currently, such a honeycomb structure material is manufactured through complicated and many processes. Typically, first, a thermosetting epoxy adhesive was applied linearly in the longitudinal direction at regular intervals on the front and back of the aramid nonwoven fabric and paper constituting the honeycomb partition walls, and this adhesive was applied. The aramid nonwoven fabric and the paper are shifted so that a honeycomb structure can be formed, and after overlapping, the adhesive is cured by heating. Next, the lowermost aramid non-woven fabric or paper is fixed, and the uppermost aramid non-woven fabric or paper is pulled up uniformly to form a hexagonal lying honeycomb structure.

  Next, the intermediate member constituting the honeycomb structure is impregnated with a phenol resin and further heated and cured to obtain a honeycomb structure. Next, slice cutting is performed on the honeycomb structure to obtain a planar honeycomb material. Next, a thin glass epoxy laminate or glass phenol laminate is attached to both ends of the honeycomb material with an epoxy resin or the like to obtain the desired honeycomb structure material.

  However, the conventional honeycomb structure material as described above has a complicated manufacturing process and is expensive, and the rigidity and the like may not be sufficient.

  In view of the above-described problems, an object of the present invention is to provide a novel lightweight, high-rigidity plate material that replaces a conventional honeycomb structure material.

In order to achieve the above object, the present invention provides:
A plurality of tube materials that are hollow inside;
At both ends of the plurality of tube materials, a pair of surface materials provided so as to seal the hollow portions of the plurality of tube materials,
It is related with the lightweight composite board | plate material characterized by comprising.

  The lightweight composite plate material of the present invention is composed of a plurality of tube materials constituting the central portion and a pair of surface materials each provided at both ends so as to seal the hollow portion of these tube materials. It exhibits an extremely simple configuration. Therefore, as described in detail below, the method for manufacturing the lightweight composite plate material can be greatly simplified, and the manufacturing cost can be greatly reduced.

  Further, by appropriately controlling the number and arrangement density of the tube materials and further the material components thereof, and by appropriately controlling the material components and thicknesses of the surface material, the inside of the tube material Due to the fact that it is hollow, its mechanical properties, in particular its rigidity, etc. can be controlled arbitrarily while ensuring lightness. As a result, a lightweight and highly rigid plate material can be easily provided.

  As described above, according to the present invention, it is possible to simply provide a new, lightweight and highly rigid plate material that replaces the conventional honeycomb structure material.

  Hereinafter, other features and advantages of the present invention will be described in detail based on the best mode for carrying out the invention.

(Tube material)
The lightweight composite plate material of the present invention includes a plurality of tube materials having a hollow inside. This tube material exists so that both end portions are sandwiched between surface materials, and constitutes the central portion of the lightweight composite plate material. Moreover, since the inside of the said tube material is a cavity, the lightweight property of the said lightweight composite board | plate material is ensured.

  As described above, since the tube material constitutes the central portion of the lightweight composite plate material, the number of arrangement, the arrangement density, the material component, and the like impart desired characteristics, particularly high rigidity, to the lightweight composite plate material. Select and control as appropriate.

  For example, by constructing the tube material from an impregnated member configured to include a sleeve made of fiber woven fabric or fiber non-woven fabric and a resin composition impregnated in the sleeve, the lightweight composite plate material High rigidity can be easily provided. Under the present circumstances, by comprising the said resin composition especially from a phenol resin, while being able to provide high rigidity easily with respect to the said tube material, ie, the said lightweight composite board | plate material, a flame retardance can be provided. .

  As the fiber woven fabric, glass cloth can be used in addition to highly crystalline organic fibers such as nylon, aramid, carbon, and polyester. In particular, when the organic fiber is used, the lightness of the tube material, that is, the lightweight composite plate material can be more reliably ensured, and the rigidity can be improved.

  In addition, as said fiber nonwoven fabric, a general purpose thing, for example, a nonwoven fabric based on carbon, aramid, nylon, and a phenol woven paper, can be used.

(Surface material)
The lightweight composite board | plate material of this invention comprises a pair of surface material in the both ends of the said tube material which comprises a center part. The pair of surface materials are arranged so as to seal the internal cavity of the tube material in order to constitute the lightweight composite plate material.

