JP2013043446A - Method for producing honeycomb panel, and honeycomb panel with use of the method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a honeycomb panel which is light and strong and can be produced inexpensively, and the honeycomb panel with use of the method.SOLUTION: In the method for producing the honeycomb panel in which a foamed resin body is packed in the cell of a honeycomb core material, the method constituted of an extrusion molding step in which a block-shaped, resin-made honeycomb core material block A which has an external frame part of a prescribed size and is long in the cell both opening direction is molded by extrusion, a foamed resin body packing step in which the foamed resin body is foamed and packed in the cell of the long resin-made honeycomb core material block A obtained by the extrusion molding step, a cutting step in which a long resin-made honeycomb core material block B obtained by the foamed resin body packing step is cut in a panel shape of a prescribed thickness, and a bonding step in which a prescribed number of resin-made honeycomb core material blocks C obtained by the cutting step are arranged lengthwise and breadthwise between two surface panels of a prescribed size, and this bonding method is bonding by an adhesive or welding, is adopted.

Description

  The present invention relates to a method for manufacturing a lightweight, strong and low-cost honeycomb panel and a honeycomb panel using the method.

  Conventionally, a honeycomb composite material for construction has a veneer plywood such as lauan material attached to both sides of an intermediate layer filled with a lightweight core material such as paper honeycomb in the space of the framed frame through an adhesive. With its structural characteristics such as lightness, toughness, flatness and surface pressure, it is widely used as a building fixture, door and flooring material for construction, as a concrete panel for building construction, and as a building structural wall material. .

  However, these composite honeycomb composite materials have many advanced functions compared to other building structural materials, but they require many complicated manufacturing processes such as assembly and extension of honeycomb panels, so the manufacturing cost There is a problem that the cost becomes high.

  Furthermore, the honeycomb core material with soundproof, fireproof, and heat insulation properties as well as lightness, toughness, flatness, and surface pressure by filling the space of the honeycomb core material with the foamed resin body is more complicated to manufacture. Since a process and advanced processing technology are required, the manufacturing cost is inevitably increased.

  For example, in the manufacture of honeycomb composites filled with foamed resin bodies using veneer plates on both sides, the production and assembly process of the frame body, the arrangement and expansion process of the honeycomb core material, the filling of the foamed resin body There is a need for an operation process and an application process for applying adhesive on veneer plates, and consistent manufacturing of these processes on a single production line requires different production times. It was difficult to assemble.

  In addition, when manufacturing a honeycomb composite material by filling a foamed resin body using synthetic resin panel plates on both sides, manufacturing and assembling processes of the frame body, arranging and expanding the honeycomb core material, filling the foamed resin body The process, the process of welding the honeycomb core material and the synthetic resin panel board is required, and the time required for each process varies depending on the manufacturing process consistently in one production line like the wooden panel board. At the same time, since a special processing device is required in the welding process, it is difficult to set up an automated production line in terms of work environment.

  Conventionally, a manufacturing technique of a honeycomb composite material filled with a foamed resin body that attempts to solve the above problem has been proposed. For example, a `` honeycomb structure and manufacturing method thereof '' is a method of manufacturing a honeycomb structure by filling a foamed resin body in a form in which the foamed resin body does not overflow from the surface of the honeycomb core into the honeycomb space with a molding mold (patent Document 1) has been proposed.

  However, the above proposal prepares a mold for molding and a ready-made honeycomb core, and manually manufactures the honeycomb structure so that the foamed resin body does not overflow by filling the honeycomb space with the foamed resin body. Therefore, it is difficult to introduce an automated line, and it is necessary to visually control the curing time and filling amount of the foamed resin body. It was not a proposal that could manage the variation deviation.

