JP3107473B2 - Method for manufacturing flexible honeycomb core and flexible honeycomb core - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a flexible honeycomb core and a method for manufacturing the same. That is, the present invention relates to a flexible honeycomb core which can be bent into a cubic curved surface or another complicated curved surface and is used for various devices and structural materials including an outer wall at the tip of a rocket, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Honeycomb cores are formed of planar aggregates of hollow columnar cells and have various characteristics such as excellent strength by weight, and are widely used for various applications. None, each cell typically has a prismatic shape such as a regular hexagon. By the way, when such a honeycomb core is bent into a curved surface, warpage, distortion, breakage, peeling, and the like are likely to occur, and it is extremely difficult to accurately bend a cubic curved surface and other complicated curved surfaces. Was. Conventionally, as such a honeycomb core for forming a curved surface, a flexible honeycomb core in which each cell wall is largely bent in the middle and each cell has a rounded and substantially convex shape ((2) in FIG. 2 described later) The flexible honeycomb core with such a special cell shape is easily and accurately formed without warping, distortion, breakage, peeling, etc., and has a cubic curved surface and other complicated curved surfaces. Could be bent.

[0003] Such a flexible honeycomb core has conventionally been manufactured as follows. First, a corrugated sheet in which special irregularities are continuously bent by processing a strip-shaped foil material (that is, a corrugated sheet matching the shape of the cell wall of the flexible honeycomb core) has been prepared. That is, by heating and pressing the foil material using a dedicated mold, a special corrugated sheet in which a large wave portion and a small wave portion of a predetermined shape are sequentially and continuously bent is formed in advance, and then the corrugated sheet is formed. After applying an adhesive to the top of the large wave part, a plurality of such corrugated sheets are stacked in a positional relationship where the upper and lower large wave parts and small wave parts overlap while maintaining the cell space, and then heated and pressed. By curing the adhesive and bonding the corrugated plates, a flexible honeycomb core has been manufactured in which each cell is bent in the middle and each cell has a rounded and substantially convex shape. In such a conventional flexible honeycomb core, a foil material made of aluminum or other metal is generally used as a base material. Recently, however, a fiber reinforced plastic (FRP) having excellent characteristics has been used. Attempts have also been made to use foil materials made of).

[0004]

The following problems have been pointed out in such a conventional example, particularly in a flexible honeycomb core using a fiber material made of fiber reinforced plastic and a method for manufacturing the same. First, a corrugated sheet in which a large wave portion and a small wave portion having a predetermined shape are successively bent (that is, a corrugated plate corresponding to the shape of a cell wall bent halfway in the final flexible honeycomb core). It is necessary to first form, but since such a corrugated sheet has a very special and complicated shape, the forming is very troublesome, requires time and time, and it is difficult to obtain a uniform shape. There was a problem. Second, similarly, in the conventional example, since the corrugated sheet formed in advance has a very special and complicated shape, the molding die also has a very special and complicated shape and structure, which increases the equipment cost. There was also. Third
In addition, an adhesive is further applied to the corrugated sheet. However, such an adhesive must be applied only to the large wave portion excluding the small wave portion, and it is not easy to form an automatic line. There is a problem that it is troublesome, requires time and effort, and is difficult to apply uniformly.

Fourthly, each of such corrugated sheets has been piled up. This piled up means that, for a plurality of corrugated sheets, the cell space exists and the upper and lower large wave portions and small wave portions are all formed. They must be carefully stacked so that they do not shift sequentially, so that they are in an overlapping positional relationship, and it is very troublesome, it takes time and effort, and it is difficult to stack them accurately in this way. There were problems such as being said. Fifth, since it is necessary to pay attention to the positional relationship between the stacked corrugated sheets having the cell space and maintaining the same, when the adhesive is cured by heating and pressing performed next,
It has been pointed out that a strong and sufficient pressure cannot be applied to each of the stacked corrugated sheets, which tends to cause insufficient heating and pressurization, and that the adhesive strength between the corrugated sheets is weak. And
Due to such first, second, third, fourth, and fifth points, the production of a conventional flexible honeycomb core made of fiber-reinforced plastic or the like is troublesome and requires labor and time. Difficulties were pointed out in terms of cost and cost, and uniform quality was not obtained and strength was uneasy.