  The material component, thickness, and the like of the surface material are appropriately selected and controlled so that desired characteristics, particularly high rigidity, can be imparted to the lightweight composite plate material. For example, by forming the surface material from an impregnated member including a board made of fiber woven fabric or fiber non-woven fabric and a resin composition impregnated in the board, the surface material is made higher than the lightweight composite plate material. Rigidity can be easily provided. Under the present circumstances, by comprising especially the said resin composition from a phenol resin, while being able to easily provide high rigidity with respect to the said surface material, ie, the said lightweight composite board | plate material, a flame retardance can be provided. .

  Moreover, the same thing as the said tube material can be used for a fiber woven fabric and a fiber nonwoven fabric.

(Lightweight composite board)
As described above, the lightweight composite plate material of the present invention includes the plurality of tube materials and a surface material provided so as to seal the internal cavity of the tube material at both ends thereof. The lightweight composite plate material can be in any form depending on the application by appropriately controlling the arrangement configuration and arrangement density of the tube material, and further the form of the surface material.

  FIG. 1 is a block diagram showing an example of a lightweight composite plate material of the present invention. FIG. 1A is a side sectional view of a lightweight composite plate, and FIG. 1B is a surface view of the lightweight composite plate. In this surface view, the surface material is omitted in order to clearly show the arrangement configuration of the tube material.

  In the lightweight composite plate material 10 shown in FIG. 1, a plurality of tube materials 11 are densely arranged in a honeycomb shape so as to contact each other, and a pair of surface materials 12 that are substantially parallel to each other are provided at both ends thereof. The plate member 10 is configured to have a flat plate shape. As shown in FIG. 1, the rigidity of the lightweight composite board | plate material 10 can be improved more by arrange | positioning so that the tube material 11 may contact mutually closely. In addition, the rigidity of the lightweight composite board | plate material 10 can be naturally reduced by reducing the arrangement density of the tube material 11. FIG.

  In addition, the cavity 13 formed in the tube material 11 ensures the lightness of the tube material 11, that is, the lightweight composite plate material 10.

  FIG. 2 is a block diagram showing another example of the lightweight composite plate material of the present invention. FIG. 2A is a side sectional view of the lightweight composite plate, and FIG. 2B is a surface view of the lightweight composite plate. In this surface view, the surface material is omitted in order to clearly show the arrangement configuration of the tube material.

  In the lightweight composite plate material 20 shown in FIG. 2, a plurality of tube materials 21 are densely arranged in a honeycomb shape inside a surface material 22 made of curved members substantially parallel to each other. Is configured to exhibit a curved variant. Also in this case, as shown in FIG. 2, the rigidity of the lightweight composite board | plate material 20 can be improved more by arrange | positioning so that the tube material 21 may mutually contact closely. In addition, the rigidity of the lightweight composite board | plate material 20 can be reduced naturally by reducing the arrangement density of the tube material 21. FIG.

  Further, the surface shape of the surface material 22 is substantially elliptical. Therefore, the lightweight composite board | plate material 20 shown in FIG. 2 can be used for uses, such as a radome. In addition, it can replace with substantially ellipse shape and can also be made into circular shape suitably.

  FIG. 3 is an enlarged view of the arrangement configuration of the tube materials 11 and 21 of the lightweight composite plate materials 10 and 20 shown in FIGS. 1 and 2. In the example shown in FIG. 3 (a), the cross-sectional shape of the tube material is circular, whereas in the example shown in FIG. 3 (b), the cross-sectional shape of the tube material is hexagonal due to the inherent force of the foaming agent. It has a shape. In general, when the tube materials are densely arranged, the tube material has a hexagonal shape as shown in FIG. 3B due to the manufacturing method shown below, and the arrangement density of the tube materials is reduced. As a result, the tube material becomes circular as shown in FIG.

(Lightweight composite plate manufacturing method)
Although the manufacturing method of the lightweight composite board | plate material of this invention is not specifically limited, Preferably it manufactures with the method as shown below.

  First, a plurality of prepreg tubes for the plurality of tube materials described above are prepared. This prepreg tube can be comprised from the impregnation member comprised, for example including the sleeve which consists of the fiber woven fabric or fiber nonwoven fabric mentioned above, and the resin composition impregnated in this sleeve. In addition, about the magnitude | sizes, such as the length of the said prepreg tube, it sets beforehand so that the said target tube material may be obtained.

