JP3143009B2 - Manufacturing method of honeycomb core - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a honeycomb core. That is, the present invention relates to a method for manufacturing a honeycomb core using a prepreg sheet of fiber reinforced plastic as a base material.

[0002]

2. Description of the Related Art Honeycomb cores of this kind have conventionally been manufactured by the following corrugation method or expansion method. First
In the corrugated method, a prepreg sheet of fiber reinforced plastic as a base material is first heated and pressed by a gear or a rack to be continuously bent into a corrugated sheet.
The corrugated sheet is cut into fixed dimensions, and the valleys and the tops are laminated together with the adhesive applied in the form of striations, and then laminated by heating and pressing at the melting point temperature of the interposed adhesive. Honeycomb cores have been manufactured by bonding between the plates. Secondly, in the stretching method, an adhesive is applied to a prepreg sheet of a fiber-reinforced plastic as a base material in the form of striations, then stacked while being shifted by a half pitch, and then heated and pressed at the melting point temperature of the adhesive. The honeycomb core was manufactured by adhering and then expanding in the direction of stacking. In addition, in such a corrugated system or an expansion system,
In any case, as a post-treatment, a polymerizable substance such as a phenol resin is attached and impregnated as a post-treatment on the manufactured honeycomb core to reinforce the rigidity and strength and replenish the weight in many cases.

[0003]

The following problems have been pointed out in such a conventional example. First, the above-mentioned corrugation method is as follows. That is, in the corrugating method, in the bonding step of bonding by heating and pressing at the melting point temperature of the adhesive interposed the laminated corrugated sheet, the corrugated sheet laminated by bending a prepreg sheet of fiber reinforced plastic is When it is sandwiched from above and below for adhesion and pressed, it is easily deformed and displaced by the pressure. As a result, the cell walls and cells formed by the corrugated sheet are deformed and displaced, causing irregularities, disorder in arrangement, displacement, crushing, breakage, etc., and in particular, the bonding position of the striations by the adhesive is incorrect. Thus, there has been a large problem in accuracy and quality of the honeycomb core, such as misalignment.

[0004] Second, the expansion method described above is as follows. In other words, in the stretching method, in the stretching step of applying a tensile force in the stacking direction, if the thickness of the stacked fiber-reinforced plastic prepreg sheet is large or the rigidity is high, the flexibility is insufficient and the stretching is difficult. In many cases, the honeycomb core cannot be manufactured. Further, in the case of the stretching method, as in the corrugating method described above, a complicated cell wall structure or cell in which a corrugated sheet and a flat sheet made of a fiber-reinforced plastic prepreg sheet as a base material are alternately laminated and adhered. There was also a disadvantage that a honeycomb core having a structure could not be manufactured.

The present invention has been made in view of such circumstances, and has been made to solve the above-mentioned problems of the prior art. After forming a prepreg sheet of fiber-reinforced plastic into a corrugated sheet, the sheet is laminated and bonded. In addition to the use of a corrugated system, a polymerizable substance is adhered and impregnated after forming into a corrugated sheet and before lamination and bonding.
Accordingly, the present invention is, firstly, to prevent the deformation and displacement of the cell walls and cells, and secondly, to realize a simple and smooth realization of a complicated structure and to easily obtain a complicated structure. It is an object of the present invention to propose a method for manufacturing a honeycomb core.

[0006]

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 of manufacturing a honeycomb core, first, a prepreg sheet of fiber-reinforced plastic as a base material is formed into a corrugated sheet in which corrugations are continuously bent, and then the corrugated sheet is polymerized. After the adhesive is impregnated and impregnated, an adhesive is streaked on the top and the valley of the corrugated sheet. Thereafter, a plurality of the corrugated sheets are laminated on top and bottom with the valley and the top together, and then bonded by heating and pressing to obtain a honeycomb core which is a planar aggregate of hollow columnar cells. .

[0007] Claim 2 is as follows. That is, in this method for manufacturing a honeycomb core, first, a prepreg sheet of fiber-reinforced plastic as a base material is formed into a corrugated sheet in which corrugations are continuously bent, and then,
After the polymerizable substance is attached to and impregnated on the corrugated sheet, an adhesive is stuck on the top and the valley of the corrugated sheet. Thereafter, a plurality of the corrugated sheets and a plurality of flat sheets of a fiber-reinforced plastic prepreg sheet as a base material, which are pre-coated and impregnated with a polymerizable substance while being flat, are alternately laminated. Then, by heating and pressing and bonding, a honeycomb core which is a planar assembly of hollow columnar cells is obtained.

[0008]

The present invention comprises the above-mentioned means, and operates as follows. That is, according to the production method of the present invention, after a prepreg sheet of a fiber-reinforced plastic as a base material is formed into a corrugated sheet, an adhesive is attached thereto.
Then, only a plurality of such corrugated sheets are laminated,
In this method, a plurality of such corrugated sheets and flat prepreg sheets are alternately laminated, and then heated and pressed to be bonded, whereby a honeycomb core made of fiber-reinforced plastic is manufactured.