  In addition, a reinforcing plate in which a paper sheet is bonded to both sides of a fiber reinforced thermoplastic resin sheet composed of a prepreg composed of continuous long fibers aligned in one direction and having a weight content of 40% to 80%. "Composite plate and manufacturing method thereof" (see Patent Document 2) integrated on one or both sides of an intermediate layer made of a core material with an adhesive, and a foamable phenolic resin and an inorganic fiber sheet on both sides of a honeycomb body The heat insulation panel and the manufacturing method thereof were integrally formed by laminating a composite material of the above, laminating a skin material on the outside via a hot melt film or a thermosetting resin, heating and pressing, and foaming and curing the foamable phenolic resin (Refer to Patent Document 3), or a foamable phenol resin composite and a honeycomb core in which a foamable phenol resin is dispersed and adhered to at least one surface of a mat-like fiber material. Laminate so that each cell of the honeycomb core is filled with resin, and the surface of the laminate of the foamable phenolic resin composite and the honeycomb core is made of a material different from the mat-like fiber on one side or any one side. A “honeycomb composite molded article and a method for manufacturing the same” (see Patent Document 4), in which materials are laminated and pressed by heating and pressing, has been proposed.

  However, those proposals are a manufacturing method in which inorganic prepreg sheet material is laminated between a honeycomb core and a surface material to pursue functionality such as fire resistance, fire resistance, toughness, and the like. This is not a proposal for reducing the cost of the honeycomb structure itself because it is a method for manufacturing a honeycomb structure using a formwork or a ready-made honeycomb core and a honeycomb panel using the method.

  In view of the above problems of the honeycomb structure and the manufacturing method thereof, the present inventor has paid attention to the cost reduction of the honeycomb structure manufacturing method and the honeycomb panel using the honeycomb structure manufacturing method. The honeycomb structure was elongated by extrusion molding under the idea that it would be impossible to build a production line by automating the manufacturing process of the honeycomb structure and the filling process of the foamed resin body, and the elongated honeycomb structure The body is filled with a foamed resin body, the elongated honeycomb structure filled with the foamed resin body is cut into a panel having a predetermined thickness, and a predetermined number of vertical and horizontal positions are arranged between two face plates of a predetermined size. Thus, a manufacturing method for bonding is developed, leading to the proposal of a “honeycomb panel manufacturing method and a honeycomb panel using the same” of the present invention.

JP 2004-276310 A JP-A-10-44281 JP-A-8-20086 JP-A-8-174732

  In view of the above problems, the present invention aims to provide a lightweight, strong and low-cost method for manufacturing a honeycomb panel and a honeycomb panel using the method.

  The present invention relates to a method for manufacturing a honeycomb panel in which cells of a honeycomb core material are filled with a foamed resin body, and has an outer frame portion having a predetermined size and is a block-shaped resin honeycomb that is long in both opening directions of the cell. Extrusion molding process for molding the core block A by extrusion, and a foamed resin body filling process for foaming and filling the foamed resin body into the cells of the long resin honeycomb core block A obtained by the extrusion molding process A cutting step of cutting the long resin honeycomb core block B obtained by the foamed resin body filling step into a panel having a predetermined thickness, and a resin honeycomb core block C obtained by the cutting step, A predetermined number of vertical and horizontal positions are arranged between two face plates of a predetermined size, and a bonding step in which these bonding means are bonded by either adhesive or welding is adopted.

  Further, the present invention is a honeycomb panel manufactured by the method for manufacturing a honeycomb panel according to claim 1, wherein the two face plates in the joining step are wooden panels having a predetermined thickness, and the wooden panel and the resin honeycomb The joining means with the core material block C and the joining means between the resin honeycomb core material blocks C provided next to each other are both made of an adhesive.

  Moreover, the present invention is a honeycomb panel manufactured by the method for manufacturing a honeycomb panel according to claim 1, wherein two face plates in the joining step are resin panels having a predetermined thickness, and the resin panel and the resin The means for joining with the honeycomb core block C made of resin and the means for joining the honeycomb core blocks C made of resin adjacent to each other are either adhesives or welding.

  According to the honeycomb panel manufacturing method of the present invention and the honeycomb panel using the same, the core material is configured by combining a plurality of resin honeycomb core blocks C cut into a panel having a predetermined thickness in the cutting step. Cutting and laminating process of honeycomb material, bonding process, hot pressing process, cutting process of honeycomb laminated body, stretching process of cut honeycomb laminated material, cutting process of frame body, punching process of frame body, frame body Since a series of complicated processes such as the assembling process can be omitted, the manufacturing cost can be greatly reduced. Furthermore, since the cell and the frame are integrally molded, the robustness by integral molding can be increased without the need for an adhesive. The material cost and work cost are lower than before, and the honeycomb panel itself is There is an excellent effect that quality can be improved.

