JP3148477B2 - Light-weight reinforcing material, light-weight structure using the same, and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the structure of a lightweight reinforcing material and the structure and manufacture of a lightweight structure having a surface material on at least one surface of the lightweight reinforcing material.

[0002]

2. Description of the Related Art Conventionally, a lightweight structure 1 having a surface material on at least one surface of a lightweight structure is shown in FIGS.
The honeycomb structure 9 or the cardboard board 10 as shown in FIG. As shown in FIG. 21, the honeycomb structure 9
Is filled with a honeycomb having a hexagonal column space at right angles to the surface material as a lightweight reinforcing material 33 between opposing plate-shaped surface materials 2, and the surface material 2 and the lightweight reinforcing material 33 are joined and integrated. Have been.

FIG. 22 shows another example of weight reduction, which is a cardboard board 10 in which a corrugated lightweight reinforcing material 34 is filled between plate-shaped surface materials 2. The surface material 2 and the corrugated lightweight reinforcing material 34 are linearly joined at a portion where they are in contact with each other.

[0004]

In each of these conventional examples, a light-weight reinforcing material is filled between substantially parallel flat plate-like surface materials 2 so as to be filled between uneven surface materials or curved surfaces. However, it has been difficult to manufacture a lightweight structure in which a lightweight reinforcing material is filled between surface materials that are not parallel to each other. In addition, the honeycomb structure is advantageous in strength and weight reduction, but is costly in structure, and the cardboard structure is advantageous in cost, but has directionality in load resistance or bending strength. Had such problems.

[0005] The present invention, on the surface material with a non-parallel surface material between or irregularities or curved can be applied, lighter, hard
Before curing, deformation is easier, and after curing, strength is increased in all directions.
High, while providing an inexpensive lightweight reinforcement using the lightweight reinforcement, it is an object of the strength in any direction in lightweight high and to provide an inexpensive lightweight structure and a manufacturing method thereof.

[0006]

The lightweight reinforcing material according to the first aspect of the present invention is made of a melt-processed open cell.
The main part of the plastic foam is covered with a curable resin.

[0007] Lightweight structure according to a second aspect of the invention, dissolved
Processed plastic cell made of open cells
Mainly skeleton of Omu is cured covered with the curable resin
At least one surface of the lightweight reinforcing material is provided with a surface material.

According to a third aspect of the present invention, there is provided a method of manufacturing a lightweight structure, comprising a process for forming a melt-processed open cell.
An open cell made by impregnating a stick foam with an uncured curable resin and mainly processing the above solution.
Lightweight reinforcement covering the skeleton of Tic Foam with curable resin
, A step of laminating a surface material on at least one surface of the lightweight reinforcing material , and a step of curing the uncured curable resin.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a lightweight structure, wherein an uncured curable resin is cured while pressing a surface material.

[0010] According to a fifth aspect of the present invention, there is provided a method for manufacturing a lightweight structure, comprising:
An open cell made by impregnating a stick foam with an uncured curable resin and mainly processing the above solution.
Lightweight reinforcement brewing covering the skeleton of ticks form a curable resin
, A step of curing the uncured curable resin, and a step of laminating a surface material on at least one surface of the lightweight reinforcing material obtained by curing the curable resin.

[0011] According to a sixth aspect of the present invention, there is provided a lightweight structure.
Item 2. The surface material is box-shaped.

According to a seventh aspect of the present invention, there is provided a lightweight structure.
Item 2. The surface material has a cylindrical shape.

[0013] The lightweight structure according to the invention of claim 8 is characterized in that
Item 2, Item 6, or Item 7, wherein the surface material has irregularities.

A method for manufacturing a lightweight structure according to the invention of claim 9
The method according to claim 5, wherein the curable resin is cured.
Lightweight reinforcement material conforms to the shape of the surface material and the protected body
In this way .

The lightweight structure Zotai according to the invention of claim 10,請
Claim 2, claim 6, claim 7, or claim 8
, A lightweight reinforcing material containing a protected body between surface materials
It is filled .

The lightweight structure according to the invention of claim 11 is a
Claim 2, Claim 6, Claim 7, Claim 8, or Claim 1
0, a facing, a lightweight reinforcement, and
At least any two of the protected objects are bonded with an adhesive.
Is what it is.

The lightweight reinforcing material according to the twelfth aspect of the present invention is
The curable resin according to claim 1, wherein the curable resin is cured by at least one of heat, ultraviolet light, and electron beam.

[0018]

According to the first aspect of the present invention, the lightweight reinforcing material is subjected to a melting treatment.
Processed plastic cell consisting of open cells
But primarily the skeleton of the arm is covered with a cured resin
is there. Plastic foam must be melt-processed
Removes the thin film at the boundary between each cell and the next cell
The border between each cell on the form and the next cell is a beam
Remains as a skeleton, and the area occupied by that skeleton
When the deformation becomes easy because the area decreases and the space increases
In both cases, the impregnated resin mainly covers the above beams,
And lighter. Therefore, the present invention can be applied to a non-parallel surface material or a surface material having irregularities or curvature, and high strength without weight and directional properties can be obtained.