The present invention has been made in view of such circumstances, and has been made in order to solve the problems of the above-mentioned conventional example. First, a composite material made of a combination of metal fiber and resin is used.
By passing between corrugated rollers, a general triangular corrugated sheet is formed utilizing the plastic deformation of metal fibers, and then such corrugated sheets are stacked and adhered, and then expanded. By adopting the method, first, it is easy to manufacture easily, it takes less time and effort, and it is excellent in cost, and it is also excellent in quality, such as uniform quality and improved strength. The purpose is to propose a manufacturing method.

[0007]

The technical means of the present invention for achieving this object is as follows. First, claim 1
Is as follows. That is, in this method for manufacturing a flexible honeycomb core, first, a band-shaped foil material made of a composite material in which a resin is combined with a metal fiber is passed between corrugated rollers, and the plastic deformation of the metal fiber is used to form a triangular waveform. A corrugated sheet is formed on a corrugated sheet having a continuously bent unevenness. Then, an adhesive is applied every other line on the top or the valley of the corrugated sheet, and the corrugated sheet is cut at a predetermined length, and then the position where the adhesive is applied is located above and below the corrugated sheet. After stacking a plurality of corrugated sheets in a positional relationship of being alternately shifted between corrugated sheets, the corrugated sheets are bonded by heating and pressing. Thereafter, the thus adhered corrugated sheet is stretched by applying a tensile force in the direction of stacking, whereby each cell wall is bent in the middle and each cell has a rounded, substantially convex shape. Thus, a flexible honeycomb core made of a hollow columnar planar assembly of the cells is obtained.

Next, claim 2 is as follows. That is, in the method for manufacturing a flexible honeycomb core, after the above-described step of claim 1, each cell wall of the flexible honeycomb core is further impregnated with a resin. Further, claim 3 is as follows.
That is, this flexible honeycomb core is formed of a planar aggregate of hollow columnar cells, and each cell wall is bent in the middle and each of the cells has a rounded substantially convex shape. The cell wall is made of a composite foil material in which a resin is combined with a metal fiber, and the foil material is passed between corrugated rollers to form a triangular waveform formed by utilizing plastic deformation of the metal fiber. The corrugated sheet is laminated, glued and spread.

[0009]

The present invention comprises the above-mentioned means, and operates as follows. In the present invention, first, a composite-made foil material in which a resin is combined with a metal fiber is passed between corrugated rollers to form a general triangular corrugated sheet using plastic deformation of the metal fiber. Then cut such corrugated sheet,
By adopting a method of stacking, bonding and then expanding, a flexible honeycomb core is manufactured in which each cell wall is bent in the middle and each cell has a rounded and substantially convex shape.

Therefore, in the present invention, first, since the corrugated sheet to be used has a general triangular waveform, it can be easily and easily formed by a corrugated roller, and has a uniform shape without any labor and time. Is obtained. Secondly, since the corrugated sheet has a general shape, the corrugated roller, which is a mold for forming the corrugated sheet, also has a gear structure having a general shape, so that the equipment cost is not increased. Third, the application of the adhesive to the corrugated sheet is easy and easy if it is performed every other section at the top or the valley, and uniform application is possible without any labor or time.