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel manufacturing method, in the honeycomb panel manufacturing method in which the cells of the honeycomb core material are filled with the foamed resin body, the extrusion molding step and the foamed resin body filling By comprising a process, a cutting process, and a joining process, all processes can be mechanized on a single production line, so the manual process is saved and the production line is automated. Has an effect.

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel, the inventory adjustment can be performed at the time when the processing is completed in the foaming resin body filling process and the subsequent process of the cutting process. After the filling process, the production can be adjusted according to the order quantity of the honeycomb panel, and after the cutting process, the production can be adjusted according to the standard of the thickness dimension of the honeycomb panel. It produces an excellent effect that allows production adjustment of lots to be performed quickly.

Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the same, after the foamed resin body filling step, the long resinous honeycomb core block B is cut into a panel having a predetermined thickness, and the cell and the foamed resin are separated. Since the cut surface of the body forms an extremely beautiful flat surface and smoothness, it has excellent effects of improving adhesion accuracy, improving dimensional accuracy when completing the honeycomb panel, and improving adhesion and robustness. .

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel, a desired shape and dimensions can be obtained by combining a plurality of resin honeycomb core blocks C into arbitrary shapes. It has excellent effects such as adapting to shapes such as punching and notching, design flexibility such as arrangement of standard dimensions, and diversification of specifications in design construction such as grasping the number of arrangements in standard design.

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel, since the foaming agent is filled in the cells of the resin honeycomb core block C, a heat insulating effect and a sound insulating effect are exhibited. It exhibits excellent effects such as energy saving measures and life sound problems.

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the same, the weight of the entire building structure can be reduced because it is much lighter than the plywood having the same length and width and the same thickness. It becomes possible. In particular, the Tohoku-Pacific Ocean Earthquake that occurred on March 11, 2011 is expected to require light weight and high rigidity for future building materials. Has an effect.

Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel, since a planar outer frame exists at the edge of the resin honeycomb core block C, the honeycomb core without such a frame is provided. Compared to honeycomb panels made of wood, it is resistant to loads applied perpendicular to the panel surface, and furthermore, the planar outer frames are bonded to each other in a planar shape, so that they are rigid against strain and deflection in the planar direction. Has the excellent effect of being strong.

  Moreover, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the same, by using a resin honeycomb core block as a core, adhesion between the resin honeycomb core blocks and adhesion to the resin panel are achieved. As the means, for example, an adhesive means such as ultrasonic welding, vibration welding, thermoplastic resin sheet welding, etc., which does not require application time of the adhesive and drying time of the adhesive, can be adopted, so that the manufacturing cost and the processing time can be reduced. There is an excellent effect to be achieved.

  Further, according to the method for manufacturing a honeycomb panel of the present invention and the honeycomb panel using the honeycomb panel manufacturing method, a thick part in which resin is filled in a part of a frame body or a part of a cell of a resin honeycomb core block C is extruded. In this way, a joining means using a joining member such as a nail, a screw, or a helicate can be used, and an excellent effect of easily joining and attaching to an external structure can be obtained.

  In addition, according to the honeycomb panel manufacturing method of the present invention and the honeycomb panel using the honeycomb panel manufacturing method, it is possible to significantly reduce the manufacturing cost by automating the manufacturing line that does not require a frame body. The prepreg sheet material can be laminated between the honeycomb core and the surface material, and an excellent effect can be obtained in which functions such as fire resistance, fire resistance, and toughness can be pursued.