The lightweight structure according to the second aspect of the present invention, dissolution
Processed plastic cell made of open cells
The main part of the skeleton is hardened by being covered with curable resin
Since the surface material is provided on at least one surface of the lightened reinforcing material, the lightening material is not cured as in claim 1.
Can be easily deformed, so that it can be applied to non-parallel surface materials of various shapes or to surface materials with irregularities or curvature.The impregnated resin mainly covers the above beams, so the amount of resin is small.
Thus, a lightweight structure having a lighter weight and high strength in any direction can be obtained at a low cost.

According to a third aspect of the present invention, there is provided a method for manufacturing a lightweight structure , wherein a plastic foam which has been subjected to a dissolution treatment is impregnated with an uncured curable resin and is mainly subjected to the dissolution treatment.
In addition, the plastic foam skeleton is covered with curable resin .
Obtaining a lightweight reinforcement step laminating a surface material on at least one surface of the light weight reinforcement, and therefore comprises a step of curing the curable resin of the uncured, lightweight reinforcement curing
Before can be applied to the surface material with a deformation is easy non-parallel surface material between or irregularities or curved, impregnated resin is mainly
In addition, since the amount of resin is reduced to cover the beam, a lightweight structure that is lighter and has high strength in any direction can be obtained at low cost.

In the method for manufacturing a lightweight structure according to the present invention, since the uncured curable resin is cured while pressing the surface material, the open cell shrinks due to the pressure in addition to the effect of the third aspect. Therefore, there is an effect that the strength is further increased.

In the method for manufacturing a lightweight structure according to the fifth aspect of the present invention, the surface material is laminated after the hardening resin of the lightweight reinforcing material is cured, so that the workability is improved in addition to the effect of the third aspect.

According to the sixth aspect of the present invention, a box having a box-shaped surface material can be easily applied, and a lightweight and strong box can be obtained.

According to the seventh aspect of the present invention, the surface material can be easily applied to a cylindrical material. For example, when applied to a pipe, an effect of preventing dew condensation can be obtained in addition to a reinforcing effect.

According to the invention of claim 8, the present invention can be applied to the case where the surface material has irregularities, and the applicable range is greatly expanded.

According to the ninth aspect of the present invention, the curable resin is hardened.
Lightened reinforcing material that matches the shape of the surface material and the
Process, so that surface materials and protected
The present invention can be applied to a case where the surface has irregularities.

[0027] According to the tenth aspect of the present invention, the covering is provided between the surface materials.
Filling with lightweight reinforcement containing the protection
The protective body can be stored while preventing stress from being applied.

According to the eleventh aspect, the surface material is lightweight.
At least any two of the reinforcing material and the protected body are in contact with each other.
Because it is adhered with an adhesive, the strength is further increased.

It should be noted, as by the invention of claim 12, in lightweight reinforcement material described above as the curable resin, heat, ultraviolet light,
It is preferable to use one that is cured by at least one of an electron beam and an electron beam.

[0030]

【Example】

Embodiment 1 FIG. Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an embodiment of the first and second aspects of the present invention, in which a part of a surface material is cut away. Note that only one portion of the surface of the lightweight reinforcing member is shown for simplicity. FIG. 2 shows a cross section of the lightweight structure of FIG. In the figure, reference numeral 2 denotes a flat surface material, and reference numeral 3 denotes an open-cell lightweight reinforcing material which has air permeability, and whose skeleton is mainly covered and cured by a curable resin.

FIG . 3 shows the dissolution processing used in this embodiment.
Completed open cell urethane foam 3
1 is an enlarged perspective view of a main part of FIG. Specifically, for example, a malt filter MF-13 manufactured by Inoac Corporation having 11 to 16 cells per inch is used, and a thin film portion at a boundary portion between each cell and an adjacent cell is removed by melt processing of a foam. The boundary between the three adjacent cells remains as a beam 35, and the open cells of a polyhedron surrounded by large and small pentagonal mesh-shaped beams 35 are continuous three-dimensionally .
Specific gravity 0.0 which becomes a skeleton and easily elastically deforms as a whole
3. An air-permeable sponge having a porosity of 97%, which is used as a filter. Light weight reinforcement of the present invention
Is a complete open cell structure processed by the above-mentioned melting process
Curable resin is applied to the beam-shaped skeleton of the urethane foam 31.
It was overturned.

It should be noted that the open-cell melt-processed
Is, for example, publications about the plastic foam 31 ( "hard plastic foam" published by Asakura Shoten, which consists of,
p. 92) etc., examples of the material include urethane, polyvinyl chloride, polyethylene, silicone, chloroprene rubber, and the like. The number of cells per unit area is 0.5 to 10 cells / cm ² (5 to 10). A filter having a size of about 50 pieces / inch ² ) is suitable. Specifically, in addition to the MF series such as the malt filter MF-13 manufactured by Inoac Corporation in the above-described embodiment, a CF series, Everlite manufactured by Bridgestone Corporation, etc. are used.

