JP2008068487A - Method for manufacturing honeycomb made of fiber-reinforced resin, honeycomb manufactured by this method, honeycomb sandwich structural body made of fiber-reinforced resin, and column material, beam material or wall material for structure or decoration - Google Patents
Method for manufacturing honeycomb made of fiber-reinforced resin, honeycomb manufactured by this method, honeycomb sandwich structural body made of fiber-reinforced resin, and column material, beam material or wall material for structure or decoration Download PDFInfo
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Abstract
Description
本発明は、繊維強化樹脂製ハニカムの製造方法とこの方法で製造されたハニカム、並びに繊維強化樹脂製ハニカムサンドイッチ構造体及びこれを用いた構造用又は装飾用の柱材、梁材又は壁材に関する。 TECHNICAL FIELD The present invention relates to a method for manufacturing a fiber reinforced resin honeycomb, a honeycomb manufactured by the method, a fiber reinforced resin honeycomb sandwich structure, and a structural or decorative column material, beam material or wall material using the same. .
ハニカムサンドイッチパネルは、軽量で高強度、高剛性であるため、航空機の補助構造材料、船舶の補助構造材料、建築部材の装飾材料などに利用されている。
このハニカムサンドイッチパネルは、６角形ハニカムの板状の心材（ハニカムコア）の上下両面に外皮材を接着させてあるパネル状の構造体で、外皮材には繊維強化樹脂（ＦＲＰ）が用いられることが多い。
Honeycomb sandwich panels are lightweight, high-strength, and high-rigidity, and are therefore used as auxiliary structural materials for aircraft, auxiliary structural materials for ships, decorative materials for building members, and the like.
This honeycomb sandwich panel is a panel-like structure in which a skin material is bonded to the upper and lower surfaces of a hexagonal honeycomb plate-like core material (honeycomb core), and fiber reinforced resin (FRP) is used for the skin material. There are many.
現在使用されているハニカムサンドイッチパネルは、通常は板材であってその用途も補助構造材料に限られ、柱材や梁材といった長くて厚い主要構造材料に使用されることはなかった。
その理由の第一は、心材であるハニカムコアの製造技術上の制約により、(１)ハニカム構成材料として強度の大きいものを用いるのが難しいこと、(２)ハニカムの長さ（パネルの厚み）の大きいものを製造するのが難しいことがあげられる。
Currently used honeycomb sandwich panels are usually plates and their use is limited to auxiliary structural materials, and they have not been used for long and thick main structural materials such as columns and beams.
The first reason is that (1) it is difficult to use a high-strength material as the honeycomb constituent material due to restrictions on the manufacturing technology of the honeycomb core as the core material, and (2) the length of the honeycomb (panel thickness) It is difficult to manufacture a large product.
まず、強度の大きいハニカム構成材料によりハニカムを製造するのが難しい理由は、以下の通りである。図１０は、従来のハニカムの製造方法の説明図である。従来のハニカムの製造方法では、ハニカム構成材料として厚紙、アルミ箔（又はアルミ薄板）を用い、折り目を付けた薄板を、図に示すように重ね合せて接着し、上下の端面を引き離し中空部を拡大させて、６角形のハニカム形状にする。 First, the reason why it is difficult to manufacture a honeycomb with a high-strength honeycomb constituent material is as follows. FIG. 10 is an explanatory diagram of a conventional honeycomb manufacturing method. In a conventional method for manufacturing a honeycomb, thick paper and aluminum foil (or aluminum thin plate) are used as a honeycomb constituting material, and creased thin plates are overlapped and bonded as shown in the figure, and the upper and lower end surfaces are separated to form hollow portions. Expand to a hexagonal honeycomb shape.
その際に、構成材料の強度が大きすぎると、薄板が折り目のところからうまく曲がらず（塑性変形せず）、上下の薄板を接着している部分が剥がれたり、上下の端面を引伸し装置に固定している部分が破損したりする危険性が高い。そのために使用するハニカム構成材料の強度に制約がある。 At that time, if the strength of the component material is too high, the thin plate will not bend well from the crease (no plastic deformation), the upper and lower thin plates will be peeled off, or the upper and lower end surfaces will be stretched and fixed to the device. There is a high risk of damage to damaged parts. Therefore, there is a limitation on the strength of the honeycomb constituent material used.
同様に、ハニカムの長さ（図のＬ）が長すぎると、薄板を折り曲げるのに必要な力が過大になり、上下の薄板を接着している部分が剥がれたり、上下の端面を引伸し装置に固定している部分が破損したりする危険性が高い。そのために製造できるハニカムの長さＬにも制約が生じ、長いハニカム（板厚大なハニカムコア）の製造が難しいという問題があった。 Similarly, if the length of the honeycomb (L in the figure) is too long, the force required to bend the thin plate becomes excessive, the part where the upper and lower thin plates are bonded is peeled off, and the upper and lower end surfaces are stretched to the device. There is a high risk of damage to fixed parts. Therefore, the length L of the honeycomb that can be manufactured is also limited, and there is a problem that it is difficult to manufacture a long honeycomb (a honeycomb core having a large plate thickness).
また、ハニカムサンドイッチ構造体が、柱材や梁材として用いられない理由の第二は、その強度に異方性が有ることによる。すなわち、図１１に示すように、ハニカムコアに掛かる力をＸ方向（ハニカム壁面と垂直で、上下端面と平行な方向）の引張力ＦＸ、Ｙ方向（ハニカム壁面と平行な方向又は壁面長手方向）の圧縮力ＦＹ、Ｚ方向（ハニカム壁面と垂直で、上下端面とも垂直な方向）の引張力ＦＺに分けて考えると、ハニカムコアはＦＹには非常に強いが、ＦＸやＦＺに著しく弱いという問題がある。 The second reason why the honeycomb sandwich structure is not used as a pillar material or a beam material is that the strength is anisotropic. That is, as shown in FIG. 11, the tensile force F X in the X direction (the direction perpendicular to the honeycomb wall surface and parallel to the upper and lower end surfaces) and the Y direction (the direction parallel to the honeycomb wall surface or the longitudinal direction of the wall surface) compressive force F Y of), perpendicular to the Z direction (the honeycomb wall surface, considering both the upper and lower ends surfaces divided into tensile force F Z perpendicular direction), the honeycomb core is very strong in the F Y, F X and F There is a problem that Z is extremely weak.
そのため、従来のハニカムサンドイッチパネルは、Ｙ方向が外皮材の面に対して垂直になるように構成されており、パネル面への上下からの圧縮力に充分耐えるようにして使用されていた。しかし、このように強度に異方性のあるハニカムコアを柱材や梁材に用いた場合には、種々の方向から力が掛かり、力の方向によって強度が著しく低下することになるため、構造用材料として不適切である。これが従来ハニカムサンドイッチ構造体がもっぱらパネル材として用いられ、柱材や梁材として用いられていない理由である。 For this reason, the conventional honeycomb sandwich panel is configured so that the Y direction is perpendicular to the surface of the skin material, and is used so as to sufficiently withstand the compressive force from above and below on the panel surface. However, when a honeycomb core having anisotropy in strength is used as a pillar or beam material, force is applied from various directions, and the strength decreases significantly depending on the direction of the force. It is inappropriate as a material for use. This is the reason why the conventional honeycomb sandwich structure is used exclusively as a panel material and not as a column material or a beam material.
また、従来のハニカムサンドイッチパネルは、ハニカムコアと外皮材との接着部の面積が小さいため、両者が剥離し易いという問題がある。すなわち、前述したように、外皮材はハニカムコアの壁面と垂直な方向に配置されているため、両者の接触面は、ハニカムを構成する薄板の６角形の断面のみであって、接着面積が著しく小さい。 In addition, the conventional honeycomb sandwich panel has a problem that since the area of the bonded portion between the honeycomb core and the outer skin material is small, both are easily peeled off. That is, as described above, since the outer skin material is arranged in a direction perpendicular to the wall surface of the honeycomb core, the contact surface between them is only the hexagonal cross section of the thin plate constituting the honeycomb, and the bonding area is remarkably large. small.
そのため、如何にしてこの接着部を強化するかが課題となる。一般に外皮材には、熱硬化性樹脂を含浸させた繊維強化樹脂が用いられるが、外皮材とハニカムコアとを強く圧着した状態で加熱硬化処理を行う必要があり、この処理は高温、高圧下で行われるため、通常はオートクレーブが用いられる。そのために製造設備が高価になリ、とくに大型のハニカムサンドイッチパネルを製造するには、大型のオートクレーブが必要になって設備費がきわめて大きくなるという問題がある。 Therefore, how to reinforce this bonding portion becomes a problem. Generally, a fiber reinforced resin impregnated with a thermosetting resin is used for the outer skin material. However, it is necessary to perform a heat curing process in a state in which the outer skin material and the honeycomb core are strongly pressure-bonded. Usually, an autoclave is used. For this reason, there is a problem that the manufacturing equipment is expensive, and in particular, in order to manufacture a large honeycomb sandwich panel, a large autoclave is required and the equipment cost becomes extremely high.
さらに、従来のハニカムサンドイッチパネルでは、外皮材がハニカムコアの壁面と直角に配置されているため、外皮材の下の大部分はハニカムセルの中空部である。そのため、局部的に集中加重を受けると、外皮材を支えるものがないため、外皮材が破れたり、外皮材とハニカムコアの接着部が破損したりすることが多く、集中加重に弱いという問題もあった。 Furthermore, in the conventional honeycomb sandwich panel, since the outer skin material is arranged at right angles to the wall surface of the honeycomb core, most of the lower portion of the outer skin material is the hollow portion of the honeycomb cell. For this reason, there is nothing to support the outer skin material when subjected to concentrated load locally, so the outer skin material is often torn or the bonded portion between the outer skin material and the honeycomb core is often damaged, and there is a problem that it is weak against concentrated load. there were.
現状では、構造物の柱や梁は、主に鉄骨や鉄筋コンクリートで形成されており、これらの材料はその比重が非常に大きい。構造物の柱材や梁材にハニカムサンドイッチ構造体を用いることができれば、構造物は著しく軽量化され、強度設計等の自由度が大幅に拡大する。したがって、ハニカムサンドイッチ構造体の用途も顕著に拡大することが期待される。 At present, the pillars and beams of the structure are mainly formed of steel frames or reinforced concrete, and these materials have a very high specific gravity. If a honeycomb sandwich structure can be used for the pillars and beams of the structure, the structure is significantly reduced in weight and the degree of freedom in strength design and the like is greatly increased. Therefore, the use of the honeycomb sandwich structure is expected to be significantly expanded.