It is the flowchart figure in the manufacturing method of the honeycomb panel in this invention, and the schematic diagram which shows a manufacturing process state. Example 1 FIG. 3 is a completed drawing of a honeycomb panel according to a manufacturing process of the honeycomb panel in the present invention. It is explanatory drawing which shows embodiment of the honeycomb panel in Claim 1. It is explanatory drawing which shows embodiment of the honeycomb panel in Claim 2. (Example 2) It is explanatory drawing which shows embodiment of the honeycomb panel in Claim 3. (Example 3)

  The present invention is a manufacturing method constituted by an extrusion molding step, a foamed resin body filling step, a cutting step, and a bonding step, and in particular, a long block-shaped resin honeycomb core block A is molded in the extrusion molding step, In the long state, the biggest feature is that the foamed resin body is foamed in the cell and then cut into a panel shape, and the core material is extruded with a resin with an outer frame. is there. Embodiments will be described below with reference to the drawings.

  The dimensions and shapes shown in the present embodiment are not particularly limited to the embodiments described below, and can be arbitrarily changed without departing from the spirit of the technical idea of the present invention.

FIG. 1 is a flow chart and a schematic diagram showing a manufacturing process state in a method for manufacturing a honeycomb panel according to the present invention.
FIG. 1A shows a flowchart, and FIG. 1B shows a schematic diagram.
The method for manufacturing a honeycomb panel according to the present invention and the honeycomb panel 1 using the method include an extrusion molding step S1, a foamed resin body filling step S2, a cutting step S3, and a joining step S4.

In the extrusion step S1, a mold having an outer frame portion 21 having a predetermined dimension and a block-shaped resin honeycomb core block 10 which is long in both opening directions of the cell 20 is composed of a honeycomb core and a frame. This is a process of forming by an extruder P having the same. Briefly explaining the processing steps, billets (materials) processed into chips or pallets are put into a hopper, dried and heated, then chopped with a screw blade and further heated to a molten state. The melted billet is extruded to a mold processed into a honeycomb shape, and then extruded to the outside from a mold imitating the shape of the honeycomb core block. Then, it is cooled through a mold or a water tank and solidified. Thereafter, since the molded resin honeycomb core block 10 is formed as a single unit, it can be manufactured without stretching the honeycomb material as compared with the conventional honeycomb material, and the side walls of the cells 20 are not required to be bonded. Expensive adhesives and bonding man-hours, and dedicated equipment for cutting, bonding and spreading are not required, and further, the outer frame of the face plate 32 is not required, so that the cost can be greatly reduced.
The shape (see FIG. 2 (a)) of the long resinous honeycomb core block 10 formed in the extrusion molding step S1 will be described below as a resin honeycomb core block A.

  The material of the resin honeycomb core block 10 is not particularly specified as long as it is a thermoplastic resin material, but it is desirable to use a synthetic resin such as polypropylene (PP) from the viewpoint of cost and weight reduction. However, other examples include polyethylene (PE), polystyrene (PS), and ABS resin (ABS).

  The shape of the cell 20 is preferably a regular hexagon as shown in each drawing, but is not particularly limited as long as it is a continuously formed shape such as a quadrangle, a triangle, a circle, or an ellipse.

  The foamed resin body filling step S2 is a processing step for filling the foamed resin body 23 into the cells 20 of the long resin honeycomb core block A obtained by the extrusion molding step S1 of the previous step. Briefly explaining the filling process of the foamed resin body 23, a general-purpose injection molding machine in which the resin honeycomb core block A is regarded as an extrusion mold, one side is sealed, and the foamed resin body 23 is injected from the other side. The foamed resin body 23 is injected into the cell 20 of the resin honeycomb core block A with H and hardened. The shape (see FIG. 2B) of the resin honeycomb core block 10 filled in the foamed resin body filling step S2 will be described as a resin honeycomb core block B hereinafter.

  The foamed resin body 23 is not particularly specified as long as it is a foamable resin, and examples thereof include extruded polystyrene (XPS) that is hard and flame-retardant, and foamable phenol resin that is highly nonflammable.