Next, one embodiment of a method for manufacturing a lightweight structure according to the third and fourth aspects of the present invention will be described with reference to FIGS. First, as shown in FIG. 5, a plastic consisting of an open cell having a thickness of 10 mm and having been subjected to the above-mentioned melting treatment.
The hard foam resin 31 in the immersion tank 12,
For example, dipping in a two-part aliphatic amine-cured epoxy resin,
The excess resin is removed by squeezing with a roll 13, and its skeleton is mainly covered with a curable resin to obtain a lightweight reinforcing material 3. With this immersed in the resin 40, along with the resin wet the surface of the beam 35 becomes a film in terms of polyhedron constituting a part open cells, but constitute a partially closed cells inhibit breathability, skeletal Is a beam, it is possible to prevent the formation of a closed cell by removing the excess resin 40 by the roll 13 , and the resin is covered only on the beam portion.
The amount of resin is reduced, and the weight is reduced.
Wear. That is, the amount of the resin 40 impregnated in the lightweight reinforcing member 3 is adjusted by adjusting the interval between the rolls 13.
The lightweight reinforcing material 3 that has passed through the roll 13 is once squeezed by the roll 13.
The original thickness is restored by the excellent deformability (elasticity) . Therefore, the resin-coated lightweight reinforcing member 3 having pores dispersed by the restored thickness is obtained. Next, this lightweight reinforcing material 3
Is placed on a surface material 2, for example, a 1 mm-thick aluminum plate whose surface is anodized, and another similar aluminum plate is laid thereon, and a total of 10 mm is set with a flat curing jig (not shown). , And cured in an oven at 80 ° C. for 1 hour in a state where the lightweight reinforcing member 3 is compressed and deformed.
The cured product is a lightweight reinforcing material made of impregnated epoxy resin.
Is hardened in a deformed state, so that it is fixed in the shape at the time of hardening, and as a lightweight reinforcing material 3, it becomes a structure resistant to compression without elasticity. At the same time, the lightweight reinforcing material 3 and the surface material 2
The lightweight reinforcing material 3 is bonded by a curable resin 4 made of an epoxy resin impregnated. This lightweight structure has a specific gravity of 0.
48, and the compressive strength was 8.5 kg / cm ² . Incidentally, the compressive strength of the lightweight reinforcing material 3 not subjected to the resin treatment is 0.07 kg / cm ² , and the strength as a structural material is changed by the resin treatment.

Embodiment 2 FIG. In the first embodiment, the case where the surface material 2 is provided on both surfaces of the lightweight reinforcing material 3 has been described. However, when the required strength is relatively low or when the design of one side is not required, the surface material 2 is only provided on one side. May be. FIG. 6 shows the configuration in that case. In this example, the surface material 2 is a lightweight reinforcing material 3
The material and the manufacturing method are the same as those in the first embodiment, except that they are arranged only on one side. This lightweight structure had a specific gravity of 0.40 and a compressive strength of 5.5 kg / cm ² .

Embodiment 3 FIG. Above, but in each of the Examples and the surface member 2 and the light-weight reinforcing material 3 has been described, which is bonded by a curable resin 4 impregnated into lightweight reinforcement 3, have been adhesively bonded, as by claim 11 Is also good. FIG. 7 is an assembled sectional view showing one embodiment of the eleventh aspect of the present invention. In the figure, reference numeral 41 denotes an adhesive.

Next, the manufacturing method will be described. Example 1
In the same manner as described above, a 10 mm-thick open cell type lightweight reinforcing material 3 impregnated with an amine-cured epoxy resin was prepared. Separately, two 1 mm-thick glass epoxy laminates were prepared as the surface material 2, and the same resin as that impregnated in the lightweight reinforcing material 3 was used as an adhesive 41 on one surface of each of the two surfaces to a thickness of about 30 μm. Coating, Figure 7
As shown in the figure, the lightweight reinforcing material 3 impregnated with resin is sandwiched with the adhesive 41 coating surface of the glass epoxy laminate 2 on the inside, and cured at 80 ° C. in a compressed state so that the total thickness becomes 10 mm. A lightweight structure having a cross section similar to that shown in FIG. 2 is obtained.

In the obtained lightweight structure, only the interface between the surface material 2 and the lightweight reinforcing material 3 was resin-rich and the compressive strength was the same as that described in Example 1. However, by coating a resin on the surface of the surface material 2 facing the lightweight reinforcing material 3 and curing the resin at the same time as the lightweight reinforcing material 3, a lightweight structure having a stronger bonding strength at the interface can be obtained. In this example, the case where the surface materials 2 are provided on both surfaces of the lightweight reinforcing material 3 has been described. However, the present invention is also applicable to the case where the surface material 2 is provided on one surface of the lightweight reinforcing material 3 as shown in FIG. It goes without saying that you can do it. Further, in the third embodiment, the same resin as that used for the lightweight reinforcing material 3 is applied to the adhesive 4.
Although the surface material 2 was coated as 1, it is not limited to this, and different kinds of resins may be used, but it is preferable to cure at the same time.

Embodiment 4 FIG. In the third embodiment, the case where the lightweight reinforcing material 3 impregnated with the curable resin is applied to the manufacturing method according to claim 4 in which the lightweight reinforcing material 3 is sandwiched between surface materials and cured while being pressed,
A lightweight reinforcing material impregnated with a curable resin and cured by applying the manufacturing method according to claim 5 may be sandwiched between surface materials with an adhesive interposed therebetween to bond the two. Hereinafter, this embodiment will be described. An open cell obtained by dissolving a sheet-shaped 10 mm thick malt filter MF-20
A plastic foam 31 made of is impregnated with the same thermosetting epoxy resin as that described in Example 1, and is punched into a shape conforming to the surface material 2 as shown in FIG. The substrate is placed on a treated plate (not shown) and heated to 80 ° C. to be cured. After curing, the plate is removed from the release-treated plate to obtain a lightweight reinforcing material 3 having a required shape and a thickness of 10 mm. Next, the lightweight reinforcing material 3 is sandwiched between the surface materials 2 with an adhesive 4 interposed therebetween, and the two are adhered with the adhesive 4 to obtain a lightweight structure.