In the manufacturing method of the present invention, the polymerizable substance is attached to and impregnated into the prepreg sheet after the forming process on the corrugated sheet and before the attachment, lamination, and bonding of the adhesive. Also, the flat plate of the prepreg sheet according to the second aspect has a polymerizable substance attached and impregnated before lamination and bonding. Therefore, in this honeycomb core manufacturing method,
The following are the first and second cases.

First, in the production method of the present invention, the prepreg sheet as a base material is reinforced with a polymer material adhered and impregnated to increase rigidity and strength, and then laminated as a corrugated plate or a flat plate. Are bonded by heating and pressing. Therefore, the prepreg sheet as a base material is corrugated or flat.
Even if it is sandwiched from above and below and heated and pressed for bonding, it is reinforced in this way, so that it does not deform or displace due to the pressure, and deformation and displacement of the cell wall and cells are prevented.

Second, in the manufacturing method of the present invention, since the honeycomb core is manufactured by the corrugated method, even when the thickness of the prepreg sheet is large or the rigidity is high, the honeycomb core is easier and smoother than the spread method. Manufacturable. Further, as described in the second aspect, a complicated cell wall structure or a honeycomb core having a cell structure in which corrugated plates and flat plates using a prepreg sheet as a base material are alternately laminated can be easily manufactured.

[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. The drawings are provided for explanation of embodiments of the present invention, and FIG. 1 (1) is a perspective view of a prepreg sheet,
(2) is a perspective view of a corrugated plate, (3) is a front view of a dipping process, and (4) is a front view of a drying and curing process.
FIG. 2A is an explanatory front view of a step of applying an adhesive;
FIG. 2B is an explanatory front view of the laminating step, and FIG. 3C is an explanatory front view of the bonding step. FIG. 3 provides a description of another embodiment,
FIG. 1A is an explanatory front view of an adhesive applying step, and FIG. 2B is an explanatory front view of a laminating step. FIG. 4 is a perspective view of the honeycomb core.

In this manufacturing method, first, a prepreg sheet 1 of a fiber-reinforced plastic as a base material shown in FIG. 1 (1) is made to have corrugated irregularities as shown in FIG. 1 (2). It is formed into a corrugated sheet 2 which is bent and formed. These are described in detail below.
A typical example of P) is a combination of a glass fiber, a Kevlar fiber, a carbon fiber, and other base fibers with a phenol resin, an epoxy resin, a polyimide resin, and other resins by adhesion and impregnation. The prepreg sheet 1 of such a fiber-reinforced plastic is heated and softened to be viscous, is in a semi-cured state, and is prepared as a flat plate 3 having an extremely thin and flat band-like sheet shape. The prepreg sheet 1 made of fiber reinforced plastic, which is the flat plate 3 prepared as described above, is heated and pressed by a corrugating device provided with a molding die such as a gear rack, a corrugated belt, etc., and is formed into a corrugated sheet 2. Is done.
In other words, the corrugated plate 2 is a corrugated plate 2 in which corrugations such as a trapezoidal shape as shown in the figure, a triangular shape, or other shapes are continuously bent at a predetermined pitch and height.
Is cooled and hardened after the fact.

Next, in this manufacturing method, FIG.
(4) As shown in the figure, the corrugated sheet 2 thus formed
The polymerizable substance 4 adheres and is impregnated. That is,
The corrugated sheet 2 is immersed in a bath 5 of a solution of a phenolic resin or other polymerizable substance 4 to adhere and impregnate the polymerizable substance 4. The corrugated sheet 2 on which the polymerizable substance 4 is adhered and impregnated is removed from the bath 5 and then dried and heated by the heat source 6 in the processing chamber. It cures while the surface of is coated. The adhesion and impregnation of the polymerizable substance 4 are repeatedly performed until the required rigidity, strength and weight are reached.

Then, in this manufacturing method, as shown in FIG. 2A, an adhesive is applied to the top and the valley of the corrugated sheet 2 on which the polymerizable substance 4 is adhered and impregnated. 7 is provided in the form of a stripe by coating or the like. In the illustrated example, the adhesive 7
Is applied to each top of the corrugated sheet 2 in the form of striations by a coating roll 8 and dried, and the corrugated sheet 2 is cut at regular intervals after the fact.

Then, in this manufacturing method, FIG.
As shown in the figure, a plurality of such corrugated sheets 2 are stacked up and down with the respective valleys and tops aligned. That is,
Each corrugated sheet 2 is laminated with an adhesive 7 therebetween, so that the corrugated sheet 2 has a block shape with a space as a whole.