  The cutting step S3 is a processing step of cutting the long resin honeycomb core block 10 obtained by the foamed resin body filling step in the previous step into a panel having a predetermined thickness. Briefly describing the cutting process, the resin honeycomb core block B filled with the long foamed resin body 23 processed in the previous step is subjected to a face plate 32 by a general-purpose cutting machine D (shearing, laser beam, water jet, etc.). It is cut into slices according to the thickness standard dimension. The cut resin honeycomb core block C is manufactured, for example, with a size obtained by subtracting the thicknesses of the two face plates 32 of the standard size of the plywood panel with a thickness of 30 cm × 30 cm. Since the cut resin honeycomb core block C is formed as a product at the time of being cut, generation of unnecessary core material and defective cutting are not generated, so that it is economical without increasing the manufacturing cost. The shape (see FIG. 2 (c)) of the resin honeycomb core block 10 cut in the cutting step S3 will be described as a resin honeycomb core block C hereinafter.

  In the bonding step S4, the resin honeycomb core blocks C obtained by the cutting step in the previous step are bonded to each other, and a predetermined number of vertical and horizontal positions are arranged between the two face plates 32 having a predetermined size. Alternatively, it is a processing step for bonding by either welding.

  In the step of joining the resin honeycomb core blocks C to each other, a plurality of resin honeycomb core blocks C are arranged in accordance with the standard panel outer dimensions, and the outer frame bodies 21 of the adjacent resin honeycomb core blocks C are connected to each other. Are bonded with a resin adhesive. There are basically three types of external dimensions (thickness is a predetermined dimension): 30 cm × 30 cm, 60 cm × 60 cm, and 90 cm × 90 cm. (See Figure 3 for details)

  The step of arranging a predetermined number of horizontal and vertical faces between two face plates 32 of a predetermined size and connecting them is a process of combining the resin honeycomb core blocks C each having a predetermined size into two resin honeycomb core blocks C having a predetermined size. A predetermined number of vertical and horizontal positions are arranged between the face plates 32 and bonded by either the adhesive 24 or welding.

  When the two face plates 32 are wooden panels 30, the bonding method employs a method of applying an adhesive by spraying or brushing, and a method of thermally welding a sheet material containing the adhesive 24. When the face plate 32 is made of a resin panel 31, the sheet material containing the adhesive 24 is bonded by either a method of heat welding or a mechanical welding means such as ultrasonic welding or vibration welding. In addition, even if it is a metal panel such as thin aluminum or steel, the face plate can be cut with a shear stress that does not cause the resin honeycomb core block C to undergo compressive failure due to a stress such as shearing in the cutting step S3. As long as it can be processed by laser cutting, water jet, or the like, it is effective to bond the same as the wooden panel 30.

FIG. 2 is a completed drawing of the honeycomb panel according to the manufacturing process of the honeycomb panel in the present invention.
FIGS. 2A to 2E are a perspective view and a plan view of a resin honeycomb core block in each step. The resin honeycomb core block A formed in the extrusion molding step S1 has a long block shape as an outer shape, and a cross-sectional shape is formed by providing a honeycomb core next to the outer frame portion 21. . Further, by forming the thick part 22 filled with resin in a part of the outer frame part 21 or a part in the cell 20 at the extrusion molding step, a joining means by a joining member such as a nail, a screw, and a helisert becomes possible It can be formed into a structure that can be easily joined and attached to an external structure.

  In the resin honeycomb core block B filled with the foamed resin body 23 in the foamed resin body filling step S2, the foamed resin body 23 is filled with the general-purpose injection molding machine H. The body 23 can be surely filled, and the type of foamed resin body 23, the degree of foaming, and the curing time can be freely changed according to the specifications of the honeycomb panel 1. The production can be adjusted with this.

  Since the resin honeycomb core block C cut into a panel having a predetermined thickness in the cutting step S3 can be cut according to the standard thickness of the face plate 32 with a general-purpose cutting machine D (shearing, laser beam, water jet, etc.) Since the cut surface is flat and smooth, the bonding effect is high and the degree of freedom in designing the thickness is high. Further, the production can be adjusted for a while within the present process according to the demand.

  The resin honeycomb core block C bonded by either the adhesive layer or the welding in the bonding step S4 does not require the frame of the honeycomb panel 1 because the resin honeycomb core block C itself functions as a frame. In addition, since the bonding process is the final process of bonding the resin honeycomb core block 10 and the resin honeycomb core block 10 and the face plate 32, the operation of each process is further eliminated. It is possible to build an automatic production line that does not require manual work.