Fourth, the stacking of the corrugated sheet can be simply and easily performed by simply stacking the top and the valleys of the upper and lower parts closely together in a positional relationship in which the applied adhesive is shifted. Accurate intussusception is possible without the hassle and time. Fifth, the densely stacked corrugated sheets do not need to be kept in mind to maintain the positional relationship between them, so that when hardening the applied adhesive, strong and sufficient pressure is applied and insufficient heat and pressure is applied. And the bonding strength between corrugated sheets is increased. Sixth, in the second aspect, since the resin is further impregnated into each cell wall, the shape retention is further enhanced. These first, second, third, fourth,
According to the fifth and sixth aspects, in the present invention, the flexible honeycomb core is manufactured easily and easily without the need for labor and time, and is manufactured with uniform quality and improved strength.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in the drawings. Each drawing is provided for describing an embodiment of the present invention. In the front explanatory views of FIGS. 1 and 2, FIG. 1A shows a foil material, FIG. 1B shows a corrugated sheet, and FIG.
FIG. 3 (3) shows a corrugated sheet coated with an adhesive, FIG. 4 (4) shows a stacked corrugated sheet, FIG. 2 (1) shows each corrugated sheet heated and pressed, and FIG. The figure shows a flexible honeycomb core manufactured by stretching. FIG. 3 is an explanatory view of a corrugating step and an adhesive applying step, and FIG. 4 is an explanatory front view of a drying apparatus in a drying step. FIG. 5 is a process block diagram of the embodiment.

First, the preparation process will be described. In this manufacturing method, a band-shaped foil material 1 made of a composite material in which a resin is combined with a metal fiber is first prepared. The preparation process will be described in detail. As shown in FIG. 5, step 1, FIG. 1 (1), FIG. 3, etc., the foil material 1, which is a strip-shaped base material wound on the reel 2, is unwound. Then, it is formed into a flat band shape and supplied to a corrugated roller 3 described later. The metal fiber of the foil material 1 is typically made of aluminum, stainless steel, titanium, or the like, and is typically formed into a fiber having a diameter of about 0.1 to 100 microns. Furthermore, a blended material of such a metal fiber and a fiber other than a metal is also conceivable.
The base material is a metal fiber having a fiber amount of about 1% to 50% of the whole, and the remaining fiber is made of glass, carbon, boron, pulp, and other organic or inorganic materials. The weave of such fibers includes plain weave, satin weave, twill weave, etc., which are provided with warp and weft, uni-directional warp only, and other various weaves. Things are possible. Next, a phenol or other thermosetting resin is used as the resin of the foil material 1, and a resin that cures at a temperature higher than the curing temperature of an adhesive described later is selectively used. Then, the foil material 1 is prepared by immersing or impregnating such a metal fiber with a resin by a coating method so that the two are combined and the resin is prepared in a semi-cured prepreg state. Is supplied.

Next, the corrugating step will be described. In this manufacturing method, the foil material 1 prepared as described above is passed between the corrugated rollers 3, and by utilizing the plastic deformation of the metal fibers of the foil material 1, a wave in which triangular corrugations are continuously bent is formed. The plate 4 is corrugated. This corrugation forming step will be described in detail with reference to step 2 in FIG. 5, FIG. 1 (2), FIG. 3 and the like. First, the corrugated rollers 3 form an upper and lower pair, and are slightly enough to sandwich the foil material 1. The triangular corrugations, which are linearly arranged along the axial direction on the surface, form a substantially gear shape formed in parallel and continuously at a predetermined pitch and height, and are driven to rotate. And the foil material 1 is such a corrugated roller 3
While passing through the gap, it is processed using the plastic deformation of the metal fiber, so that it has, for example, a bending angle of 60 degrees with a radius, and a triangular corrugation with a predetermined pitch and height. Folded corrugated sheet 4 made of composite material
Is corrugated.

Next, the step of applying the adhesive 5 and the step of cutting will be described. That is, after such a corrugating process, the corrugated sheet 4 is bonded to the adhesive 5 shown in Step 3 of FIG.
It is sent to the coating process, and as shown in FIG.
The adhesive 5 is applied to the top or the valley every other line.
That is, in FIG. 3, reference numeral 6 denotes a tray for applying the adhesive 5, and the adhesive 5 in the tray 6 is applied to the surface of the rotating application roller 8 via the rotating pickup roller 7. By the convex portion 9 of the top or the valley of the triangular waveform of the corrugated plate 4,
It is applied every other line (in the example shown, it is applied to the top surface). In FIG. 3, reference numeral 10 denotes a backup roller. Thereafter, the corrugated sheet 4 to which the adhesive 5 has been applied as described above is subjected to a predetermined length by a cutter (not shown) in the cutting step shown in Step 4 of FIG. Each is cut into a long rectangular shape.