ハニカムサンドイッチ構造体を構造用の柱材や梁材に用いるためには、まず、ハニカムコアの強度を大幅に高める必要があり、ハニカム構成材料に、従来使用されている厚紙、アルミ箔等薄板などよりも大幅に強度の大きいものを用いる必要がある。軽量で高強度の材料として着目されるのは、炭素繊維、ガラス繊維等の高強度繊維で強化された繊維強化樹脂（ＦＲＰ）である。 In order to use a honeycomb sandwich structure as a structural column or beam, it is first necessary to significantly increase the strength of the honeycomb core. It is necessary to use a material having a strength significantly greater than that. As a lightweight and high-strength material, fiber reinforced resin (FRP) reinforced with high-strength fibers such as carbon fiber and glass fiber is attracting attention.
しかしながら、ＦＲＰのハニカムを製造することは必ずしも容易ではない。ＦＲＰの成形品は、通常は強化繊維のシートに未硬化の樹脂を含浸させたプリプレグを所定の形状に成形した後、樹脂を硬化させて作成される。しかし、プリプレグを積層してハニカム形状に加工しようとすると、プリプレグ相互が接着し易く、形状精度の良いハニカムにすることが難しい。一方、樹脂が硬化したＦＲＰの薄板に、図１０に示したような従来のハニカムの製造方法を適用しても、ＦＲＰの強度が過大で、到底塑性変形させることができない。 However, it is not always easy to manufacture an FRP honeycomb. A molded product of FRP is usually formed by molding a prepreg obtained by impregnating a sheet of reinforcing fibers with an uncured resin into a predetermined shape and then curing the resin. However, if an attempt is made to stack prepregs and process them into a honeycomb shape, the prepregs are easily bonded to each other, and it is difficult to form a honeycomb with good shape accuracy. On the other hand, even if the conventional method for manufacturing a honeycomb as shown in FIG. 10 is applied to an FRP thin plate on which a resin is cured, the strength of the FRP is excessive and plastic deformation cannot be achieved.
そのため、特許文献１には、強化繊維シートを管状に成形し、この管状体を長手方向を揃えて、管状体相互が外周面で接触するように配列し、この配列体を加熱して樹脂を硬化させる「ハニカム構造体の製造方法」が開示されている。
この方法では、正確な６角形ハニカムを作成できず、管状丸棒による擬似ハニカムとなる。そのため、６角形ハニカムより重くなること、セル（管状体）相互の接着面積が小さく、構造体としての強度が小さくなることなどの欠点が予想される。また、プリプレグを管状に加工し、これを束ねてハニカム構造体を製造するという２段工程になるため、作業効率に劣るという問題もある。
Therefore, in Patent Document 1, a reinforcing fiber sheet is formed into a tubular shape, the tubular bodies are aligned in the longitudinal direction, and are arranged so that the tubular bodies are in contact with each other on the outer peripheral surface, and the arrayed body is heated to form a resin. A “honeycomb structure manufacturing method” to be cured is disclosed.
According to this method, an accurate hexagonal honeycomb cannot be produced, and a pseudo honeycomb made of a tubular round bar is obtained. Therefore, defects such as being heavier than a hexagonal honeycomb, a small adhesion area between cells (tubular bodies), and a strength as a structure are expected. In addition, since the prepreg is processed into a tubular shape and bundled together to produce a honeycomb structure, there is a problem that the working efficiency is inferior.
そこで、本発明の第一の課題は、特許文献１のような擬似ハニカムではなく、６角形セルの形状精度が良く、セル相互が強固に接着した繊維強化樹脂製の高強度ハニカムを、プリプレグから直接製造する方法を提供することにある。 Therefore, the first problem of the present invention is not a pseudo honeycomb as in Patent Document 1, but a high-strength honeycomb made of fiber reinforced resin in which hexagonal cells have good shape accuracy and the cells are firmly bonded to each other. It is to provide a method for direct manufacturing.
また、本発明の第二の課題は、このように製造された繊維強化樹脂製ハニカムをコア材とするハニカムサンドイッチ構造体であって、構造用の柱材や梁材等に用いることのできるものを提供することにある。 A second subject of the present invention is a honeycomb sandwich structure having a fiber reinforced resin honeycomb manufactured as described above as a core material, which can be used for structural column materials, beam materials, and the like. Is to provide.
そのためには、前述した従来のハニカムサンドイッチパネルの種々の問題点を克服する必要がある。具体的には、セル壁面長さの大きいハニカムを製造すること、強度の若干の異方性があっても、構造用材料として具備すべき強度や剛性を確保しうること、外皮材とハニカムコアが剥離し難くすること、外皮材表面への局部的集中荷重に耐え得るようにすること等である。本発明は、これらの問題点を解決して、構造用の柱材や梁材に用いることのできる繊維強化樹脂製ハニカムサンドイッチ構造体を提供することを第二の課題としている。 For that purpose, it is necessary to overcome various problems of the conventional honeycomb sandwich panel described above. Specifically, it is possible to produce a honeycomb having a large cell wall length, to ensure the strength and rigidity to be provided as a structural material even if there is a slight anisotropy in strength, and to provide a shell material and a honeycomb core. For example, making it difficult to peel off, and making it able to withstand localized concentrated loads on the surface of the skin material. A second object of the present invention is to solve these problems and provide a honeycomb sandwich structure made of fiber reinforced resin that can be used for structural column materials and beam materials.
上記課題を解決するための本発明の繊維強化樹脂製ハニカムの製造方法の第一は、強化繊維のシートに樹脂を含浸させた変形可能なプリプレグを順次積層する工程と、６角形ハニカム形状に成形した状態で前記プリプレグが上下段で重複する辺（以下「重複辺」という）の幅方向両側端部又はその付近で、固定金具を用いて上下のプリプレグ相互を、この辺の長手方向のほぼ全長に亘って縫い付ける工程と、次いで、内圧により所定径の柱状に膨張する伸縮性及び必要に応じて耐熱性を有する材料からなるハニカム中空セル数と同数の成形チューブを、ハニカム壁の長手方向に平行にそのほぼ全長に亘って延在させ、前記プリプレグの上下段間で千鳥配置なるように、前記プリプレグ各層間に配置する工程と、次いで、前記の成形チューブを配置したプリプレグを成形後のハニカムに相当する大きさの外型枠内に収容して、該成形チューブを気体により内部から加圧し、前記プリプレグを６角形ハニカム壁面の形状に変形させる工程と、この成形チューブの内部圧力と前記外型枠の反力によって、ハニカム壁面相互が強固に圧着される状態で、前記プリプレグの含浸樹脂を硬化・接着させる硬化処理工程と、次いで、前記成形チューブ内の気体圧を減じて、該チューブをハニカムセル中空部から除去する工程とを具備することを特徴とする繊維強化樹脂製ハニカムの製造方法である。 In order to solve the above problems, the first method of manufacturing a fiber reinforced resin honeycomb according to the present invention includes a step of sequentially laminating a deformable prepreg impregnated with a resin to a reinforcing fiber sheet, and forming into a hexagonal honeycomb shape. In the state where the prepreg is overlapped in the upper and lower stages (hereinafter referred to as “overlapping side”), the upper and lower prepregs are made to be almost the entire length in the longitudinal direction of the side by using a fixing bracket at or near both ends in the width direction. Next, the number of molded tubes equal to the number of honeycomb hollow cells made of a material having expandability that expands into a columnar shape with a predetermined diameter by internal pressure and heat resistance as necessary is parallel to the longitudinal direction of the honeycomb wall. Extending between substantially the entire length of the prepreg and arranging the prepreg between the upper and lower stages of the prepreg, A step of accommodating the placed prepreg in an outer mold frame having a size corresponding to a honeycomb after molding, pressurizing the molded tube from the inside with gas, and deforming the prepreg into a hexagonal honeycomb wall surface; and A curing process for curing and adhering the impregnating resin of the prepreg in a state where the honeycomb wall surfaces are firmly pressure-bonded by the internal pressure of the molded tube and the reaction force of the outer mold, and then the gas in the molded tube And a step of removing the tube from the hollow portion of the honeycomb cell by reducing pressure, and a method for producing a fiber-reinforced resin honeycomb.
この第一発明の製造方法においては、前記成形チューブの一端に気体吹込み口を設けて、この吹込み口から吹き込まれた気体圧力により該成形チューブを膨張させて、前記プリプレグを内部から一様に変形させることが好ましい。
これにより、成形チューブで相互に圧着される６角形ハニカム壁面相互の面圧が一定になり、プリプレグを変形させる力が一様になるため、ハニカムのセルサイズにバラツキが生じるのを防止することができる。
In the manufacturing method of the first invention, a gas blowing port is provided at one end of the molded tube, the molded tube is expanded by the gas pressure blown from the blowing port, and the prepreg is uniformly formed from the inside. It is preferable to deform it.
As a result, the surface pressure between the hexagonal honeycomb wall surfaces that are pressure-bonded to each other by the forming tube becomes constant, and the force for deforming the prepreg becomes uniform, thereby preventing variations in the cell size of the honeycomb. it can.
本発明の繊維強化樹脂製ハニカムの製造方法の第二は、強化繊維のシートに樹脂を含浸させた変形可能なプリプレグを順次積層する工程と、前記重複辺の幅方向両側端部又はその付近で、固定金具を用いて上下のプリプレグ相互を、この辺の長手方向のほぼ全長に亘って縫い付ける工程と、次いで、加熱されて発泡する物質がその内部に充填され、該物質の発泡膨脹時の内圧により所定径の柱状に膨張する伸縮性及び耐熱性を有する材料からなるハニカム中空セル数と同数の成形チューブを、ハニカム壁面の長手方向に平行にそのほぼ全長に亘って延在させ、かつ前記プリプレグの上下段間で千鳥配置なるように、前記プリプレグ各層間に配置する工程と、次いで、前記の成形チューブを配置したプリプレグを成形後のハニカムに相当する大きさの外型枠内に収容し、該プリプレグを所定温度に加熱して、前記発泡物質を膨張させ、前記プリプレグをハニカム壁面の形状に変形させるとともに、この成形チューブの内部圧力と前記外型枠の反力によって、ハニカム壁面相互が強固に圧着される状態で、前記プリプレグの含浸樹脂を硬化・接着させる熱処理工程とを具備し、発泡物質が充満した成形チューブをハニカムセルの中空部に内包する高強度ハニカムを製造することを特徴とするものである。 The second method for manufacturing a fiber-reinforced resin honeycomb according to the present invention includes a step of sequentially laminating a deformable prepreg impregnated with a resin in a sheet of reinforcing fibers, and at or near both ends of the overlapping sides in the width direction. , A step of sewing the upper and lower prepregs together with the fixing bracket over almost the entire length in the longitudinal direction of the side, and then filling the inside with a substance to be foamed by heating, and the internal pressure at the time of the foam expansion of the substance The number of formed tubes equal to the number of honeycomb hollow cells made of a stretchable and heat-resistant material that expands into a columnar shape with a predetermined diameter is extended over almost the entire length in parallel with the longitudinal direction of the honeycomb wall surface, and the prepreg A step corresponding to a honeycomb after forming the prepreg in which the forming tube is arranged, and a step of arranging the prepreg between the prepregs so as to be arranged in a staggered manner between the upper and lower stages. The prepreg is heated to a predetermined temperature to expand the foamed material, and the prepreg is deformed into the shape of a honeycomb wall surface. And a heat treatment step for curing and adhering the impregnating resin of the prepreg in a state where the honeycomb wall surfaces are firmly pressure-bonded by the reaction force, and the molded tube filled with the foaming substance is included in the hollow portion of the honeycomb cell. A high-strength honeycomb is manufactured.