FIG. 3 is an explanatory view showing an embodiment of a honeycomb panel according to claim 1.
FIG. 3A is an explanatory view showing an embodiment in which the external dimensions of the resin honeycomb core block C are 30 cm × 30 cm (thickness is a predetermined dimension).
For example, in the case of the sub-block plate (90 cm × 180 cm), the resin honeycomb core block C is arranged 3 × 6 in length on the face plate 32, and the other face plate 32 is covered and bonded.

FIG. 3B is an explanatory view showing an embodiment in which the external dimensions of the resin honeycomb core block C are 60 cm × 60 cm (thickness is a predetermined dimension).
For example, in a bee board (120 cm × 240 cm), a resin honeycomb core block C is arranged in 2 × 4 on the face plate 32, and the other face plate 32 is covered and bonded.

FIG. 3 (c) is an explanatory view showing an embodiment in which the external dimensions of the resin honeycomb core block C are 90 cm × 90 cm (thickness is a predetermined dimension).
For example, in the case of a sub-block plate (90 cm × 180 cm), a resin honeycomb core block C is arranged in a vertical 1 × double 2 on the face plate 32 and the other face plate 32 is covered and bonded.

FIG. 4 is an explanatory view showing an embodiment of a honeycomb panel according to claim 2.
The honeycomb panel 1 manufactured by the method for manufacturing a honeycomb panel according to claim 2 is a wooden panel 30 in which the two face plates 32 in the joining step are a predetermined thickness, and the wooden panel 30 and the resin honeycomb core block C The joining means between the adjacent honeycomb core blocks C made of resin is a means using the adhesive 24.

  The use of the face plate 32 made of wood can be widely used as a building fixture, door, and flooring material for construction, as a concrete panel for foundation work, and as a building structure wall material. Further, by forming a thick portion 22 filled with resin in a part of the outer frame portion 21 or in a part of the cell 20 at the extrusion molding step, a joining means using a joining member such as a nail, a screw, and a helicate becomes possible. By displaying a mark point indicating the position of the thick portion 22 on the surface of the face plate 32, the honeycomb panel 1 that can be easily joined and attached to the external structure can be provided.

  As the adhesive 24 for bonding the resin honeycomb core block C and the wooden face plate 32, an epoxy resin adhesive is used, for example, Super X of Cemedine.

FIG. 5 is an explanatory view showing an embodiment of a honeycomb panel according to claim 3.
The honeycomb panel 1 manufactured by the method for manufacturing a honeycomb panel according to claim 3, wherein the two face plates 32 in the joining step are resin panels 31 having a predetermined thickness, and the resin panel 31 and the resin honeycomb core block The means for joining with C and the means for joining the adjacent resin honeycomb core blocks C adopt means by either the adhesive 24 or welding.

  As a bonding method for bonding the resin honeycomb core block C and the resin face plate 24, a method of applying by spraying or brush coating, a method of thermally welding a sheet material containing the adhesive 24, and ultrasonic welding Bonding is performed by any one of mechanical welding methods such as vibration welding.

  The method of applying by spraying or brushing is effective when it is produced in a small factory, and has an economic merit that it does not require initial capital investment.

  The method of adhering the sheet material containing the adhesive is that the entire resin honeycomb core block 10 is formed between the cell 20 and the outer frame portion 21 other than the foamed resin body 23 of one sheet material or resin honeycomb core block 10. It can be efficiently bonded or heat-welded using a sheet material that has been cut out.

  The mechanical welding methods such as ultrasonic welding and vibration welding are heat welding by mechanical welding means without using the conventional expensive adhesive 24, and cost is high, work load by a person, drying time, adhesion accuracy, etc. It is possible to solve this problem.

  As the material of each member used in the welding method, a low melting point resin is used for the resin honeycomb core block 10 and the face plate 32 and a high melting point foam resin is used for the foamed resin body 23 from the correlation of melting points. It is desirable.