In the fourth embodiment, the case where the lightweight reinforcing material 3 impregnated with the curable resin is punched into a desired shape and then cured, but the lightweight reinforcing material impregnated with the curable resin is cured in a sheet form. After curing and curing, it is also possible to cut and fill into a desired shape. In this case, the cured lightweight reinforcing material is mass-produced, and can be cut into a desired shape and used as needed, so that the hardening treatment does not have to be performed every time, and the workability is good.

In each of the above embodiments, a case was described in which a relatively lightweight and high-strength aluminum plate was mainly used as the surface material 2. However, depending on the use of the lightweight structure, a glass epoxy laminate, an SMC, Reinforced resin plates such as BMC, wood plates such as plywood, and other metals can be used. For example, when an iron plate or stainless steel plate having a higher specific gravity than an aluminum plate and a high strength is used, the plate thickness can be reduced. .

The plate-like lightweight structure obtained in the above embodiment is used for, for example, a panel around an elevator, a floor or a wall of a building, etc., and is lightweight and high in addition to vibration suppression, Soundproofing and heat insulating effects can also be expected. Further, when the surface material 2 is provided only on one side, a sound absorbing effect can be obtained.

Embodiment 5 FIG. An embodiment of the invention will be described with reference to FIG. In this example, the surface member 2 is box-shaped, and the light-weight reinforcing member 3 is provided between the opposing box-shaped surface members 2 to constitute a box-shaped light-weight reinforcing member 8.

Next, a manufacturing method according to claims 3 and 4 will be described with reference to FIG. First, a lightweight reinforcing material 3 made of a malt filter impregnated with an epoxy resin 4 is wound around the inner surface material 2, that is, the outer periphery of the inner box. Press it into Next, the whole is heated to cure the epoxy resin 4 impregnated in the lightweight reinforcing material 3. Thus, the lightweight box 8 shown in FIG. 9 was obtained.

In the fifth embodiment, an example is shown in which the present invention is applied to a box-shaped structure having a double structure. However, by selecting a resin to be impregnated into a lightweight reinforcing material in accordance with the material of the box, the curing temperature can be increased. Can be lowered to room temperature, and an uncured, light-weight reinforcing material that can be punched can be obtained by a resin treatment for forming a B-stage, and a structure having high compressive strength can be formed by heating after filling.

Embodiment 6 FIG. An embodiment of the present invention will be described with reference to FIG. The present invention relates to a case where a surface material is cylindrical. A resin-impregnated malt filter MF-20 is wound as a lightweight reinforcing material 3 on the surface of a cylindrical inner surface material, that is, a metal duct 11, and a plastic sheet is wound on the surface thereof as a cylindrical outer surface material 2. Since the metal duct is lightweight and has a reinforcing effect, the thickness of the metal duct can be reduced, dew condensation can be prevented, and the surface of the metal duct 11 can be made insulating.

[0046] Then claim 3, it will be explained in claim 11. First, as shown in a perspective view in FIG. 12, a 10 mm thick malt filter MF20 obtained by spray impregnating the surface of a metal duct 11 with a room temperature curing polyester resin containing a curing agent and an accelerator as a curable resin. , That is, the lightweight reinforcing material 3 is spirally wound. Next, a PVC tape treated with a pressure-sensitive adhesive on one side as an outer surface sheet material 2 on the surface of the lightweight reinforcing material 3 is wound around the adhesive surface by half wrap to obtain a tubular lightweight structure. Was. In addition, the timing of winding the outer surface material 2 may be after the curable resin impregnated in the lightweight reinforcing material 3 is cured, or may be semi-cured or uncured. This example is an embodiment of the invention of claim 11 , in which the lightweight reinforcing member 3 and the outer surface material 2 are bonded with an adhesive.

Embodiment 7 FIG. In the manufacturing method according to the sixth embodiment, the melt processing is performed.
And has been described for the case of curable resin spray impregnated with plastic foam 31 made of open-cell, not limited to this, for example, as in Example 1, for example, malt filter MF20 (dissolution treatment pressure
Engineered, open-cell plastic foam
31) was passed through, for example, an epoxy resin tank, and the excess resin was squeezed out with two rolls.
May be attached to such an extent that the entire surface of the beam portion is wet, so that a sufficient space remains in the open cell of the malt filter MF20. Then, the surface sheet material 2 is wound while the impregnated resin is not yet cured, and then cured at room temperature for 24 hours to form a duct covered with a lightweight material having the strength of a structure having a cellular void therein. can get.