この第二発明の製造方法においては、前記成形チューブとして、強化繊維を伸縮性のある細長い袋状に製造したものを用いることが好ましい。ハニカム壁面と同じ材質で製造される成形チューブの外皮は、ハニカム壁面用プリプレグに含浸されているマトリックス樹脂によって内壁面に強固に接着される。必要に応じて細長い袋状成形チューブ表面にハニカム壁面用プリプレグと同じマトリックス樹脂を塗布することもできる。強化繊維チューブが個々のハニカムセル内部に残存することにより、一層強度の大きなハニカムを製造することができる。 In the manufacturing method of the second invention, it is preferable to use a reinforcing fiber manufactured in a stretchable and slender bag shape as the molded tube. The outer shell of the molded tube manufactured from the same material as the honeycomb wall surface is firmly bonded to the inner wall surface by the matrix resin impregnated in the honeycomb wall surface prepreg. If necessary, the same matrix resin as that for the honeycomb wall prepreg can be applied to the surface of the elongated bag-shaped tube. Since the reinforcing fiber tube remains inside each honeycomb cell, a honeycomb having a higher strength can be manufactured.
上記の第一発明及び第二発明の製造方法のいずれにおいても、前記の固定金具として、コの字型のホッチキス針類似の形状のものを用い、前記重複辺の幅方向両側端部又はその付近を長手方向に断続的に縫い付けることが好ましい。
この場合に、前記のホッチキス針類似の固定金具によるプリプレグの縫付けに際して、
該固定金具の先端を所定方向に折り曲げガイドする２列の穴型が設けられた帯板状の折曲げ治具を、縫い付けられるプリプレグの下側に配置するとともに、前記固定金具を上側から前記折曲げ治具の穴型に押し付けて、固定金具の先端を前記穴型に沿って折り曲げる打ち込み装置を用いることが好ましい。その理由は、この縫い付け方法がきわめて簡便かつ確実な方法の一つであるためである。
In any of the manufacturing methods of the first invention and the second invention described above, the fixing metal fitting is similar to a U-shaped staple, and both side ends of the overlapping sides in the width direction or the vicinity thereof. Is preferably sewn intermittently in the longitudinal direction.
In this case, when sewing the prepreg with a fixing bracket similar to the stapler needle,
A band plate-shaped bending jig provided with two rows of hole molds for bending and guiding the front end of the fixing bracket in a predetermined direction is disposed below the prepreg to be sewn, and the fixing bracket is inserted from above. It is preferable to use a driving device that presses against the hole mold of the bending jig and bends the tip of the fixture along the hole mold. The reason is that this sewing method is one of extremely simple and reliable methods.
また、前記の固定金具による上下プリプレグの縫付け完了後、前記折曲げ治具をプリプレグの下から引き抜き、この折曲げ治具が引き抜かれて生じた間隙に、膨張前の前記成形チューブを挿入することが好ましい。
これにより、容易にプリプレグの間に成形チューブを挿入することができる。
Further, after completion of the sewing of the upper and lower prepregs by the fixing bracket, the bending jig is pulled out from under the prepreg, and the molded tube before expansion is inserted into the gap formed by pulling out the bending jig. It is preferable.
Thereby, a shaping | molding tube can be easily inserted between prepregs.
さらに、前記の折曲げ治具及び／又は成形チューブが接触するプリプレグの面に予めプラスチックシートからなる平滑テープを貼り付け、前記折曲げ治具及び／又は成形チューブとプリプレグの未硬化樹脂との接触を防止して、その出入れを容易にすることが好ましい。
未硬化のプリプレグはマトリックス樹脂にベトツキがあり、折曲げ治具や成形チューブに付着して、その出し入れが困難になる。上記の平滑テープを用いることにより、プリプレグと折曲げ治具や成形チューブが直接接触するのを防止することができる。
Further, a smooth tape made of a plastic sheet is attached in advance to the surface of the prepreg with which the bending jig and / or the forming tube come into contact, and the bending jig and / or the forming tube and the uncured resin of the prepreg are brought into contact with each other. It is preferable to prevent this and make it easy to enter and exit.
An uncured prepreg has a sticky matrix resin, and adheres to a bending jig or a molded tube, making it difficult to take in and out. By using the smooth tape, it is possible to prevent the prepreg and the bending jig or the formed tube from coming into direct contact.
また、前記成形チューブの挿入方向先端付近にプルリングを取り付け、該プルリングを挿入方向に牽引することによることにより、前記成形チューブのプリプレグ間隙への挿入を行うことが好ましい。
これにより、剛性のない成形チューブでも容易にプリプレグの間隙に挿入することができる。
Further, it is preferable to insert the molded tube into the prepreg gap by attaching a pull ring near the distal end of the molded tube in the insertion direction and pulling the pull ring in the insertion direction.
Thereby, even a non-rigid shaped tube can be easily inserted into the gap of the prepreg.
本発明は、上記の第一発明の方法で製造された、セル内部が中空の繊維強化樹脂製ハニカム、及び上記の第二発明の方法で製造された、発泡物質が充満した成形チューブがセル内部に内包された繊維強化樹脂製ハニカムを含むものである。 The present invention provides a fiber-reinforced resin honeycomb having a hollow cell produced by the method of the first invention, and a molded tube filled with a foaming material produced by the method of the second invention. Including a fiber reinforced resin honeycomb encapsulated therein.
本発明のハニカムサンドイッチ構造体の第一は、ハニカムコアに外皮材が接着された構造体であって、前記ハニカムコアが繊維強化樹脂からなり、前記外皮材がハニカム壁面と平行に配され、少なくとも前記重複辺と平行な２面に外皮材が配されてなることを特徴とするものである。 A first honeycomb sandwich structure of the present invention is a structure in which a skin material is bonded to a honeycomb core, the honeycomb core is made of a fiber reinforced resin, the skin material is arranged in parallel with the honeycomb wall surface, and at least The outer skin material is arranged on two surfaces parallel to the overlapping side.
また、本発明のハニカムサンドイッチ構造体の第二は、ハニカムコアに外皮材が接着された構造体であって、前記ハニカムコアが繊維強化樹脂からなり、発泡物質が充満した成形チューブがハニカムのセル内部に内包されており、かつ前記外皮材がハニカム壁面と平行に配され、少なくとも前記重複辺と平行な２面に外皮材が配されてなることを特徴とするものである。 The second of the honeycomb sandwich structures of the present invention is a structure in which a skin material is bonded to a honeycomb core, and the honeycomb core is made of a fiber reinforced resin, and a molded tube filled with a foamed material is a honeycomb cell. It is contained inside, and the outer skin material is arranged in parallel to the honeycomb wall surface, and the outer skin material is arranged at least on two surfaces parallel to the overlapping side.
この第一発明及び第二発明の構造体のいずれにおいても、前記外皮材に隣接するハニカム外側の台形凹部が、フィラー材で充満されていることが好ましい。 In any of the structures of the first invention and the second invention, it is preferable that the trapezoidal concave portion outside the honeycomb adjacent to the outer skin material is filled with the filler material.
また、第一発明及び第二発明の構造体においても、ハニカムコアとして上記第一発明又は第二発明の製造方法で製造されたハニカムを用いることが好ましい Also in the structures of the first invention and the second invention, it is preferable to use the honeycomb manufactured by the manufacturing method of the first invention or the second invention as the honeycomb core.
さらに本発明は、上記の第一発明又は第二発明のハニカムサンドイッチ構造体からなる構造用柱材、梁材又は壁材及び装飾用柱材、梁材又は壁材を含むものである。 Furthermore, the present invention includes structural column materials, beam materials or wall materials and decorative column materials, beam materials or wall materials comprising the honeycomb sandwich structure of the first invention or the second invention described above.
本発明により、６角形セルの形状精度が良く、セル相互が強固に接着した繊維強化樹脂製の高強度ハニカムを、プリプレグから直接製造することが可能になった。とくにプリプレグの変形の際に成形チューブ内の気体圧力を利用する。このことから、ハニカム長さが変化しても、ハニカム長さに応じて成形チューブに封入する気体の量を増減することで、成形チューブの内部圧力（プリプレグを変形させる内部からの作用力）はハニカム長さに制限されることなく一定に設定可能である。したがって、ハニカムが長くなっても、変形力不足になることがなく、長尺のハニカムを容易に製造することができる。 According to the present invention, a high-strength honeycomb made of a fiber reinforced resin in which hexagonal cells have good shape accuracy and the cells are firmly bonded to each other can be directly manufactured from the prepreg. In particular, the gas pressure in the forming tube is used when the prepreg is deformed. From this, even if the honeycomb length changes, the internal pressure of the molded tube (the working force from the inside that deforms the prepreg) is increased by increasing or decreasing the amount of gas sealed in the molded tube according to the honeycomb length. It can be set constant without being limited by the honeycomb length. Therefore, even if the honeycomb becomes long, the deformation force is not insufficient, and a long honeycomb can be easily manufactured.
また、本発明により、構造用材料として具備すべき強度や剛性を確保することができ、外皮材とハニカムコアが剥離し難く、かつ外皮材表面への局部的集中荷重に耐えることのできるハニカムサンドイッチ構造体を提供することが可能になった。このハニカムサンドイッチ構造体は、構造用又は装飾用の柱材、梁材又は壁材として用いることができる。 Further, according to the present invention, a honeycomb sandwich that can ensure strength and rigidity to be provided as a structural material, is difficult to peel off from the skin material and the honeycomb core, and can withstand localized concentrated loads on the surface of the skin material. It became possible to provide a structure. The honeycomb sandwich structure can be used as a structural or decorative column, beam, or wall material.