Thereafter, in this manufacturing method, FIG.
As shown in FIG.
Is heated and pressed at the melting point temperature of the adhesive 7 in a furnace or the like, whereby the adhesive 7 is melt-hardened, so that the laminated corrugated sheets 2 are bonded to each other. In addition, when the pressurizing pressure at the time of this bonding is high and there is a possibility of deformation of the laminated corrugated sheet 2, both ends are restricted.

By approaching each of these steps, as shown in FIG. 4, the corrugated plate 2 is used as a cell wall 9, and a planar aggregate of hollow columnar cells 10 divided into independent spaces is formed. A honeycomb core 11 made of fiber reinforced plastic
Is manufactured. That is, the honeycomb core 11 is formed by laminating and adhering a prepreg sheet 1 which is formed into a corrugated sheet 2 in which corrugated irregularities are continuously bent and to which a polymerizable substance 4 is previously adhered and impregnated. Become. The cell 10
The cross-sectional shape of the cell wall 9 may be triangular, quadrangular, trapezoidal, or other various shapes in addition to the hexagonal shape shown in the figure. And the honeycomb core 11 is generally excellent in weight ratio strength, is lightweight and has high rigidity and strength,
In addition, it is known that it has excellent rectifying effect, flatness accuracy, heat insulation, sound insulation, and a large surface area per unit volume. The honeycomb core 11 made of fiber reinforced plastic is reinforced with fibers, and therefore has particularly excellent strength by weight.

Next, another embodiment of the present invention will be described with reference to FIG. In the manufacturing method of the embodiment of FIG. 3, first, the prepreg sheet 1 of fiber-reinforced plastic as a base material is formed by continuously bending corrugated irregularities in the same manner as described in the embodiment of FIG. The corrugated sheet 2 is formed and processed, and then the polymerizable substance 4 is adhered to and impregnated into the corrugated sheet 2, and then the adhesive 7 is applied to the tops and valleys of the corrugated sheet 2 in a line-like manner. Attached. As shown in FIG. 3A, the adhesive 7 is applied to the outer surface of both the top and the valley of the corrugated sheet 2 by the application roll 8 (see each drawing of FIG. 1). ). Next, in the embodiment of FIG. 3, instead of laminating only the corrugated sheet 2 as in the embodiment of FIG. 2 described above, as shown in FIG. 2 and a flat plate 3 of a fiber-reinforced plastic prepreg sheet 1 (see FIG. 1 (1)) as another base material which is previously flat and pre-adhered and impregnated with a polymerizable substance 4 so as to be alternately positioned. Laminated. Then, by applying heat and pressure, the corrugated plate 2 and the flat plate 3 are bonded with the adhesive 7 which has been melt-hardened.

In the embodiment shown in FIG. 3, the honeycomb core 1 made of fiber-reinforced plastic is pressed by approaching such a process.
1 is manufactured. The honeycomb core 11 has a hollow columnar cell 10 similar to the embodiment of FIG.
A cell wall 9 forming a cell 10
As a base material, a prepreg sheet 1 of fiber reinforced plastic is used. The honeycomb core 11 of the embodiment shown in FIG. 3 is formed into a corrugated sheet 2 and pre-polymerized, unlike the above-described embodiment of FIG. 2 in which only the corrugated sheet 2 is laminated (see FIG. 4). The prepreg sheet 1 as a base material to which the polymerizable substance 4 is attached and impregnated, and the prepreg sheet 1 as another base material to which the polymerizable substance 4 is previously adhered and impregnated as a flat plate 3 are alternately laminated. ((2) in FIG. 3)
See figure). The honeycomb core 11 of the embodiment shown in FIG.
And other methods of manufacturing the same are shown in FIG.
Therefore, the same reference numerals are given and the description thereof is omitted.

The present invention has been described above. Then, it becomes as follows. That is, in the manufacturing method of the present invention, the honeycomb core 11 made of fiber reinforced plastic is obtained by forming the prepreg sheet 1 of fiber reinforced plastic as a base material into the corrugated sheet 2 and then attaching the adhesive 7 thereto. In the second embodiment, a plurality of such corrugated sheets 2 are used.
In the embodiment of FIG. 3, a plurality of such corrugated plates 2 and the flat plates 3 of the pre-flex sheet 1 that are flat are alternately laminated, and then heated and pressed to adhere. It is manufactured as a planar assembly of hollow columnar cells 10 formed by the cell walls 9. Here, the polymerizable substance 4 is adhered to and impregnated into the prepreg sheet 1 after the forming process on the corrugated sheet 2 and before the attachment, lamination, and adhesion of the adhesive 7. The prepreg sheet 1 as it is in the flat plate 3 of the embodiment of FIG. 3 also has a polymerizable substance 4 attached and impregnated before lamination and bonding. Therefore, the method of manufacturing the honeycomb core 11 is as follows.