Embodiment 8 FIG. In the above-described sixth and seventh embodiments, the case where the surface materials 2 and 11 are provided on both surfaces of the lightweight reinforcing member 3 has been described, but it may be provided on only one surface. That is, FIG. 12 shows a state in the middle of the manufacturing process of the sixth embodiment. As a manufacturing method, for example, a malt filter MF20 resin-treated as a lightweight reinforcing material 3 is pre-heated at 80 ° C. and made into a B stage (tack-free), wound around the surface of the metal duct 11, and the end or the entire surface is adhered. In the state of being fixed with the agent, the mixture is heated at 150 ° C. for 20 minutes to perform full curing, thereby obtaining a light-weight, high-strength tubular lightweight structure having heat insulation and dew condensation preventing effects.

In each of Embodiments 6, 7 and 8, the example of the round pipe-shaped duct 11 has been described. However, since the uncured lightweight reinforcing member 3 is easily deformed, it can be easily applied to a deformed duct. Of course, the material of the duct 11 and the material of the surface sheet material 2 can be applied without being particular.

Embodiment 9 FIG. An embodiment of the invention will be described with reference to FIG. The present invention relates to a case where a surface material has irregularities. FIG. 13 shows, for example, a part of a box body extracted. The surface material 2 is an ABS (acrylonitrile butadiene-styrene) resin molded product.
One surface is flat, while the other opposing surface has an uneven portion, opposes at different intervals locally as a whole, and both surfaces are not in a parallel state. However, by deforming and curing the uncured light-weight reinforcing material 3 that has been treated with a resin plate, a lightweight structure in which the surface materials 2 are easily filled with no gap can be obtained.

FIG. 14 shows a manufacturing process of the lightweight structure having the irregular surface shown in FIG. 13, in which one surface material 2 made of ABS resin is coated with the curable resin 4 described in the first embodiment.
A malt filter impregnated with is placed as a lightweight reinforcing material 3, and an ABS resin molded article 2 having irregularities is stacked thereon and compressed until the gap between both surface materials 2 is filled with the lightweight reinforcing material 3, and the uncured resin treatment is performed. The lightened reinforcing material 3 is deformed and cured at 80 ° C. for 1 hour in that state to obtain a lightweight structure having an uneven surface.

Embodiment 10 FIG. Although the manufacturing method described in the eighth embodiment is based on claim 4, the present invention is not limited to this. For example, the manufacturing method may be based on claim 5 or 9 . That is, dissolution processing
Open cell plastic foam 3
The uncured curable resin impregnated in 1, of curing the curable resin
The obtained lightweight reinforcing material may be processed so as to match the unevenness of the surface material 2, and may be sandwiched between the surface materials 3 and bonded to each other with an adhesive.

In each of Embodiments 9 and 10, the case where one surface member 2 has irregularities has been described. However, both surface members 2 may have irregularities. Only the surface material may be provided, and the surface material may have irregularities. Further, the present invention is applicable not only to the unevenness but also to the case where the distance between the opposing surface materials gradually changes.

Although FIG. 13 shows a portion filled with a surface material having irregularities, for example, it is applied to a space inside a device such as a calculator or a personal computer in which functional parts are stored in a box. It is possible to improve the strength of the box against compression, and thereby reduce the thickness of the box itself. By increasing the density of the open cells of the filling matrix, the density of the lightweight reinforcement is reduced, and the increase in weight due to filling is small.

Embodiment 11 FIG. 15 and 1 for one embodiment of the invention of claim 10
5 will be described with reference to FIG. 16 which is a sectional view taken along line AA of FIG. The present invention relates to a lightweight reinforcing member in which a protected body 6 is accommodated between surface materials 2.
3 is applied. This example is a non-contact type IC which is a portable semiconductor device as a lightweight structure.
This is an example in which the present invention is applied to a card 1. In FIG.
Is a frame that forms the outer periphery of the card 1, 61 is a circuit board, 6
Reference numeral 2 denotes an electronic component mounted on the circuit board 61. The electronic component 62 and other components (not shown) are mounted on the circuit board 61 to form a module, that is, the protected body 6. I
The C card 1 accommodates a module 6 including a circuit board 61 on which electronic components 62 and other components (not shown) are mounted. , The module 6, the frame 5, and the space between the top sheet material 2 and the lightweight reinforcing material 3.

[0056] Then claim 4, FIG. 17 with the claim 10
A description will be given based on (a) and (b). First, as shown in FIG. 17 (a), one side of a frame 5 made of PBT (polybutylene terephthalate)
A polyester sheet having a thickness of 5 mm is fitted and adhered, the module 6 is inserted, and a lightweight reinforcement member 3 having a thickness of 5 mm, which is obtained by treating an epoxy resin in the same malt filter as described in Example 1, is overlaid on the module 6. The other top sheet material 2 is placed on the top, and the state shown in FIG. In this state, the top sheet material 2 is compressed so as to fit into the frame 5 so as to have a total thickness of about 2.5 mm, and is cured at 80 ° C. for 1 hour in this state. Card 1 was obtained. At the time of curing, the IC card 1 was sandwiched between flat plates having a smooth surface.