まず、本発明の繊維強化樹脂製ハニカムの製造方法について説明する。本発明の製造方法の第一は、セル内部が中空のハニカムを製造する方法であって、Ａ：プリプレグを積層する工程（積層工程）、Ｂ：所定の位置で上下のプリプレグを縫い付ける工程（縫付け工程）Ｃ：成形チューブを配置する工程（成形チューブ配置工程）、Ｄ：成形チューブを挿入してあるプリプレグを外型枠で挟んで、成形チューブを加圧してプリプレグをハニカム形状に変形させる工程（変形工程）、Ｅ：プリプレグの樹脂を硬化させる工程（硬化処理工程）、Ｆ：成形チューブの圧力を抜いて、セル中空部から取り出す工程（成形チューブ取出工程）とを具備する。 First, the manufacturing method of the fiber reinforced resin honeycomb of this invention is demonstrated. The first of the production methods of the present invention is a method for producing a honeycomb having a hollow cell interior: A: a step of laminating prepregs (lamination step), B: a step of sewing upper and lower prepregs at predetermined positions ( Sewing step) C: Step of placing the molded tube (molded tube placement step), D: Holding the prepreg with the molded tube inserted between the outer mold frames, pressurizing the molded tube to deform the prepreg into a honeycomb shape A step (deformation step), E: a step of curing the resin of the prepreg (curing treatment step), and F: a step of releasing the pressure of the formed tube and taking it out from the cell hollow portion (formed tube removing step).
図１は、この第一製造方法の説明図で、図１(ａ)はＡ積層工程を示す。この図では、プリプレグ１が４枚の場合を示しているが、その枚数は、ハニカムのセル数を勘案して定められる。プリプレグ１は、図に見られるように予め折り目２を付けておくことが好ましい。これにより、上下プリプレグの重ね合せや、Ｂ縫付け工程での位置決めが容易になる。 FIG. 1 is an explanatory view of this first manufacturing method, and FIG. 1 (a) shows the A stacking step. This figure shows a case where there are four prepregs 1, but the number is determined in consideration of the number of honeycomb cells. The prepreg 1 is preferably provided with a crease 2 in advance as seen in the figure. This facilitates positioning of the upper and lower prepregs and positioning in the B sewing process.
図１２は、成形後のハニカムの一部を示す図で、この図を用いて、ハニカム各部の名称について説明する。ハニカム壁３で、Ｌ方向を「長手方向」、Ｗ方向を「幅方向」」とする。また、６角形のハニカム壁３の６辺のうち、上下の辺では、上下２枚のプリプレグが重ね合わされているが、他の４辺は１枚のプリプレグで構成されている。本明細書では、この上下２枚のプリプレグが重複している辺４を「重複辺」と呼ぶ。 FIG. 12 is a view showing a part of the honeycomb after forming, and the names of the respective parts of the honeycomb will be described with reference to this drawing. In the honeycomb wall 3, the L direction is the “longitudinal direction” and the W direction is the “width direction”. Of the six sides of the hexagonal honeycomb wall 3, two upper and lower prepregs are overlapped on the upper and lower sides, and the other four sides are constituted by one prepreg. In the present specification, the side 4 where the two upper and lower prepregs overlap is referred to as an “overlapping side”.
上記Ｂ縫付け工程では、図１(ｂ)に示すように、重複辺４の幅(Ｗ)方向両側端部又はその付近で、固定金具５を用いて上下のプリプレグ相互を、この辺の長手(Ｌ)方向のほぼ全長に亘って縫い付ける。これにより、Ｄ変形工程でプリプレグをハニカム状に変形させたときに、６角形のハニカムセル形状を安定的に製造することができる。 In the B sewing step, as shown in FIG. 1B, the upper and lower prepregs are fixed to each other by using the fixing bracket 5 at or near both ends in the width (W) direction of the overlapping side 4. Sew over almost the entire length in the L) direction. Thus, when the prepreg is deformed into a honeycomb shape in the D deformation step, a hexagonal honeycomb cell shape can be stably manufactured.
次いで、Ｃ成形チューブ配置工程では、図１(ｃ)に示すように、その長さがハニカム壁３の長手方向のほぼ全長に亘る成形チューブ６を、上下の重複辺４で挟まれる位置で、ハニカム壁の長手方向に平行に、プリプレグの各層間に挿入する。その結果、成形チューブ６はプリプレグの上下段間で千鳥配置になるように配置される。
成形チューブ６は、その内部に気体圧を印加したときにある程度以上の径の柱状に膨張することが必要で、伸縮性のある材料もしくは伸縮性をもった構造のものが用いられる。また、加熱硬化処理に耐える程度の耐熱性材料であることが必要で、例えばシリコンゴム、フッ素樹脂又はフッ素樹脂コーティングしたシリコンゴム等を好適に用いることができる。なお、必要な成形チューブの本数は、ハニカムのセル数と同じである。
Next, in the C-formed tube arrangement step, as shown in FIG. 1 (c), the length of the formed tube 6 covering almost the entire length in the longitudinal direction of the honeycomb wall 3 is sandwiched between the upper and lower overlapping sides 4, It is inserted between the layers of the prepreg in parallel with the longitudinal direction of the honeycomb wall. As a result, the molded tubes 6 are arranged in a staggered arrangement between the upper and lower stages of the prepreg.
The molded tube 6 needs to expand into a columnar shape having a diameter of a certain degree or more when a gas pressure is applied to the inside thereof, and a stretchable material or a stretchable structure is used. Further, it is necessary to be a heat-resistant material that can withstand heat curing treatment, and for example, silicon rubber, fluorine resin, or fluorine-coated silicon rubber can be suitably used. Note that the number of formed tubes is the same as the number of cells in the honeycomb.
次いで、Ｄ変形工程では、図１(ｄ)に示すように、成形チューブ６に気体圧を印加して、円柱状に膨らませる。これにより、プリプレグ１は固定金具で縫い付けられた重複辺４の幅方向両側端部を折れ目として、６角形に折れ曲がり、ハニカム形状に成形される。
印加する気体圧力は、通常は０．５〜１．０気圧程度で十分である。また、ハニカム壁の長さ(Ｌ)が大きくなると、プリプレグの変形にようする力もＬに比例して大きくなるが、成形チューブ６の長さもＬに比例するため、変形に必要な気体圧はＬに依存しない。そのため、本発明によれば、Ｌの大きなハニカムを容易に製造することができる。
Next, in the D deformation step, as shown in FIG. 1 (d), a gas pressure is applied to the formed tube 6 to expand it into a columnar shape. As a result, the prepreg 1 is bent into a hexagonal shape with the both ends in the width direction of the overlapped side 4 sewn with the fixing metal as a fold, and is formed into a honeycomb shape.
The applied gas pressure is usually about 0.5 to 1.0 atm. Further, as the length (L) of the honeycomb wall increases, the force for deforming the prepreg also increases in proportion to L. However, since the length of the formed tube 6 is also proportional to L, the gas pressure required for deformation is L Does not depend on. Therefore, according to the present invention, a honeycomb having a large L can be easily manufactured.
なお、この変形工程では、成形チューブ６を配置した積層プリプレグを、成形後のハニカムに相当する大きさの外型枠２２内に収容して、前記成形チューブへの加圧を行い、全てのハニカムセル内に挿入してある成形チューブ６と外型枠２２からの反力で、ハニカムを形成するプリプレグの各壁面を相互に加圧しあうことが好ましい。この外型枠は、次ぎの硬化処理工程までそのまま用い、プリプレグ樹脂が硬化して、ハニカムが成形された後取り外せばよい。なお、外型枠は、上下と側面の４面（成形チューブを出し入れする面を除く）を拘束してもよいが、少なくとも上下２面にあればよい。 In this deformation step, the laminated prepreg in which the formed tube 6 is arranged is accommodated in the outer mold frame 22 having a size corresponding to the formed honeycomb, and pressure is applied to the formed tube so that all the honeycombs are formed. It is preferable to pressurize each wall surface of the prepreg forming the honeycomb with the reaction force from the forming tube 6 and the outer mold 22 inserted in the cell. The outer mold can be used as it is until the next curing process, and can be removed after the prepreg resin is cured and the honeycomb is formed. In addition, although an outer mold | type frame may restrain four surfaces (except the surface which takes in and out a shaping | molding tube) of upper and lower sides, it should just be on at least two upper and lower surfaces.
この状態で、Ｅ硬化処理工程に移行する。プリプレグの樹脂が熱硬化性樹脂である場合は、変形されたプリプレグを加熱することにより、硬化する。プリプレグの樹脂が常温（反応）硬化性樹脂である場合は、硬化剤添加後所定時間で硬化するから、この間放置すれば硬化処理が完了する。プリプレグの樹脂が熱可塑性樹脂である場合は、Ｄ変形工程に先立って、プリプレグ１を加熱して樹脂を軟化させた後、成形チューブに加圧してハニカム形状を形成し、その後常温に戻して放置すれば硬化処理が完了する。 In this state, the process proceeds to the E curing process. When the resin of the prepreg is a thermosetting resin, it is cured by heating the deformed prepreg. When the resin of the prepreg is a room temperature (reaction) curable resin, the resin is cured in a predetermined time after the addition of the curing agent. When the resin of the prepreg is a thermoplastic resin, the prepreg 1 is heated to soften the resin prior to the D deformation step, and then the formed tube is pressed to form a honeycomb shape, and then returned to room temperature and left to stand. Then, the curing process is completed.
次いで、成形チューブの圧力を抜けば、成形チューブは収縮するから、容易にセル中空部から取り出すことができ、これで中空ハニカムの製造が完了する。 Next, when the pressure of the forming tube is released, the forming tube contracts and can be easily taken out from the cell hollow portion, thereby completing the manufacture of the hollow honeycomb.
本発明において、プリプレグ１の繊維や樹脂を特に限定する必要はないが、繊維としては、例えば、炭素繊維、ガラス繊維、スチール繊維、アラミド繊維等の有機繊維、ロックウール、セラミックス繊維などがあげられる。また、マトリックスの樹脂又は接着剤としては、例えば、メラミン樹脂、尿素樹脂、フェノール樹脂、エポキシ系、ポリウレタン系、不飽和ポリエステル、反応型アクリル系、付加型ポリイミド等の熱硬化性樹脂、ニトロゴム、クロロプレンゴム、スチレンブタジエンゴム（ＳＢＲ）、スチレン系ブロック重合体、シリコンゴム等のゴム系のもの、ビニルフェノリック、ニトリルフェノリック、エポキシナイロン等の混合系のものや、低融点ガラス、アルカリ金属シリケート、ホスフェート、コロイダルシリカ等の無機系のものも用いることができる。 In the present invention, the fiber and resin of the prepreg 1 need not be particularly limited. Examples of the fiber include organic fibers such as carbon fiber, glass fiber, steel fiber, and aramid fiber, rock wool, and ceramic fiber. . Examples of the matrix resin or adhesive include thermosetting resins such as melamine resin, urea resin, phenol resin, epoxy-based, polyurethane-based, unsaturated polyester, reactive acrylic, and addition-type polyimide, nitro rubber, and chloroprene. Rubber, styrene butadiene rubber (SBR), styrene block polymer, rubber type such as silicon rubber, mixed type such as vinyl phenolic, nitrile phenolic, epoxy nylon, low melting point glass, alkali metal silicate, phosphate, Inorganic materials such as colloidal silica can also be used.