First, in this manufacturing method, the prepreg sheet 1 serving as a base material is reinforced by the adhered and impregnated polymerizable substance 4 to increase rigidity and strength, and then laminated and bonded by heating and pressing. Is done. Therefore, as corrugated plate 2 or flat plate 3,
Even if it is sandwiched from above and below and heated and pressed for bonding, it is reinforced in this manner, so that it is not deformed or displaced by the pressure. Therefore, the deformation and displacement of the cell wall 9 and the cell 10 of the honeycomb core 11, which have been pointed out in the above-mentioned conventional example of the corrugated system, are surely prevented.

Second, in this manufacturing method, since the honeycomb core 11 is manufactured by the corrugated method as described above,
As pointed out in the above-described conventional example of the stretching method, when the thickness of the prepreg sheet 1 as the base material is large or the rigidity is high, the production is not difficult, and the production is easy and smooth. Manufacturable. Further, as shown in the embodiment of FIG. 3, a honeycomb having a complicated cell wall 9 or cell 10 structure in which corrugated plates 2 and flat plates 3 each having a prepreg sheet 1 as a base material are alternately laminated and bonded. Core 1
1 can also be easily manufactured.

[0024]

As described above, the method for manufacturing a honeycomb core according to the present invention employs a corrugated method in which a prepreg sheet of fiber-reinforced plastic is formed into a corrugated sheet, and then laminated and bonded. The following effects are exerted by adhering and impregnating the polymerizable substance after forming into the corrugated sheet and before laminating and bonding.

First, deformation and displacement of the cell walls and cells are prevented. That is, in the case of the honeycomb core made of fiber reinforced plastic manufactured by this manufacturing method, irregularities in cell walls and cells, irregular arrangement, misalignment, displacement, crushing, and breakage, which were pointed out in the above-described conventional example of this type, were observed. And so on, and particularly the so-called misalignment does not occur because the striation line bonding position is accurate. Thus, a honeycomb core excellent in accuracy and quality can be obtained.

Secondly, this can be realized easily and smoothly, and a complicated structure can be easily obtained. That is, the above-described honeycomb core excellent in accuracy and crystalline surface is manufactured by a simple and easy manufacturing method, and is excellent in manufacturing cost. Further, even when the prepreg sheet is thick or has high rigidity as compared with the above-described conventional example of this type, the prepreg sheet can be manufactured smoothly without any problem. Furthermore, a honeycomb core having a complicated cell wall or cell structure in which corrugated plates and flat plates are alternately laminated and bonded can be easily manufactured. As described above, the effects exhibited by the present invention are remarkably large, for example, the problems existing in this type of conventional example are eliminated.

[Brief description of the drawings]

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is provided for describing an embodiment of a method for manufacturing a honeycomb core according to the present invention, and FIG. 1 (1) is a perspective view of a prepreg sheet,
(2) is a perspective view of a corrugated plate, (3) is a front view of a dipping process, and (4) is a front view of a drying and curing process.

FIG. 2 is an explanatory front view for explaining the embodiment;
FIG. 1A shows an adhesive application step, FIG. 2B shows a lamination step, and FIG. 3C shows an adhesion step.

FIGS. 3A and 3B are front explanatory views for explaining another embodiment of the present invention, wherein FIG. 3A shows an adhesive applying step, and FIG. 3B shows a laminating step.

FIG. 4 is a perspective view of a honeycomb core.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 prepreg sheet 2 corrugated plate 3 flat plate 4 polymerizable substance 5 bathtub 6 heat source 7 adhesive 8 coating roll 9 cell wall 10 cell 11 honeycomb core

Claims (2)

(57) [Claims] First, a prepreg sheet made of fiber reinforced plastic as a base material is formed into a corrugated sheet in which corrugations are continuously bent, and then a polymerizable substance is attached to the corrugated sheet. After impregnating, after applying an adhesive to the tops and valleys of the corrugated sheet in the form of striations, a plurality of the corrugated sheets are stacked up and down together with the valleys and tops, and then heated and pressed. To obtain a honeycomb core, which is a planar assembly of hollow columnar cells,
A method for manufacturing a honeycomb core, comprising: 2. First, a prepreg sheet of fiber reinforced plastic as a base material is formed into a corrugated sheet in which corrugations are continuously bent, and then a polymerizable substance is adhered to the corrugated sheet. After the impregnation, an adhesive is applied to the top and the valley of the corrugated sheet in the form of striations, and a polymerizable substance adheres to a plurality of corrugated sheets in advance while remaining flat.
By laminating a plurality of impregnated prepreg sheets of fiber-reinforced plastic, which are different base materials, so that they are alternately positioned, and then bonding them by applying heat and pressure, a planar assembly of hollow columnar cells is formed. Obtaining a honeycomb core as a body.