The melt-processed e-fiber used in the present invention.
Plastic foam made of open cells is a lot of empty
It has gaps and easily deforms with volume shrinkage, uncured
The lightweight reinforcing material 3 impregnated with the curable resin also has many voids.
And, since the easily deformed with the volume shrinkage, along the shape of the electronic component 62 mounted on the circuit board 61 easily varying <br/> form, filled without a gap inside the IC card 1, and in this state It hardens to fix its shape and changes to a structural material with compressive strength. Since the lightweight reinforcing material 3 is deformed by a weak force in an uncured state, it does not hurt the electronic parts and completely fills the gap, so that the light-weight reinforcing material 3 is supported by the entire surface sheet 2 and is impregnated with the resin. Since it is bonded together with curing, it becomes a durable IC card 1 even when a thin topsheet material 2 is applied, and a void of open cells or closed cells is left inside the lightweight reinforcing material 3 after curing, so that a cushion effect is also obtained. In addition, the IC card 1 that is strong against external impact can be obtained.

Embodiment 12 FIG. FIG. 18 is a cross-sectional view of another embodiment of the tenth aspect of the present invention.
In this example, the end portion of the top sheet material 2 becomes thicker as shown in FIG.
Also serves as the frame 5. Reference numeral 63 denotes a coil mounted on the circuit board 61.

Next, the manufacturing method will be described with reference to FIGS.
This will be described with reference to FIGS. Manufacturing method described above in Example 11 was the shall by the claims 4 and 10, in this example will be explained in claim 5, 9 and 11. First, as shown in FIG. 17 (a), a lightweight reinforcing member 3 made of a 5 mm thick malt filter treated with the same epoxy resin as described in Example 1 was cut into a predetermined size, and is shown in the figure. Although not shown in FIG.
As shown in (1), it is molded into a shape conforming to the irregularities of the protected object and cured. Also here, the amount of resin impregnated in the lightweight reinforcing material 3 is set to an amount that sufficiently leaves voids in open cells after molding. Next, as shown in FIGS. 20 (a) and 20 (b), assembling procedures of the IC card 1, a circuit in which electronic components 62 such as an IC, a coil 63 and the like are mounted on a lower case 2 which is one side of the IC card 1 is first shown. The substrate 61 is placed, the light-weight reinforcing material 3 formed in the shape of the gap in the IC card 1 is covered in a fitted state, the upper case 2 serving as the other surface is covered, and the upper and lower cases 2 are joined to each other. To obtain an IC card 1 in which a protected body, that is, a built-in product is sealed as shown in FIG. Also in this example, IC card 1
Is a case in which a module, that is, a protected body 6 is housed in a case made of PBT resin, that is, a surface material 2, and a gap is filled with a molded lightweight reinforcing material 3. Has no void and does not easily deform even when pressed.

Embodiment 13 FIG. The invention of claim 12 will be described. In each of the above embodiments, the case where a thermosetting resin is used as the curable resin impregnated in the lightweight reinforcing member 3 is described. However, the present invention is not limited to this. For example, an ultraviolet curable resin or an electron beam curable resin may be used. In short, any effect can be obtained as long as the resin is in a liquid state and uncured during the impregnation treatment and changes into a strong resin upon curing. When the impregnating resin is an ultraviolet curable resin or an electron beam curable resin, it is necessary that at least one surface is open or at least one surface material 2 transmits ultraviolet light or an electron beam. Needless to say,

Embodiment 14 FIG. Next, a description will be given of a manufacturing method using the B-stage state of the resin. For example, an ultraviolet / thermosetting epoxy resin gels and becomes tack-free by ultraviolet irradiation, but is not cured. After being temporarily fluidized by heating, it is completely cured and becomes the C stage. Therefore, first, an impregnating treatment with an ultraviolet ray / thermosetting epoxy resin is performed, and the impregnated resin on the surface is mainly gelled by irradiating the ultraviolet ray to make the tack-free lightweight reinforcing material 3 in the B-stage state.
Get. Next, after punching the lightweight reinforcing material 3 of the B stage into a desired shape, the surface material 2 is arranged on both surfaces and the temperature is reduced to 110 ° C.
Then, the lightweight reinforcing member 3 of the B stage is locally deformed to obtain a lightweight structure. In this way, by using the B stage, lightweight reinforcing materials are mass-produced in a long form,
If necessary, a light-weight structure can be obtained by punching or cutting into a required shape, filling between surface materials, and thermosetting to improve the productivity.
In Example 14, the impregnated resin was an ultraviolet / thermosetting resin. However, the present invention is not limited to this. For example, a similar lightweight reinforcing material can be obtained by impregnating a thermosetting resin and setting the stage to the B stage.

As described above in some embodiments,
According to the invention of claim 3 and 4, it was dissolved treatment processing, Oh
Uses plastic foam made of open cells
Because the space is large and the skeleton is small,
Mainly of plastic foams made of open cells
Light reinforcing materials with curable resin attached to the skeleton have a lot of space
Fits into gaps to be filled because there are few skeletons
In this state, it is possible to make the structure with mechanical strength by curing the thermosetting resin attached, so that the density of open cells and the type of resin to be attached can be changed. By selecting the material, a lightweight reinforcing material corresponding to the shape of the gap to be filled can be obtained, and a lightweight structure having the required mechanical strength after deformation hardening can be obtained.

Further, since the lightweight reinforcing material can be easily deformed and its volume can be easily compressed, a plate-shaped open cell type having a standard thickness which can be mass-produced for gaps of various shapes. It is very advantageous in terms of cost, because it is possible to apply a resin-treated material to the lightweight reinforcing material, so that several standard plates can be prepared, and it is possible to match the filling space for various types of lightening by punching and other processes. It is.