Next, the stacking step and the heating and pressing step will be described. Next, the corrugated sheet 4 that has been subjected to the above-described adhesive 5 applying step and cutting step is stacked in a plurality of sheets in a positional relationship in which the position where the adhesive 5 is applied is sequentially and alternately shifted between the upper and lower corrugated sheets 4. After that, the corrugated plates 4 are bonded by heating and pressing.
That is, in the stacking process, as shown in step 5 of FIG. 5 and FIG. 1 (4), the positional relationship in which a plurality of corrugated sheets 4 are shifted by one wave from top to bottom every time one stage is stacked, 1
The adhesive 5 applied on every other row is densely stacked in a multilayer block shape while the tops and the valleys are aligned with each other in a positional relationship where the adhesive 5 is shifted left and right between upper and lower sides. Thereafter, the corrugated sheet 4 stacked in this stacking process is interposed between the upper and lower plates 12 in the heating and pressurizing process, as shown in step 6 of FIG. 5 and FIG. After that, plate 1
The adhesive 2 is heated and pressurized by moving up and down, and the adhesive 5 is melt-hardened by hot pressing, so that the stacked corrugated plates 4 are bonded between the tops in the illustrated example.

Next, the expanding step will be described. Following the stacking process and the heating and pressing process as described above, the stacked and bonded corrugated plates 4 are stretched by applying a tensile force in the stacking direction. That is, as shown in step 7 of FIG. 5 and FIG. 2 (2), a tensile force is applied to the corrugated plate 4 that is stacked and partially adhered, with the stacking direction being the extension direction. Thereby, the non-adhesive portion of each corrugated sheet 4 is stretched, deformed, separated, and separated. By such corrugated sheet 4, the flexible honeycomb core 15 is obtained in which each cell wall 13 is largely bent while keeping a radius in the middle, and each cell 14 has a rounded and substantially convex shape.

Finally, the impregnation step and the drying step will be described. In the illustrated example, the flexible honeycomb core 15 thus obtained is further immersed in a resin in the impregnation step of step 8 in FIG.
3 is impregnated with a resin. then,
The flexible honeycomb core 15 is completed in step 10 by being dried in the drying step of step 9 in FIG. FIG. 4 shows a drying chamber 16 in such a drying step, in which a flow of air F composed of hot air for drying is formed by a fan E for drying, and the flexible honeycomb core 15 impregnated with resin is: It is dried in such a drying chamber 16.

Now, the flexible honeycomb core 15 is manufactured in this manner. This flexible honeycomb core 15 is formed of a planar assembly of hollow columnar cells 14, and each cell wall 13 is bent while keeping a radius on the way,
Each cell 14 has a rounded and substantially convex shape. The cell wall 13 is made of a composite foil material 1 in which a resin is combined with a metal fiber, and the foil material 1 is passed between corrugated rollers 3 to be formed by utilizing the plastic deformation of the metal fiber. It is manufactured by stacking, bonding, and spreading corrugated sheets 4 having a triangular waveform. And, like the general honeycomb core, the flexible honeycomb core 15 is excellent in weight ratio strength, has high rigidity and strength as well as light weight, and is excellent in rectification effect, heat insulation, sound insulation, etc. It has characteristics such as a large surface area per volume.