次に、実施例に基づいて、本発明における上記の縫付け工程の好ましい実施態様について説明する。図２は、本発明の一実施例で用いた固定金具と折曲げ治具の形状を示す図である。この実施例では固定金具５は、図２(ａ)に示すように、コの字形のホッチキス針と類似のものを用いている。この金具によりプリプレグを縫い付ける方法も、ホッチキスで紙を綴じる方法と同様で、コの字形の針の２本の脚部７を内側に折り曲げて、この脚部７と胴部８の間にプリプレグを挟んで固定する。 Next, based on an Example, the preferable embodiment of said sewing process in this invention is demonstrated. FIG. 2 is a diagram showing the shapes of the fixing bracket and the bending jig used in one embodiment of the present invention. In this embodiment, the fixture 5 is similar to a U-shaped staple as shown in FIG. The method of sewing the prepreg with this metal fitting is the same as the method of binding paper with a stapler. The two legs 7 of the U-shaped needle are bent inward, and the prepreg is sandwiched between the legs 7 and the trunk 8. Fix it with a pinch in between.
図２(ｂ)は、この固定金具の針先端の折り曲げに用いる折曲げ治具を示す斜視図である。この治具９は、帯板状の台１０に、固定金具５の脚部７の先端をガイドする穴型１１が、２列に台１０の長手方向の全長に亘って、断続的に設けられているものである。
この例では、穴型１１として細長い穴（長さが固定金具の脚部７の間隔ｄに対応）のものを用いているが、間隔ｄの点から内側に延びる一対の穴が設けられた穴型でもよい。２列の穴型列間の間隔は、ハニカムの重複辺４の幅と同じか、これよりやや短く設定する。同一列の穴型間の間隔はとくに限定を要しないが、ｄの１〜２倍程度にすればよい。
FIG. 2B is a perspective view showing a bending jig used for bending the needle tip of the fixing metal fitting. This jig 9 is provided with a hole plate 11 that guides the tip of the leg 7 of the fixing bracket 5 intermittently over the entire length in the longitudinal direction of the base 10 on the strip-like base 10. It is what.
In this example, a long and narrow hole (the length corresponds to the distance d between the legs 7 of the fixing bracket) is used as the hole mold 11, but a hole provided with a pair of holes extending inward from the point of the distance d. It may be a mold. The interval between the two hole-shaped rows is set to be the same as or slightly shorter than the width of the overlapping side 4 of the honeycomb. The distance between the hole molds in the same row is not particularly limited, but may be about 1 to 2 times d.
この折曲げ治具を用いて、プリプレグの縫い付けを行うには、図２(ｃ)に示すように、折曲げ治具９の上に２枚のプリプレグ（図示していない）を置き、穴型１１の位置で、固定金具５をプリプレグの上から軽く差し込んで仮止めし、これを打ち込み装置１２により押圧する。これにより、固定金具５の脚部先端が穴型１１に沿って折れ曲がって、ホッチキスによる綴じ込みと同様に、２枚のプリプレグ相互が縫い付けられる。 In order to sew a prepreg using this folding jig, two prepregs (not shown) are placed on the folding jig 9 as shown in FIG. At the position of the mold 11, the fixing metal 5 is inserted lightly from above the prepreg and temporarily fixed, and pressed by the driving device 12. Thereby, the leg part front-end | tip of the fixing metal fitting 5 bends along the hole type | mold 11, and two prepregs are sewn together similarly to the binding by a stapler.
なお、この例では、打ち込み装置１２として、固定金具１個分の小型のものを用いているが、より大型のもの例えば、固定金具１列分又は２列分を同時に押圧できるようなものを用いてもよい。また、打ち込み装置の押圧に機械力を用いてもよい。 In this example, as the driving device 12, a small one for the fixing bracket is used, but a larger one, for example, one that can simultaneously press one or two rows of the fixing bracket is used. May be. Further, mechanical force may be used for pressing the driving device.
図３は、本実施例における縫付け工程の作業手順を示す図である。まず、図３(ａ)に示すように，最下段のプリプレグ１ａの下に、所定の間隔で複数列の折曲げ治具９ａを平行に配置する（折曲げ治具の長さは、プリプレグの長さＬより大きくする）。さらにプリプレグ１ａの上で、２列の折曲げ治具９ａの中間に，２段目の折曲げ治具９ｂを９ａと平行に複数列配置する。その上に、２段目のプリプレグ１ｂを積層する（図３(ａ)はここまでの作業が終了した状態を示している）。 FIG. 3 is a diagram illustrating a work procedure of the sewing process in the present embodiment. First, as shown in FIG. 3 (a), a plurality of rows of bending jigs 9a are arranged in parallel at predetermined intervals under the lowermost prepreg 1a (the length of the bending jig is the length of the prepreg). Larger than the length L). Further, on the prepreg 1a, a plurality of rows of second-stage folding jigs 9b are arranged in parallel to the middle of the two rows of folding jigs 9a. On top of that, the second stage prepreg 1b is laminated (FIG. 3A shows a state where the operations so far are completed).
この状態で、下段の折曲げ治具９ａの上には２層のプリプレグ１ａ及び１ｂが積層されている。折曲げ治具９ａの穴型１１の位置で、ホッチキス針状の固定金具５をプリプレグの上から軽く差し込んで仮止めし、これらの固定金具全体をその上部に配した打ち込み装置１２により押圧する（図３(ｂ)）。このようにして、固定金具５の脚部先端を折曲げ治具９ａの穴型１１に沿って折り曲げることにより、ホッチキスによる綴じ込みと同様に、２枚のプリプレグ１ａ，１ｂ相互が縫い付けられる（この状態を図３(ｃ)に示す）。 In this state, two layers of prepregs 1a and 1b are laminated on the lower bending jig 9a. At the position of the hole mold 11 of the bending jig 9a, the stapler-like fixing metal fitting 5 is lightly inserted from the top of the prepreg and temporarily fixed, and the whole fixing metal fitting is pressed by the driving device 12 disposed on the upper part ( FIG. 3 (b)). In this way, by bending the leg end of the fixture 5 along the hole mold 11 of the bending jig 9a, the two prepregs 1a and 1b can be sewn together as in the case of binding by stapler (this) The state is shown in FIG.
次いで、縫付けの終わった部分（折曲げ治具９ｂの列の中間）に３段目の折曲げ治具９ｃを９ｂと平行に複数列配置する。その上に、３段目のプリプレグ１ｃを積層する。２段目の折曲げ治具９ｂの上には２層のプリプレグ１ｂ及び１ｃが積層されているので、図３(ｂ)と同様に、折曲げ治具９ｂの穴型の位置で、固定金具５をプリプレグの上から仮止めし、固定金具全体をその上部に配した打ち込み装置１２により押圧して、２段目と３段目のプリプレグ１ｂ，１ｃの縫い付けを行う（図３(ｄ)）このようにして、必要な段数分下から順次千鳥状に縫い付けを行うことができる。 Next, a plurality of rows of third-stage bending jigs 9c are arranged in parallel with 9b at the end of sewing (in the middle of the row of bending jigs 9b). A third prepreg 1c is laminated thereon. Since two layers of the prepregs 1b and 1c are laminated on the second-stage bending jig 9b, the fixing bracket is mounted at the position of the hole of the bending jig 9b as in FIG. 5 is temporarily fixed from the top of the prepreg, and the whole fixing bracket is pressed by the driving device 12 disposed on the upper part thereof, and the second and third prepregs 1b and 1c are sewn (FIG. 3 (d)). ) In this way, it is possible to sew in a zigzag pattern sequentially from the required number of steps.
次に、図４に基づいて、本実施例で用いた成形チューブについて説明する。図４(ａ)は、加圧して膨らませる前の成形チューブ、図４(ｂ)は、加圧して膨らませた後の成形チューブを示している。成形チューブ６の本体１３は、伸縮性と耐熱性を有するチューブ（通常はプラスチック又はゴム）からなり、一方の端部に気体吹込み口１４が設けられている。本体１３の長さは、プリプレグの長さＬと同程度又はこれよりやや長くし、膨らませた状態で、その径がハニカムセルの６角形の対角線長よりやや大きい円柱状になるものを用いる。 Next, the molded tube used in the present embodiment will be described with reference to FIG. FIG. 4A shows a molded tube before being pressurized and inflated, and FIG. 4B shows a molded tube after being pressurized and inflated. A main body 13 of the molded tube 6 is made of a tube having elasticity and heat resistance (usually plastic or rubber), and a gas blowing port 14 is provided at one end thereof. The length of the main body 13 is approximately the same as or slightly longer than the length L of the prepreg, and a cylindrical shape whose diameter is slightly larger than the hexagonal diagonal length of the honeycomb cell is used in an inflated state.
この成形チューブ６を、積層したプリプレグの各層間に配置する工程は、前述した縫付け工程が終了した後、折曲げ治具９を引き出した後に隙間ができるので、この隙間に膨張前の成形チューブ６を差し込むという方法で実施するのが好ましい。 In the step of arranging the molded tube 6 between the layers of the laminated prepreg, there is a gap after the bending jig 9 is pulled out after the above-described sewing process is completed. It is preferable to carry out the method by inserting 6.
また、成形チューブ６には剛性が無いので、気体吹込み口１４側を保持して押し込んでも、なかなか狭い隙間には入り難い。そのため、本実施例では、本体１３の先端側（気体吹込み口１４の反対側）のプルリング取付け部１５にプルリング１６を取り付けて、成形チューブ６の進行方向前方から、プルリング１６を引っ張ることにより、成形チューブ６をプリプレグ１の各層間に挿入するようにしている。 Further, since the molded tube 6 does not have rigidity, even if it is pushed in while holding the gas blowing port 14 side, it is difficult to enter the narrow gap. Therefore, in this embodiment, the pull ring 16 is attached to the pull ring attaching portion 15 on the front end side (opposite side of the gas blowing port 14) of the main body 13, and the pull ring 16 is pulled from the front in the traveling direction of the molded tube 6, The formed tube 6 is inserted between the layers of the prepreg 1.
なお、未硬化樹脂を含浸しているプリプレグは、表面にベタツキがあり、折曲げ治具９の引出しや成形チューブ６の差込みの作業がし難い。そのため、本実施例では、折曲げ治具や成形チューブと接触するプリプレグの表面に平滑テープを貼って、ベタツキを防止するようにしている。 In addition, the prepreg impregnated with the uncured resin has a sticky surface, and it is difficult to pull out the bending jig 9 and insert the molded tube 6. For this reason, in this embodiment, a smooth tape is applied to the surface of the prepreg that comes into contact with the bending jig or the formed tube to prevent stickiness.