Then, a plurality of resin-treated lightweight reinforcing members may be laid over a wide area, and can be wound around a curved portion, so that various structures can be easily reduced in weight.

Further, since the lightweight reinforcing material treated with the resin has many pores inside even after the resin is cured, for example, a metal and a plastic having different thermal expansion coefficients on both surfaces of the structure are combined with the surface material. Also, the deformation of the beam portions of the individual cells absorbs thermal stress, and does not cause any trouble such as warpage or peeling.

Further, the open-cell type foam of the lightweight reinforcing material is three-dimensionally substantially uniform and has no particular directionality. There is no directionality for bending, and it is also possible to increase the load resistance, provide a heat insulating effect, or provide a sound insulating effect by changing the volume of the impregnated resin with respect to the lightweight reinforcing material.

Further, according to the present invention, for example, an open cell of a plate-shaped elastic foam is impregnated with a curable resin,
The purpose is to cure the impregnated material, and is not limited to the density of the open cells or the material of the foam. Needless to say, the resin to be impregnated can be applied as long as it has mechanical properties capable of fixing the shape of the foam that has been elastically deformed after curing.

[0068]

As described above, the lightweight reinforcing material according to the first aspect of the present invention is made of a melt-processed open cell.
Mainly because skeleton of the plastic foam that those covered by the cured resin, on the surface material with a non-parallel surface material between or irregularities or curved can be applied, a high no directional lightweight Strength is obtained.

Further, the lightweight structure according to the second aspect of the present invention is a positive structure comprising an open cell which has been subjected to a melting process.
Since at least one surface of the lightweight reinforcing material whose skeleton part is mainly covered with the curable resin and cured is provided with a surface material, it can be used between non-parallel surface materials or surface materials having irregularities and curvature. A lightweight structure that can be applied and is lightweight and has high strength in any direction can be obtained at low cost.

Further, the method for manufacturing a lightweight structure according to the third aspect of the present invention comprises an open cell which has been subjected to a melting treatment.
Consists of an open cell that has been impregnated with an uncured curable resin into a plastic foam,
Plastic foam skeleton covered with curable resin and lightweight
The method includes a step of obtaining a reinforcing material, a step of laminating a surface material on at least one surface of the lightweight reinforcing material , and a step of curing the uncured curable resin. The present invention can be applied to a surface material having texture, and a lightweight structure having light weight and high strength in any direction can be obtained at low cost.

In the method for manufacturing a lightweight structure according to the fourth aspect of the present invention, the uncured curable resin is cured while pressing the surface material. Since the cell shrinks, the strength is further increased.

The method of manufacturing a lightweight structure according to the fifth aspect of the present invention is a method of manufacturing a lightweight structure comprising an open cell.
An open cell made by impregnating a stick foam with an uncured curable resin and mainly processing the above solution.
Lightweight reinforcement brewing covering the skeleton of ticks form a curable resin
, A step of curing the uncured curable resin, and a step of laminating a surface material on at least one surface of the lightweight reinforcing material obtained by curing the curable resin. Workability is improved in addition to the effect.

The lightweight structure according to the invention of claim 6 is
Item 2. Since the surface material is box-shaped, a lightweight and high-strength box can be obtained.

[0074] Lightweight structure according to the invention of claim 7, wherein
Item 2 has a cylindrical surface material, so that a lightweight and high-strength cylindrical body can be obtained. For example, when applied to a pipe, a dew condensation preventing effect can be obtained in addition to a reinforcing effect.

[0075] Lightweight structure according to the invention of claim 8, wherein
According to the second, sixth or seventh aspect , the present invention can be applied to a surface material having irregularities, and the applicable range is greatly expanded.

A method for manufacturing a lightweight structure according to the ninth aspect of the present invention.
The method according to claim 5, wherein the curable resin is cured.
Lightweight reinforcement material conforms to the shape of the surface material and the protected body
Process, so that surface materials and
The present invention can also be applied to a case where a protected object has irregularities.

The lightweight structure according to the tenth aspect of the present invention is
Claim 2, claim 6, claim 7, or claim 8
, A lightweight reinforcing material containing a protected body between surface materials
Because it is filled, it puts a burden on the protected body
Can be stored while preventing.

The lightweight structure according to the eleventh aspect of the present invention is
Claim 2, Claim 6, Claim 7, Claim 8, or Claim 1
0, a facing, a lightweight reinforcement, and
At least any two of the protected objects are bonded with an adhesive.
It increases the strength.

The lightweight reinforcing material according to the twelfth aspect of the present invention is
2. The method according to claim 1, wherein the curable resin is heat, ultraviolet light,
It is preferable to use one that is cured by at least one of an electron beam and an electron beam.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating a plate-shaped lightweight structure according to a first embodiment of the present invention.

FIG. 2 is a diagram showing a cross section of the lightweight structure of FIG. 1;

FIG. 3 shows a melt-processed e-fiber used in the present invention.
It is a principal part expansion perspective view of the plastic foam which consists of an open cell .

FIG. 4 is an assembled sectional view showing a method of manufacturing the lightweight structure of FIG. 1;

FIG. 5 is composed of an open cell processed by dissolution processing
FIG. 2 is a cross-sectional configuration diagram illustrating an example of a method for impregnating a plastic foam with a curable resin.