The present invention has been described above. Then, it becomes as follows. In the flexible honeycomb core 15 and the method of manufacturing the same, first, a composite foil material 1 in which a metal fiber is combined with a resin is passed between corrugated rollers 3 in a corrugation forming step, and is processed using plastic deformation of the metal fiber. By doing so, the corrugated corrugated plate 4 in which the triangular waveforms are continuously bent with a radius is formed. Then, the corrugated sheet 4 is applied in the adhesive 5 applying step.
After the adhesive 5 is applied to the sheet and the corrugated sheet 4 is cut in the cutting step, a plurality of sheets are stacked in the stacking step, and they are bonded to each other by heating and pressing in the heating and pressing step. Thus, the flexible honeycomb core 15 in which each cell wall 13 is bent with a radius in the middle and each cell 14 has a rounded and substantially convex shape is produced. The flexible honeycomb core 15 can be easily and accurately formed into a cubic curved surface or another complicated curved surface. By the way, this flexible honeycomb core 1
5 and the manufacturing method thereof are as follows in the first, second, third, fourth, fifth and sixth.

First, the corrugated sheet 4 to be used has a monotonous shape in which a very common triangular waveform is continuously bent. Therefore, the corrugated plate 4 has a special and complicated shape in which the large wave portion and the small wave portion are continuously bent as in the above-described conventional example (that is, the cell wall of the final flexible honeycomb core 15). Compared to the conventional corrugated sheet 13), the corrugated roller 3 can be easily and easily formed by using the corrugated roller 3, and a uniform shape can be obtained without any trouble and time.

Secondly, since the corrugated sheet 4 has a monotonous shape in which a general triangular waveform is continuously bent, a corrugated roller 3 which is a molding die of such a corrugated sheet 4 is used. Also have a gear structure of a general shape. Therefore, this corrugated roller 3 is different from a mold having a special and complicated shape and structure like the molding die in the above-mentioned conventional example, and the equipment cost is not increased.

Third, the application of the adhesive 5 to the corrugated plate 4 may be performed every other line at the top or the valley. In other words, the application of the adhesive 5 is required to be performed only for the large wave portion excluding the small wave portion as in the above-described conventional example, and it is easy and easy to perform unlike the automatic line forming is not easy. It is possible to perform the coating uniformly without requiring any labor and time.

Fourthly, such an accumulation of the corrugated sheets 4 can be achieved by simply aligning the upper and lower tops and valleys in a positional relationship in which the applied adhesive 5 is displaced, without leaving any space. It is done by going over. In this way, the stacking of the corrugated sheet 4 is, as in the stacking in the above-described conventional example, such that a space exists between a plurality of sheets and the upper and lower large wave portions and small wave portions are all overlapped with each other. It is easy and easy to carry out without the necessity of carefully stacking up and down one by one so as not to be displaced from top to bottom, and accurate lamination is possible without labor and time.

Fifth, since the corrugated sheets 4 densely stacked in this way do not need to pay attention to the positional relationship between them and their maintenance, the bonding between the stacked corrugated sheets 4 is not required. That is, a strong and sufficient pressure can be applied when the applied adhesive 5 is cured. As described above, the bonding between the corrugated sheets 4 is performed in order to maintain the positional relationship between the stacked members having a space and maintaining the same as in the bonding in the above-described conventional example.
Unlike the case where a strong and sufficient pressure cannot be applied, the heating and pressurizing can be performed without shortage, and the adhesive strength between the corrugated plates 4 is increased.

Sixth, in the illustrated example, since the cell walls 13 are impregnated with the resin, the shape retention is further enhanced. Further, in the illustrated example, the heating and pressurizing step and the drying step after the impregnation of the resin result in curing by heating twice, so that the resin of the flexible honeycomb core 15 can be more reliably and uniformly formed. It also has the advantage of being cured.

According to the first, second, third, fourth, fifth, and sixth examples in the illustrated example, in the present invention, in the present invention, each cell wall 13 is bent with a radius in the middle and each cell wall 13 is bent. The flexible honeycomb core 15 made of a composite material having a special cell 14 shape, in which the cells 14 have a rounded and substantially convex shape, is simple and easy, does not require labor and time, and has uniform quality and improved strength. Manufactured.

[0028]

As described above, the flexible honeycomb core and the method of manufacturing the same according to the first, second, and third aspects of the present invention provide a composite material obtained by combining a metal fiber and a resin with a corrugated roller. First, by passing
By utilizing the plastic deformation of metal fibers to form a corrugated sheet with a general triangular corrugation, and then stacking and bonding such corrugated sheets, and then using a method of stretching, Demonstrate the effect of.