図５は、平滑テープを用いて、縫付け工程を行う作業手順の説明図である。まず、最下段のプリプレグ１ａにおいては、図５(ａ)に示すように、下側の折曲げ治具９ａに接する位置、及び上側の折曲げ治具９ｂに接する位置で、プリプレグの上下に平滑テープ１７を予め貼付してから、折曲げ治具９ａの上に載置する。 FIG. 5 is an explanatory diagram of a work procedure for performing a sewing process using a smooth tape. First, in the lowermost prepreg 1a, as shown in FIG. 5 (a), the upper and lower sides of the prepreg are smoothed at a position in contact with the lower bending jig 9a and a position in contact with the upper bending jig 9b. After affixing the tape 17 in advance, it is placed on the bending jig 9a.
次いで、２段目のプリプレグ１ｂにおいては、図５(ｂ)に示すように、下側の折曲げ治具９ｂに接する位置、及び上側の折曲げ治具９ｃに接する位置で、プリプレグの上下に平滑テープ１７を予め貼付してから、折曲げ治具９ｂの上に載置する。このように予め平滑テープ１７を貼付したプリプレグを、折曲げ治具を挟んで積層すれば、縫付け工程において、折曲げ治具とプリプレグが接触する面を全て平滑テープでカバーすることができる。 Next, in the second-stage prepreg 1b, as shown in FIG. 5 (b), the prepreg 1b is positioned above and below the prepreg at a position in contact with the lower folding jig 9b and a position in contact with the upper folding jig 9c. After applying the smooth tape 17 in advance, it is placed on the bending jig 9b. Thus, if the prepregs to which the smooth tape 17 has been applied in advance are stacked with the bending jig interposed therebetween, the surface where the bending jig and the prepreg come into contact with each other can be covered with the smooth tape in the sewing step.
一方、成形チューブは、折曲げ治具を抜き出した隙間に挿入するので、この隙間の上下面には平滑テープが貼られており、成形チューブとプリプレグとの接触も完全に防止することができる。 On the other hand, since the formed tube is inserted into the gap where the bending jig is extracted, smooth tape is stuck on the upper and lower surfaces of the gap, and the contact between the formed tube and the prepreg can be completely prevented.
この平滑テープ１７は、表面が平滑なプラスチックの薄いシート又はフィルムを用いればよく、その材質をとくに限定する必要はない。プリプレグ１を積層する前に予め、所定の位置に平滑テープ１７を当てがえば、プリプレグの樹脂の粘着力により、自然に接着される。また、この平滑テープ１７は、ハニカム成形後も取り外す必要は無く、そのままハニカムの一部として使用することができる。 The smooth tape 17 may be a thin plastic sheet or film having a smooth surface, and the material of the smooth tape 17 is not particularly limited. If the smooth tape 17 is applied in advance to a predetermined position before the prepreg 1 is laminated, the prepreg 1 is naturally bonded by the adhesive force of the resin of the prepreg. Further, the smooth tape 17 does not need to be removed after the honeycomb is formed, and can be used as a part of the honeycomb as it is.
上述した本発明の繊維強化樹脂製ハニカムの製造方法は、下記の特徴を有している。
(１)成形チューブの気体圧力によって、ハニカム壁面となるプリプレグを内部から押し広げ、かつ外型枠で挟み込むことで内部圧力に等しい反力がハニカム構造の全てに発生する。その結果、ハニカム壁面を構成するプリプレグの各面に加えられる面圧力が一様で、中空セルの大きさも一様になる。そのためセルサイズの揃ったハニカムを製造することができる。
(２)縫付け工程で重複辺の両端を縫い合わせた後、プリプレグを変形させるので、セルの６角形の形状精度の良好なハニカムを製造することができる。
(３)重複辺では、２枚のプリプレグが上下から成形チューブで押圧された状態で樹脂が硬化するので、プリプレグ相互の接着力が強く構造全体が強固なハニカムを製造することができる。
(４)前述したように、ハニカム壁面を構成するプリプレグは成形チューブの内部圧力によって変形させられる。加えられる内部圧力は成形チューブに充填される気体体積に比例するため、ハニカム長さＬに相当する長さの成形チューブを製造し、ハニカム長さＬに比例する気体量を充填すれば、Ｌの大きい（長尺の）ハニカムを容易に製造することができる。
The above-described method for manufacturing a fiber-reinforced resin honeycomb of the present invention has the following characteristics.
(1) The reaction force equal to the internal pressure is generated in all the honeycomb structures by spreading the prepreg serving as the honeycomb wall surface from the inside by the gas pressure of the forming tube and sandwiching it with the outer mold frame. As a result, the surface pressure applied to each surface of the prepreg constituting the honeycomb wall surface is uniform, and the size of the hollow cells is also uniform. Therefore, a honeycomb having a uniform cell size can be manufactured.
(2) Since the prepreg is deformed after both ends of the overlapping sides are stitched together in the sewing step, a honeycomb having a good shape accuracy of a hexagonal cell can be manufactured.
(3) At the overlapping side, the resin cures in a state where the two prepregs are pressed from above and below by the forming tube, so that a honeycomb having a strong adhesive force between the prepregs and a strong overall structure can be manufactured.
(4) As described above, the prepreg constituting the honeycomb wall surface is deformed by the internal pressure of the forming tube. Since the applied internal pressure is proportional to the gas volume filled in the formed tube, if a formed tube having a length corresponding to the honeycomb length L is manufactured and filled with an amount of gas proportional to the honeycomb length L, the amount of L Large (long) honeycombs can be easily manufactured.
次に、本発明の第二の製造方法である、セル内部が発泡材で充満しているハニカムの製造法について説明する。上述した中空セルハニカムの製造方法と、この第二発明の方法との主な相違点は、使用する成形チューブとその膨らまし方が相違すること、および第二の方法では、プリプレグが硬化した後、成形チューブを取り除くことなく、ハニカム構成材料の一部としてそのまま使用する点である。 Next, the manufacturing method of the honeycomb which is the 2nd manufacturing method of this invention and the inside of a cell is filled with the foaming material is demonstrated. The main difference between the manufacturing method of the hollow cell honeycomb described above and the method of the second invention is that the forming tube to be used and its expansion method are different, and in the second method, after the prepreg is cured, It is a point which uses as it is as a part of honeycomb constituent material, without removing a forming tube.
すなわち、Ａプリプレグ積層工程、Ｂ縫付け工程、Ｃ成形チューブ配置工程は、第一発明の方法とほぼ同じであるから、説明を省略する。Ｄ変形工程とＥ硬化処理工程が必要なことは第一発明の方法と同じであるが、その実施内容が相違するので、以下に説明する。また、第二発明の方法ではＦ成形チューブ取出工程は不要である。 That is, the A prepreg laminating step, the B sewing step, and the C-shaped tube arranging step are substantially the same as the method of the first invention, and thus description thereof is omitted. Although it is the same as that of the method of 1st invention that D deformation process and E hardening process process are required, since the implementation content differs, it demonstrates below. Further, in the method of the second invention, the F-shaped tube take-out step is unnecessary.
この第二発明の方法においては、成形チューブを膨らませるのに、気体圧力を用いるのではなく、加熱されてガスを発生する発泡物質を成形チューブに封入しておき、熱処理時に、発泡物質から発生するガスにより成形チューブを膨らませる。成形チューブに封入するものは、発泡物質と必要に応じてこれに充填剤を加えたものが封入される。発泡物質としては、いわゆる発泡性樹脂を用いてもよく、単にガスのみ発生させる発泡剤を用いてもよい。前者の場合は、充填剤を用いても用いなくても良いが、後者の場合には充填剤は不可欠である。充填剤としては、ゴム系のもの、炭素系のものやこれらを混合したものなどを例示することができる。 In the method of the second invention, instead of using gas pressure to inflate the molded tube, a foamed material that generates gas when heated is sealed in the molded tube, and is generated from the foamed material during heat treatment. The formed tube is inflated with the gas to be used. What is sealed in the molded tube is a foamed material and optionally a filler added thereto. As the foaming material, a so-called foaming resin may be used, or a foaming agent that only generates gas may be used. In the former case, a filler may or may not be used, but in the latter case, the filler is indispensable. Examples of the filler include rubber-based materials, carbon-based materials, and mixtures thereof.
図６は、この第二発明の方法で製造されたハニカムの断面を示す模式図である。図に見られるように、ハニカム壁３で囲まれたセル内には、成形チューブ本体１３の外皮が残存し、その内部に発泡物質１８が充満している。
この場合、成形チューブ本体の外皮が製品ハニカム内に残存するので、その材質もハニカムの強度に貢献するようなものを選ぶことが好ましい。この観点から、成形チューブの外皮には、強化繊維を伸縮性のある布状に織ったシートに熱硬化性樹脂を含浸させたものが好適である。軽量・高強度で、ハニカム壁の繊維強化樹脂と馴染み易く、これと良く接着することが期待されるためである。
FIG. 6 is a schematic view showing a cross section of a honeycomb manufactured by the method of the second invention. As can be seen in the figure, the outer shell of the molded tube main body 13 remains in the cell surrounded by the honeycomb wall 3, and the foamed substance 18 is filled in the outer skin.
In this case, since the outer shell of the molded tube body remains in the product honeycomb, it is preferable to select a material that contributes to the strength of the honeycomb. From this point of view, it is preferable that the outer shell of the molded tube is obtained by impregnating a thermosetting resin into a sheet in which reinforcing fibers are woven in a stretchable cloth shape. This is because it is lightweight and has high strength, is easily compatible with the fiber reinforced resin of the honeycomb wall, and is expected to adhere well thereto.
このセル内部に発泡物質が充満したハニカムは、以下の特徴を有すると考えられる。
(１)セル内部が中空のハニカムに比して、ハニカムの強度自体が増大することや、強度の異方性が小さくなることが期待される。
(２)セル内部が中空でないので、釘打ちやネジ止めをすることが可能になり、他の部材を取り付けるような施工が容易になる。
The honeycomb in which the foam material is filled inside the cell is considered to have the following characteristics.
(1) Compared to a honeycomb having a hollow cell interior, it is expected that the strength of the honeycomb itself is increased and the anisotropy of the strength is reduced.
(2) Since the inside of the cell is not hollow, it becomes possible to perform nailing and screwing, and the construction for attaching other members is facilitated.
なお、この第二発明の方法においても、成形チューブを配置した積層プリプレグの外側に外型枠を置いてプリプレグの変形を行うことが好ましい。また、Ｂ縫付け工程において、第一発明の実施例（図２）で示した固定金具や折曲げ治具を用い、前記と同様な施工方法によることが好ましい。さらに、成形チューブにプルリングを設けること、プリプレグの表面に平滑テープを用いること等の必要性は、第一発明の方法と同様である。 In the method of the second invention also, it is preferable to deform the prepreg by placing an outer mold frame on the outside of the laminated prepreg in which the molded tube is arranged. Further, in the B sewing step, it is preferable to use the fixing method and the bending jig shown in the embodiment of the first invention (FIG. 2) and the construction method similar to the above. Furthermore, the necessity of providing a pull ring on the molded tube and using a smooth tape on the surface of the prepreg is the same as in the method of the first invention.