  Next, a gas generating agent is adhered to the inner wall portion of the prepreg tube. The gas generating agent generates a predetermined gas in the heating process described below, forms a cavity in the prepreg tube, and forms a target tube material. Examples of the gas generating agent include sodium bicarbonate.

  Next, a pair of prepreg boards for the pair of surface materials is provided so as to be in close contact with both ends of the plurality of prepreg tubes. This prepreg board can also be comprised from the impregnation member made to contain the board which consists of a fiber woven fabric or fiber nonwoven fabric mentioned above, for example, and the resin composition impregnated in this board.

  At this time, the prepreg board may be a single layer, or a plurality of the prepreg boards may be laminated. For example, a three-layer prepreg board can be prepared and used by laminating them.

  Next, the prepreg tube and the pair of prepreg boards are heated under pressure to adhere to each other. At this time, as described above, the prepreg tube is cured and tensioned by the gas generated from the gas generating agent, and the both ends of the tube material are sandwiched between the surface materials in association with the curing process by the heating. The lightweight composite board | plate material of this invention can be obtained.

  In the lightweight composite plate material, when the tube materials are arranged in a honeycomb shape, for example, the corresponding prepreg tubes need to be arranged in the same form. Such an arrangement is carried out by preparing a predetermined mold and arranging the mold so as to fill the prepreg tube. As the mold, a wooden mold or a mold can be used.

  Moreover, when manufacturing the lightweight composite member of a structure as shown in FIG. 1, a square thing is used as said type | mold. Moreover, when manufacturing the lightweight composite member of a structure as shown in FIG. 2, a ring-shaped formwork is used. In the mold, a wax such as carnauba wax can be appropriately applied for release.

  In addition, in the said heating operation, when the said adhesion | attachment is not enough, the adhesion degree can be adjusted suitably using an adhesive agent.

  Furthermore, when manufacturing an odd-shaped lightweight composite plate material having a curved shape as shown in FIG. 2, in addition to the mold 31 as a base, it is fitted into the curved shape of the lightweight composite plate material to be formed as shown in FIG. Combined curved additional molds 32 and 33 are used in combination.

  FIG. 5 is a block diagram showing an example of an apparatus for continuously producing the lightweight composite plate material of the present invention. A lightweight composite member manufacturing apparatus 40 shown in FIG. 5 includes a hopper 41 for holding and supplying the prepreg tubes 11A and 22A, and rollers 42 and 43 for supplying a prepreg board as appropriate. The roller 42 supplies a prepreg board for sealing the cavity of the tube material from below, and the roller 43 supplies a prepreg board for sealing the cavity of the tube material from above.

  The device 40 includes a belt 44 for conveying the prepreg tube and the prepreg board, and is configured to be conveyed and driven by a support roll 45 and a guide roll 46. Further, the device 40 includes a heating / pressing press 47 at the front end of the belt 44 in the conveying direction.

  In the apparatus 40 shown in FIG. 5, the prepreg tubes 11 </ b> A and 22 </ b> A are continuously supplied from a hopper 44 into a mold (not shown), and are conveyed toward the heating / pressing press 47 by the belt 44 together with the mold. On the other hand, the prepreg board is appropriately conveyed from the rollers 42 and 43, and the prepreg boards are positioned on the upper and lower surfaces of the prepreg tubes 11A and 22A accommodated in the mold. Subsequently, the laminated body thus obtained is conveyed by a belt 44 and heated under pressure by a heating / pressing press 47 to obtain the above-described lightweight composite plate materials 10 and 20 as described above.

  If such an apparatus 40 is used, the target lightweight composite board | plate material can be manufactured continuously and efficiently.

(speaker)
Next, a speaker will be described as a specific application example using the lightweight composite plate material of the present invention. When the lightweight composite plate material is used in a speaker, the lightweight composite plate material is used as a diaphragm.

  FIG. 6 is a configuration diagram when the lightweight composite plate material of the present invention is applied to a speaker. As shown in FIG. 6, by providing the sound generating exciter 50 on the lightweight composite plate material 10, the lightweight composite plate material 10 functions as a vibration plate to constitute a speaker. According to the configuration shown in FIG. 6, a highly rigid and lightweight speaker can be provided at low cost.