First, the formation of the corrugated sheet is simple and easy, and a corrugated sheet having a uniform shape can be obtained without any labor or time. Second,
The corrugated roller, which is a corrugating mold, has a gear structure of a general shape, is obtained at a low cost, and does not increase the equipment cost. Third, the application of the adhesive to the corrugated plate is simple and easy, and uniform application is possible without any labor or time. Fourth, the stacking of corrugated sheets is simple and easy, and accurate stacking is possible without the need for labor and time. Fifth, the heating and pressurizing of the stacked corrugated sheets can be carried out without sufficient shortage, and the adhesive strength between the corrugated sheets is strong. Sixth, since the flexible honeycomb core manufactured in claim 2 is impregnated with a resin, the flexible honeycomb core has stronger shape retention.

According to the first, second, third, fourth, fifth, and sixth aspects, the flexible honeycomb core made of a composite material in which the resin is combined with the metal fiber according to the present invention. And its manufacturing method, first, it is inexpensive and excellent in cost, for example, it can be easily and easily manufactured and requires no labor or time, and furthermore, it is possible to obtain a product with uniform quality and improved strength. The surface is also excellent. In this way, the problems existing in this kind of conventional example are wiped out,
The effects exhibited by the present invention are remarkably large.

[Brief description of the drawings]

FIG. 1 is an explanatory front view for explaining an example of a method for manufacturing a flexible honeycomb core according to the present invention;
(1) shows a foil material, (2) shows a corrugated sheet, (3) shows a corrugated sheet coated with an adhesive, and (4) shows a stacked corrugated sheet.

FIG. 2 is an explanatory front view for explaining the embodiment;
FIG. 1A shows each corrugated sheet to be heated and pressed, and FIG. 2B shows a flexible honeycomb core manufactured by stretching.

FIG. 3 is a process explanatory view of a corrugate forming step and an adhesive applying step in the embodiment.

FIG. 4 is an explanatory front view of a drying device used in a drying step.

FIG. 5 is a process block diagram of the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Foil material 2 Reel 3 Corrugated roller 4 Corrugated plate 5 Adhesive 6 Tray 7 Pickup roller 8 Application roller 9 Convex part 10 Backup roller 12 Plate 13 Cell wall 14 Cell 15 Flexible honeycomb core 16 Drying room E Fan F Air flow

Claims (3)

(57) [Claims] First, a strip-shaped foil material made of a composite material in which a resin is combined with a metal fiber is passed between corrugated rollers, and the triangular corrugations are continuously folded by utilizing the plastic deformation of the metal fiber. The corrugated corrugated sheet is formed into a corrugated sheet. Next, an adhesive is applied to every other part of the corrugated sheet at the top or the valley, and the corrugated sheet is cut at a predetermined length. After stacking a plurality of the corrugated sheets in a positional relationship where the position where the agent is applied is alternately shifted between the upper and lower corrugated sheets, the corrugated sheets are bonded by heating and pressing, and then, The corrugated sheet thus adhered is stretched by applying a tensile force in the direction of stacking, whereby each cell wall is bent in the middle and each cell has a rounded, substantially convex shape, a hollow columnar shape. Obtaining a flexible honeycomb core comprising a planar assembly of the cells of Manufacturing method of a flexible honeycomb core. 2. The method for manufacturing a flexible honeycomb core according to claim 1, further comprising: impregnating each cell wall of the flexible honeycomb core with a resin after the step of the above-described method. 3. A flexible honeycomb core comprising a planar aggregate of hollow columnar cells, wherein each cell wall is bent in the middle and each cell has a rounded and substantially convex shape, wherein said cell wall is Is made of a composite material made of a metal fiber and a resin, and the triangular corrugated corrugated sheet formed by passing the foil material between the corrugated rollers and utilizing the plastic deformation of the metal fiber is weighted. Flexible honeycomb core characterized by being stacked, glued and expanded.