FIG. 6 is a sectional view showing a plate-shaped lightweight structure according to a second embodiment.

FIG. 7 is an assembly sectional view illustrating a manufacturing method according to a third embodiment;

FIG. 8 is a perspective view illustrating a manufacturing method according to a fourth embodiment.

FIG. 9 is a sectional view showing a box-shaped lightweight structure according to a fifth embodiment.

10 is a cross-sectional view illustrating a method for manufacturing the box-shaped lightweight structure of FIG.

FIG. 11 is a sectional view showing a cylindrical lightweight structure according to a sixth embodiment.

FIG. 12 is a perspective view illustrating a method for manufacturing the cylindrical lightweight structure of FIG.

FIG. 13 is a sectional view showing a main part of a lightweight structure according to a ninth embodiment.

14 is an assembled sectional view for explaining the method for manufacturing the lightweight structure of FIG.

FIG. 15 is a plan view showing a lightweight structure accommodating a protected body according to an eleventh embodiment.

16 is a sectional view taken along line AA of FIG.

FIG. 17 is an assembly sectional view for explaining the method of manufacturing the lightweight structure in FIG. 15;

FIG. 18 is a sectional view showing a lightweight structure accommodating a protected body according to a twelfth embodiment.

FIG. 19 is a cross-sectional view illustrating a method of manufacturing the lightweight reinforcing member used in FIG.

20 is an assembled sectional view illustrating the method for manufacturing the lightweight structure of FIG. 18.

FIG. 21 is a perspective view showing a conventional lightweight structure having a honeycomb structure.

FIG. 22 is a perspective view showing a conventional lightweight structure having a cardboard plate shape.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 IC card 2 Surface material 3 Light-weight reinforcing material 31 Melting-processed open cell plastic
Stick Form 33 Honeycomb 34 Corrugated Lightweight Reinforcement 35 Beam 4 Curable Resin 5 Frame 6 Protected Body 61 Circuit Board 62 Electronic Components 63 Coil 9 Honeycomb Structure 10 Corrugated Cardboard 11 Duct

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Sachi Yamada 8-1-1, Tsukaguchi-Honcho, Amagasaki-shi Mitsubishi Electric Corporation Materials and Devices Laboratory (72) Inventor, Fumiaki Baba 8-1-1, Tsukaguchi-Honcho, Amagasaki-shi In the Materials and Devices Laboratory, Mitsubishi Electric Corporation (72) Inventor Osamu Murakami 8-1-1, Tsukaguchi-Honmachi, Amagasaki-shi In the Materials and Devices Laboratory, Mitsubishi Electric Corporation (56) References JP-A-1-197538 (JP, A JP-A-3-195748 (JP, A) JP-A-3-227210 (JP, A) JP-A-63-192931 (JP, A) JP-A-53-181 (JP, U) (58) Field (Int.Cl. ⁷ , DB name) B32B 5/18 B32B 31/00 C08J 9/26 C08J 9/42

Claims (12)

(57) [Claims] 1. From an open cell which has been subjected to a dissolution processing.
Lightweight reinforcement mainly skeleton of the plastic foam has cracks covered by the curing resin made. 2. From an open cell which has been subjected to dissolution processing.
At least one side of the lightweight reinforcing material whose skeleton is mainly covered with the curable resin and cured of the plastic foam ,
Lightweight structure with surface material. 3. From an open cell processed by dissolution processing
An open cell, which has been mainly impregnated with an uncured curable resin into a plastic foam
Light covers the skeleton of plastic foam with a curable resin that
A method for producing a lightweight structure , comprising: obtaining a mass reinforcing material; laminating the lightweight reinforcing material on a surface material or sandwiching the material between facing surface materials; and curing the uncured curable resin. 4. The method according to claim 3, wherein the uncured curable resin is cured while pressing the surface material. 5. From an open cell processed by dissolution processing
An open cell, which has been mainly impregnated with an uncured curable resin into a plastic foam
Systeme covering the skeleton of the foamed plastic that a curable resin
A step of obtaining an amount of reinforcing material, a step of curing the uncured curable resin, and a step of laminating a lightweight reinforcing material obtained by curing the curable resin on a surface material or sandwiching it between facing surface materials. The method of manufacturing the structure. 6. The method according to claim 2, wherein the surface material has a box shape .
Lightweight structure. 7. The surface material according to claim 2, wherein the surface material has a cylindrical shape .
Lightweight structure. 8. The method according to claim 2, wherein the surface material has irregularities.
A lightweight structure according to claim 6 or claim 7. 9. A lightweight reinforcing material obtained by curing a curable resin.
Process to match the shape of face material and protected object
The method for manufacturing a lightweight structure according to claim 5, further comprising: 10. A lightweight supplement containing an object to be protected between surface materials.
Claim 2, claim 6, claim 7, or contractor filled with a strong material
The lightweight structure according to claim 8. 11. A surface material, a lightweight reinforcing material, and an object to be protected.
That at least one of the two is bonded with an adhesive
Claim 2, Claim 6, Claim 7, Claim 8, or Claim 1
The lightweight structure according to 0. 12. The lightweight reinforcing material according to claim 1, wherein the curable resin is cured by at least one of heat, ultraviolet light, and an electron beam.