  The present invention has been described in detail based on the above specific examples. However, the present invention is not limited to the above specific examples, and various modifications and changes can be made without departing from the scope of the present invention.

  The lightweight composite plate material of the present invention can be used in various fields such as architecture, furniture, various housings, game boards, aircrafts, ships, vehicles, automobiles, etc. in addition to the above-described speaker.

It is a block diagram which shows an example of the lightweight composite board | plate material of this invention. It is a block diagram which shows the other example of the lightweight composite board | plate material of this invention. It is the figure which expanded and showed the arrangement configuration of the tube material of the lightweight composite board | plate material shown in FIG.1 and FIG.2. It is a figure which shows an example of the type | mold used when manufacturing the lightweight composite board | plate material shown in FIG. It is a block diagram which shows an example of the apparatus which manufactures the lightweight composite board | plate material of this invention continuously. It is a block diagram at the time of applying the lightweight composite board | plate material of this invention with respect to a speaker.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10, 20 Light weight composite board | plate material 11,21 Tube material 12,22 Surface material 13,23 Cavity 31-33 type | mold 40 Light weight composite member manufacturing apparatus 41 Hopper 42,43 Roller 44 for supplying a prepreg board 44 Belt 45 Support roll 46 Guide roll 47 Heating and pressing machine 50 Sound generator

Claims (14)

A plurality of tube materials that are hollow inside;
At both ends of the plurality of tube materials, a pair of surface materials provided so as to seal the hollow portions of the plurality of tube materials,
A lightweight composite board characterized by comprising:   The lightweight composite plate material according to claim 1, wherein the tube material includes a sleeve made of a fiber woven fabric or a fiber nonwoven fabric, and a resin composition impregnated in the sleeve.   The lightweight composite board according to claim 1 or 2, wherein the surface material includes a board made of a fiber woven fabric or a fiber nonwoven fabric and a resin composition impregnated in the board.   The lightweight composite board according to claim 2, wherein the resin composition is made of a phenol resin, and the lightweight composite board exhibits flame retardancy.   The lightweight composite plate material according to any one of claims 1 to 4, wherein the fiber woven fabric is a highly crystalline organic fiber.   The lightweight composite plate material according to any one of claims 1 to 5, wherein the plurality of tube materials are arranged in a honeycomb shape.   The lightweight composite plate material according to any one of claims 1 to 6, wherein the pair of surface materials are flat plate members substantially parallel to each other, and the lightweight composite plate material is a flat plate material.   The pair of surface materials are curved members that are substantially parallel to each other, and the lightweight composite member is a plate material that exhibits a curved shape. 7. The lightweight material according to any one of claims 1 to 6, Composite board material.   The lightweight composite plate material according to claim 8, wherein the pair of surface materials have a substantially elliptical shape or a substantially circular shape. It is a manufacturing method of the lightweight compound board material as described in any one of Claims 1-9,
Preparing a plurality of prepreg tubes for the plurality of tube materials;
Attaching a gas generating agent to the inner walls of the plurality of prepreg tubes;
Providing a pair of prepreg boards for the pair of surface materials so as to be in close contact with both ends of the plurality of prepreg tubes;
Heating and bonding the prepreg tube and the pair of prepreg boards together under pressure, and curing and tensioning the prepreg tube with a gas generated from the gas generating agent;
A method for producing a lightweight composite plate material, comprising:   The plurality of prepreg tubes are continuously supplied in a predetermined arrangement, and the pair of prepreg boards are respectively supplied to both ends of the plurality of prepreg tubes to continuously manufacture the lightweight composite plate material. The method for producing a lightweight composite plate material according to claim 10, characterized in that it is configured as described above.   The lightweight composite plate material according to claim 11, wherein the plurality of prepreg tubes and the pair of prepreg boards are continuously supplied to a press by rollers, and are pressure-formed while being heated by the press. Production method.   A speaker comprising the light-weight composite plate material according to claim 1 as a diaphragm.   The speaker according to claim 13, further comprising a sound generating exciter on at least one of the pair of surface members of the lightweight composite plate member.

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