  The method for manufacturing a honeycomb panel and the honeycomb panel using the honeycomb panel according to the present invention are not limited to a concrete panel for building construction, a building construction wall, a door, a flooring material, a building construction wall, an automobile, an aircraft, It can be widely used in all fields of honeycomb structural materials such as soundproofing / vibration-proofing materials for ships and railways, packing / conveying materials for transportation, and packaging materials for precision equipment. It is understood that the industrial applicability of the honeycomb panel is extremely large.

DESCRIPTION OF SYMBOLS 1 Honeycomb panel 10 Resin honeycomb core block 20 Cell 21 Outer frame part 22 Thick part 23 Foamed resin body 24 Adhesive 30 Wooden panel 31 Resin panel 32 Face plate S1
Extrusion process S2
Foamed resin body filling process S3
Cutting process S4
Bonding process A Resin honeycomb core block B Resin honeycomb core block C Resin honeycomb core block P Extrusion machine D General-purpose cutting machine H General-purpose injection molding machine

The present invention relates to a method for manufacturing a honeycomb panel in which cells of a honeycomb core material are filled with a foamed resin body, and has an outer frame portion having a predetermined size and is a block-shaped resin honeycomb that is long in both opening directions of the cell. Extrusion molding process for molding the core block A by extrusion, and a foamed resin body filling process for foaming and filling the foamed resin body into the cells of the long resin honeycomb core block A obtained by the extrusion molding process And a cutting step of cutting the long resin-made honeycomb core block B obtained by the foamed resin body filling step in a direction perpendicular to a direction connecting both side openings of the cells so as to form a panel with a predetermined thickness; In the case where the resin honeycomb core block C obtained by the cutting step is arranged with the cut surface and the face plate in surface contact between two face plates of a predetermined size , or when the two face plates are large Multiple resin cages The cam core block C is disposed between the two face plates with the cut surface and the face plate being in surface contact with each other in a predetermined length and width, and a means for joining the two face plates and the resin honeycomb core block C; The joining means of the resin honeycomb core block C adjacent to each other is composed of a joining step in which joining is performed by either adhesive or welding.

Further, a honeycomb panel manufactured by the manufacturing method of the honeycomb panel 請 Motomeko 1, wherein the two face plates in binding step is wood panel having a predetermined thickness, the wood panel made with the resin honeycomb core material It is also effective to adopt a means in which the joining means with the block C and the joining means between the adjacent resin-made honeycomb core blocks C are made of an adhesive .

Further, a honeycomb panel manufactured by the manufacturing method of the honeycomb panel 請 Motomeko 1, wherein two side plates in said binding step is a resin panel having a predetermined thickness, the resin panel and the resin-made honeycomb It is also effective to adopt means in which the joining means with the core material block C and the joining means between the resin honeycomb core material blocks C provided adjacent to each other are based on either an adhesive or welding .

Claims (3)

In the manufacturing method of the honeycomb panel in which the foamed resin body is filled in the cells of the honeycomb core material,
An extrusion step of forming a block-shaped resin honeycomb core block A having an outer frame portion of a predetermined dimension and elongated in both opening directions of the cells by extrusion;
A foamed resin body filling step of foaming and filling the foamed resin body into the cells of the long resinous honeycomb core block A obtained by the extrusion molding step;
A cutting step of cutting the long resin honeycomb core block B obtained by the foamed resin body filling step into a panel shape having a predetermined thickness;
A resin honeycomb core material block C obtained by the cutting step is disposed in a predetermined number of lengths and widths between two face plates of a predetermined size, and a bonding step in which these bonding means are bonded by either an adhesive or welding. ,
A method for manufacturing a honeycomb panel, comprising: A honeycomb panel manufactured by the method for manufacturing a honeycomb panel according to claim 1,
The two face plates in the joining step are wood panels having a predetermined thickness, joining means between the wooden panels and the resin honeycomb core block C, and joining between the resin honeycomb core blocks C provided next to each other. A honeycomb panel characterized in that the means are all made of an adhesive. A honeycomb panel manufactured by the method for manufacturing a honeycomb panel according to claim 1,
The two face plates in the joining step are resin panels having a predetermined thickness, the joining means between the resin panels and the resin honeycomb core block C, and the resin honeycomb core blocks C provided next to each other. The honeycomb panel is characterized in that the bonding means is based on either adhesive or welding.