次に、本発明のハニカムサンドイッチ構造体について説明する。この構造体は、ハニカムコアに繊維強化樹脂（ＦＲＰ）のハニカムを用いること、及び外皮材を接着する面がハニカムの壁面と平行な面であることが特徴である。図７は、このハニカムサンドイッチ構造体の説明図で、ハニカムコア１９を挟んで、ハニカム壁３と平行な面に外皮材２０（通常はＦＲＰのシート）が接着されている。ここで用いるハニカムコア１９は、セル内部が中空のもの（前記第一製造方法によるもの）であっても、セル内部に発泡物質が充満したもの（前記第二製造方法によるもの）のいずれであってもよい。 Next, the honeycomb sandwich structure of the present invention will be described. This structure is characterized in that a honeycomb of fiber reinforced resin (FRP) is used for the honeycomb core, and the surface to which the outer skin material is bonded is a surface parallel to the wall surface of the honeycomb. FIG. 7 is an explanatory diagram of this honeycomb sandwich structure, and a skin material 20 (usually an FRP sheet) is bonded to a surface parallel to the honeycomb wall 3 with the honeycomb core 19 interposed therebetween. The honeycomb core 19 used here is either one having a hollow cell interior (according to the first production method) or one having a cell filled with a foaming substance (according to the second production method). May be.
従来のハニカムサンドイッチパネルでは、通常はハニカム壁３と直角な面に外皮材が貼られるのに対して、本発明のハニカムサンドイッチ構造体は、ハニカム壁３と平行な面に外皮材を貼ることが大きな相違点である。とくに、少なくとも重複辺４と平行な２面に外皮材を配置することが望ましい。 In the conventional honeycomb sandwich panel, the outer skin material is usually pasted on the surface perpendicular to the honeycomb wall 3, whereas in the honeycomb sandwich structure of the present invention, the outer skin material can be pasted on the surface parallel to the honeycomb wall 3. This is a big difference. In particular, it is desirable to arrange the skin material on at least two surfaces parallel to the overlapping side 4.
また、上記の構造体においては、図７(ｂ)に示すように、外皮材２０に隣接するハニカム外側の台形凹部（図の斜線部分）が、フィラー材２１で充満されていることが好ましい。フィラー材２１の材質をとくに限定する必要はないが、例えば前記台形凹部の面積に相当する太さに、炭素繊維やガラス繊維などの強化繊維でワイヤー状の長尺ひもを作成し、プリプレグの樹脂マトリックスを含浸させたもの等が好ましい。なお、ワイヤー形状は台形である必要はなく、台形凹部の面積に相当する断面積をもつ円形でよい。 In the above structure, it is preferable that the trapezoidal concave portion (shaded portion in the figure) outside the honeycomb adjacent to the skin material 20 is filled with the filler material 21 as shown in FIG. The material of the filler material 21 is not particularly limited. For example, a wire-like long string is made of reinforcing fibers such as carbon fiber and glass fiber in a thickness corresponding to the area of the trapezoidal recess, and a resin for prepreg Those impregnated with a matrix are preferred. The wire shape does not need to be trapezoidal, and may be circular with a cross-sectional area corresponding to the area of the trapezoidal recess.
本発明のハニカムサンドイッチ構造体は、上記の構成により以下の特長を有する。
(１)ハニカムコアにＦＲＰ製のものを用いることにより、その強度を大幅に高め、外皮材の配置方向の自由度を大きくしたこと。
すなわち、ハニカムコアが厚紙やアルミ箔（薄板）で形成されていた従来のハニカムサンドイッチ構造体では、ハニカム壁面と直角な方向の力（例えば図７(ａ)の矢印方向の力）に対する強度が小さいが、ＦＲＰ製のハニカムコアを用いることにより、このような力に対する抗力が十分大きくなることが、本発明の構成を可能にした理由である。
(２)外皮材とハニカムコアが面（重複辺と平行な面）で接着されているため、局部的集中荷重に対しても、接着部が破壊されることがなく、その結果構造体全体の強度を高めることにつながっている。
(３)外皮材の下側が中空でなく、フィラー材又はハニカム壁が存在するため、局部的集中荷重があっても、外皮材が破れ難い。
(４)ハニカムコアの長さＬの大きいものを用いることにより、柱や梁の形状の構造体を容易に製造することができる。
The honeycomb sandwich structure of the present invention has the following features by the above configuration.
(1) By using a honeycomb core made of FRP, its strength has been greatly increased, and the degree of freedom in the arrangement direction of the skin material has been increased.
That is, in the conventional honeycomb sandwich structure in which the honeycomb core is formed of cardboard or aluminum foil (thin plate), the strength against the force in the direction perpendicular to the honeycomb wall surface (for example, the force in the arrow direction in FIG. 7A) is small. However, the reason why the configuration of the present invention is made possible is that the resistance against such a force becomes sufficiently large by using the honeycomb core made of FRP.
(2) Since the outer skin material and the honeycomb core are bonded to each other by a surface (a surface parallel to the overlapping side), the bonded portion is not broken even with a localized concentrated load. This leads to increased strength.
(3) Since the lower side of the outer skin material is not hollow and there is a filler material or a honeycomb wall, the outer skin material is hardly broken even if there is a localized concentrated load.
(4) By using a honeycomb core having a large length L, a pillar-shaped or beam-shaped structure can be easily manufactured.
上記の特徴から、本発明のハニカムサンドイッチ構造体は、構造用の柱材又は梁材として好適なことが理解される。なお、本発明の構造体においてＦＲＰ製ハニカムコアの製造方法を限定する必要はないが、本発明の製造方法により製造されたハニカムコアは、６角形のセルの形状精度がよく、構造体としての強度が大きいこと、ハニカム壁の長さＬの大きいものの製造が容易なこと等から、とくに上記の構造体のハニカムコアとして好適である。 From the above characteristics, it is understood that the honeycomb sandwich structure of the present invention is suitable as a structural column or beam. In addition, although it is not necessary to limit the manufacturing method of the FRP honeycomb core in the structure of the present invention, the honeycomb core manufactured by the manufacturing method of the present invention has a good hexagonal cell shape accuracy. Particularly, it is suitable as a honeycomb core of the above structure because of its high strength and easy manufacture of a honeycomb wall having a large length L.
また、本発明の製造方法においては、ハニカムの成形と外皮材の接着を同時に行うことができる。図８は、この同時成形・接着工程の説明図で、図８(ａ)はセルが中空のハニカムの場合、図８(ｂ)はセル内部に発泡物質が充満したハニカムの場合を示す。図８(ａ)においては、ハニカムの変形工程（図１(ｄ)の工程）において、成形チューブ６が配置されたプリプレグ１の上下に外皮材２０を配し、その外側を外型枠２２で拘束して、成形チューブ６の気体吹込み口１４から気体を吹き込んで、プリプレグ１を変形させる。その際、外皮材２０に隣接するハニカム外側の台形凹部（図の斜線部分）には、予めフィラー材２１を充填しておく。プリプレグがハニカムの形状に変形した後、熱処理によりプリプレグのマトリックスを硬化させれば、ハニカムの成形と外皮材の接着を同時に行うことができる。 Moreover, in the manufacturing method of the present invention, the formation of the honeycomb and the adhesion of the outer skin material can be performed simultaneously. FIG. 8 is an explanatory diagram of this simultaneous molding / bonding process. FIG. 8A shows a case where the cell is a hollow honeycomb, and FIG. 8B shows a case where the cell is filled with a foaming substance. 8 (a), in the honeycomb deformation step (step of FIG. 1 (d)), the skin material 20 is arranged above and below the prepreg 1 on which the forming tube 6 is arranged, and the outside is covered by the outer mold frame 22. The prepreg 1 is deformed by restraining and blowing a gas from the gas blowing port 14 of the molded tube 6. At that time, a filler material 21 is filled in advance in the trapezoidal concave portion (shaded portion in the figure) outside the honeycomb adjacent to the skin material 20. If the matrix of the prepreg is cured by heat treatment after the prepreg is deformed into the shape of the honeycomb, the formation of the honeycomb and the adhesion of the skin material can be performed simultaneously.
同様に図８(ｂ)においても、内部に発泡物質１８が充填された成形チューブ本体１３をプリプレグ１の各層間に配置し、上下に外皮材２０を配し、外皮材２０に隣接するハニカム外側の台形凹部（図の斜線部分）には、予めフィラー材２１を充填しておく。その外側に外型枠２２を配し、熱処理により発泡物質１８を発泡させ、成形チューブ本体１３を膨らませて、プリプレグ１を変形させる。熱処理によりプリプレグのマトリックスが硬化し、外皮材と接着するから、ハニカムの成形と外皮材の接着を同時に行うことができる。 Similarly, in FIG. 8B, the molded tube body 13 filled with the foaming substance 18 is disposed between the layers of the prepreg 1, and the outer skin material 20 is disposed on the upper and lower sides, and the outer side of the honeycomb adjacent to the outer skin material 20. The trapezoidal recess (shaded portion in the figure) is filled with a filler material 21 in advance. The outer mold 22 is arranged on the outside, the foamed material 18 is foamed by heat treatment, the molded tube body 13 is expanded, and the prepreg 1 is deformed. Since the matrix of the prepreg is cured by the heat treatment and adheres to the outer skin material, the formation of the honeycomb and the adhesion of the outer skin material can be performed simultaneously.
図８に示したハニカムの成形と外皮材の接着を同時に行う方法により、セル内部が中空又は発泡物質が充満したハニカムサンドイッチ構造体を試作し、製造の難易とその形状精度及び製品重量の評価を行った。試作した構造体は、以下の４種である。
試作材Ａ
平板型パネル材（ハニカム段数５段）
外皮材：カーボンファイバープリプレグ３枚＋ガラスファイバープリプレグ４枚のハイブリッド積層
外皮材の厚さ：１．８ｍｍ（０．２×３＋０．３×４＝１．８）
ハニカムコア材：ガラスファイバープリプレグ
フィラー材：軟質ポリウレタンゴム
セル内充填物質：発泡ポリウレタン（一部中空セル）
構造体サイズ：高さ１９６×幅２８２×厚み３１ｍｍ
重量：０．４７５ｋｇ
試作材Ｂ
平板型パネル材（ハニカム段数３段）
外皮材：カーボンファイバープリプレグ５枚
外皮材の厚さ：１．０ｍｍ（０．２×５＝１．０）
ハニカムコア材：ガラスファイバープリプレグ
フィラー材及びセル内発泡物質：無し（中空セル）
構造体サイズ：高さ１９６×幅２３６×厚み２５ｍｍ
重量：０．３６１ｋｇ
試作材Ｃ
曲面型パネル材（ハニカム段数３段）
外皮材：ガラスファイバープリプレグ５枚
外皮材の厚さ：１．５ｍｍ（０．３×５＝１．５）
ハニカムコア材：ガラスファイバープリプレグ
フィラー材：軟質ポリウレタンゴム
セル内発泡物質：発泡ポリウレタン
構造体サイズ：高さ１９５×幅２３５×厚み２２ｍｍ
重量：０．４１５ｋｇ
試作材Ｄ
曲面型パネル材（ハニカム段数３段）
外皮材：カーボンファイバープリプレグ５枚
外皮材の厚さ：１．０ｍｍ（０．２×５＝１．０）
ハニカムコア材：カーボンファイバープリプレグ
フィラー材：軟質ポリウレタンゴム
セル内発泡物質：発泡ポリウレタン
構造体サイズ：高さ２００×幅２４８×厚み２２ｍｍ
重量：０．４１０ｋｇ
A honeycomb sandwich structure in which the inside of the cell is hollow or filled with foamed material is prototyped by the method of simultaneously forming the honeycomb and bonding the outer shell material shown in FIG. 8, and evaluates the difficulty of manufacturing and the accuracy of the shape and the product weight. went. The prototypes are the following four types.
Prototype material A
Flat panel material (5 honeycomb stages)
Outer material: Hybrid carbon fiber prepreg 3 sheets + 4 glass fiber prepregs Hybrid laminated outer cover material thickness: 1.8 mm (0.2 × 3 + 0.3 × 4 = 1.8)
Honeycomb core material: Glass fiber prepreg filler material: Soft polyurethane rubber Filling material in cell: Polyurethane foam (partially hollow cell)
Structure size: height 196 x width 282 x thickness 31 mm
Weight: 0.475kg
Prototype material B
Flat panel material (3 honeycomb stages)
Outer material: 5 carbon fiber prepregs Thickness of outer material: 1.0 mm (0.2 × 5 = 1.0)
Honeycomb core material: Glass fiber prepreg filler material and cell foam: None (hollow cell)
Structure size: height 196 x width 236 x thickness 25 mm
Weight: 0.361kg
Prototype material C
Curved panel material (3 honeycomb stages)
Outer material: 5 glass fiber prepregs Outer material thickness: 1.5 mm (0.3 × 5 = 1.5)
Honeycomb core material: Glass fiber prepreg filler material: Soft polyurethane rubber Foam material in cell: Expanded polyurethane structure Size: Height 195 x 235 width x thickness 22 mm
Weight: 0.415kg
Prototype material D
Curved panel material (3 honeycomb stages)
Outer material: 5 carbon fiber prepregs Thickness of outer material: 1.0 mm (0.2 × 5 = 1.0)
Honeycomb core material: carbon fiber prepreg filler material: soft polyurethane rubber Foam material in cell: foamed polyurethane structure Size: height 200 x width 248 x thickness 22 mm
Weight: 0.410kg
これらの試作材Ａ〜Ｄの外観写真を図９に示す。いずれの試作材も製作上とくに困難なことはなく、ハニカム形状や構造体厚みの寸法精度も良好であった。これの構造体の比重は、０．２７７〜０．４１１ｇ／ｃｍ３の範囲内であり、きわめて軽量、高強度であることが確かめられた。 The appearance photographs of these prototype materials A to D are shown in FIG. None of the prototypes were particularly difficult to manufacture, and the dimensional accuracy of the honeycomb shape and the structure thickness was good. The specific gravity of this structure was in the range of 0.277 to 0.411 g / cm 3 , and it was confirmed that it was extremely light and strong.
１，１ａ，１ｂ，１ｃ：プリプレグ
２：折り目
３：ハニカム壁
４：重複辺
５：固定金具
６：成形チューブ
７：固定金具の脚部
８：固定金具の胴部
９，９ａ，９ｂ，９ｃ：折曲げ治具
１０：折曲げ治具の台
１１：折曲げ治具の穴型
１２：打ち込み装置
１３：成形チューブ本体
１４：気体吹込み口
１５：プルリング取付け部
１６：プルリング
１７：平滑テープ
１８：発泡物質
１９：ハニカムコア
２０：外皮材
２１：フィラー材
２２：外型枠
1, 1a, 1b, 1c: prepreg 2: crease 3: honeycomb wall 4: overlapping side 5: fixing bracket 6: molded tube 7: leg portion 8 of fixing bracket: trunk portions 9, 9a, 9b, 9c of fixing bracket: Bending jig 10: Bending jig base 11: Bending jig hole mold 12: Driving device 13: Molded tube main body 14: Gas blowing port 15: Pull ring mounting portion 16: Pull ring 17: Smooth tape 18: Foam material 19: honeycomb core 20: outer skin material 21: filler material 22: outer mold frame
Claims (18)
６角形のハニカム形状に成形した状態で前記プリプレグが上下段で重複する辺（以下「重複辺」という）の幅方向両側端部又はその付近で、固定金具を用いて上下のプリプレグ相互を、該辺の長手方向のほぼ全長に亘って縫い付ける工程と、
次いで、内圧により所定径の柱状に膨張する伸縮性及び必要に応じて耐熱性を有する材料からなる多数の成形チューブを、ハニカム壁の長手方向に平行にそのほぼ全長に亘って延在させ、前記プリプレグの上下段間で千鳥配置なるように、前記プリプレグ各層間に配置する工程と、
次いで、前記成形チューブを配置したプリプレグを成形後のハニカムに相当する大きさの外型枠内に収容して、該成形チューブを気体により内部から加圧し、前記プリプレグを６角形ハニカム壁面の形状に変形させる工程と、
該成形チューブの内部圧力と前記外型枠の反力によって、ハニカム壁面相互が強固に圧着される状態で、前記プリプレグの含浸樹脂を硬化・接着させる硬化処理工程と、
次いで、前記成形チューブ内の気体圧を減じて、該チューブをハニカムセル中空部から除去する工程とを具備することを特徴とする繊維強化樹脂製ハニカムの製造方法。 A step of sequentially laminating a deformable prepreg impregnated with a resin in a sheet of reinforcing fibers;
In the state where the prepreg is formed into a hexagonal honeycomb shape, the upper and lower prepregs are connected to each other using fixing brackets at or near both ends in the width direction of the side where the prepreg overlaps in the upper and lower stages (hereinafter referred to as “overlapping side”). A process of sewing over substantially the entire length of the side,
Next, a large number of molded tubes made of a material having a stretchability and a heat resistance if necessary, which expands into a columnar shape with a predetermined diameter due to internal pressure, are extended over almost the entire length in parallel to the longitudinal direction of the honeycomb wall, A step of arranging between the prepreg layers so as to be staggered between upper and lower stages of the prepreg;
Next, the prepreg having the formed tube disposed therein is accommodated in an outer mold frame having a size corresponding to the honeycomb after forming, the formed tube is pressurized from the inside with gas, and the prepreg is shaped into a hexagonal honeycomb wall surface. A step of deforming;
A curing treatment step of curing and adhering the impregnating resin of the prepreg in a state where the honeycomb wall surfaces are firmly pressure-bonded by the internal pressure of the molded tube and the reaction force of the outer mold frame;
And a step of reducing the gas pressure in the molded tube to remove the tube from the hollow portion of the honeycomb cell.
前記重複辺の幅方向両側端部又はその付近で、固定金具を用いて上下のプリプレグ相互を、該辺の長手方向のほぼ全長に亘って縫い付ける工程と、
次いで、加熱されて発泡する物質がその内部に充填され、該物質の発泡膨脹時の内圧により所定径の柱状に膨張する伸縮性及び耐熱性を有する材料からなる多数の成形チューブを、ハニカム壁面の長手方向に平行にそのほぼ全長に亘って延在させ、かつ前記プリプレグの上下段間で千鳥配置なるように、前記プリプレグ各層間に配置する工程と、
次いで、前記の成形チューブを配置したプリプレグを成形後のハニカムに相当する大きさの外型枠内に収容し、該プリプレグを所定温度に加熱して、前記発泡物質を膨張させ、前記プリプレグをハニカム壁面の形状に変形させるとともに、該成形チューブの内部圧力と前記外型枠の反力によって、ハニカム壁面相互が強固に圧着される状態で、前記プリプレグの含浸樹脂を硬化・接着させる熱処理工程と、を具備し、
発泡物質が充満した成形チューブをハニカムセルの中空部に内包する高強度ハニカムを製造することを特徴とする繊維強化樹脂製ハニカムの製造方法。 A step of sequentially laminating a deformable prepreg impregnated with a resin in a sheet of reinforcing fibers;
A step of sewing the upper and lower prepregs over the substantially entire length in the longitudinal direction of the sides using fixing brackets at or near both ends in the width direction of the overlapping sides;
Next, a large number of formed tubes made of a material having elasticity and heat resistance, which is filled with a substance that is heated and foamed and expands into a columnar shape with a predetermined diameter by an internal pressure during expansion of the substance, is formed on the honeycomb wall surface. Extending the entire length of the prepreg in parallel with the longitudinal direction, and arranging the layers between the prepreg layers so as to be arranged in a staggered manner between the upper and lower stages of the prepreg;
Next, the prepreg in which the molded tube is arranged is accommodated in an outer mold frame having a size corresponding to the honeycomb after molding, the prepreg is heated to a predetermined temperature, the foamed material is expanded, and the prepreg is expanded to the honeycomb. A heat treatment step of curing and adhering the impregnating resin of the prepreg in a state where the honeycomb wall surfaces are firmly pressure-bonded by the internal pressure of the forming tube and the reaction force of the outer mold frame, while being deformed into the shape of the wall surface; Comprising
A method for manufacturing a fiber-reinforced resin honeycomb, characterized by manufacturing a high-strength honeycomb in which a molded tube filled with a foaming substance is enclosed in a hollow portion of a honeycomb cell.
該固定金具の先端を所定方向に折り曲げガイドする２列の穴型が設けられた帯板状の折曲げ治具を、縫い付けられるプリプレグの下側に配置するとともに、
前記固定金具を上側から前記折曲げ治具の穴型に押し付けて、固定金具の先端を前記穴型に沿って折り曲げる打ち込み装置を用いることを特徴とする請求項５に記載の繊維強化樹脂製ハニカムの製造方法。 When sewing a prepreg with a fixing bracket similar to the above stapler needle,
A band plate-like bending jig provided with two rows of hole molds for bending and guiding the front end of the fixing bracket in a predetermined direction is disposed below the prepreg to be sewn;
6. The fiber-reinforced resin honeycomb according to claim 5, wherein a driving device is used to press the fixing bracket from above to the hole mold of the bending jig and bend the tip of the fixing bracket along the hole mold. Manufacturing method.
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