JP3193590B2 - Method of manufacturing honeycomb core made of fiber reinforced plastic - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a honeycomb core made of fiber reinforced plastic. That is, a fiber-reinforced plastic (FR
P), and a method for manufacturing a honeycomb core.

[0002]

2. Description of the Related Art FIG. 2 is a front view for explaining a manufacturing method of a conventional example of this kind, in which (1) FIG. 2 shows a prepared prepreg sheet, (2) FIG. (3)
The figure shows the formed corrugated sheet, and the figure (4) shows the process of stacking and joining the corrugated sheets. As shown in the figure, a honeycomb core made of fiber reinforced plastic has conventionally been generally manufactured by following the following steps. That is, as shown in FIG. 2A, first, a pre-prepared prepreg sheet 1 made of fiber reinforced plastic, which is a base material prepared in advance, is cut into predetermined lengths, and then, as shown in FIG. As shown, gear and rack 2
By applying to the corrugating apparatus 3 and heating and pressurizing the corrugated sheet, the corrugated sheet is formed into a corrugated sheet 4 as shown in FIG. 2 (3) and then cut into predetermined lengths. The corrugated sheets 4 are stacked and joined in a positional relationship where the valleys and the tops are aligned with each other, and as shown in FIG. The honeycomb core C made of fiber-reinforced plastic was obtained. Thus, in this kind of conventional manufacturing method,
A prepreg sheet 1 made of fiber reinforced plastic, in which a resin is combined with a fiber substrate by adhesion, impregnation, mixing, or the like, is prepared, and then the prepreg sheet 1 is corrugated.
And the honeycomb core C was manufactured.

[0003]

The following problems have been pointed out in such a conventional example. First, as described above, conventionally, a prepreg sheet 1 made of fiber-reinforced plastic prepared by previously combining resin by adhering, impregnating, mixing, or the like to a fiber base material has been prepared. It has been pointed out that the processing and preparation of the material require much time and cost. In other words, in order to attach, impregnate, or mix the resin into the fiber base material, the solvent with low fluidity and viscosity at the time of melting is once mixed with a solvent and diluted, and a special furnace or other high-level high-temperature, high-pressure equipment is used. In order to integrate the fibrous base material and the resin tightly and securely without voids, voids and gaps, it is necessary to set very strict conditions for the liquid temperature, viscosity, heating temperature, etc. Management was required. As described above, conventionally, in order to process and prepare the prepreg sheet 1 made of the fiber-reinforced plastic in advance, that is, to attach, impregnate, mix, or the like a resin to the fiber base material, it takes a great deal of time and labor, and Preparing and processing the prepreg sheet 1 requires special equipment, condition setting, and management, and the prepared and processed prepreg sheet 1 is extremely expensive. As a result, the cost of the manufactured fiber reinforced plastic honeycomb core C is extremely high. The problem was pointed out. Conventionally, the preparation and processing costs for such a prepreg sheet 1 have been lightly more than double the material costs.

Secondly, in connection with the above, when processing and preparing the prepreg sheet 1 made of fiber reinforced plastic,
Conventionally, a solvent was once mixed and diluted with the resin, and the solvent was subsequently evaporated and removed. However, the setting and management of the liquid temperature, viscosity, heating temperature, etc. during that time were troublesome and delicate, and the amount of resin was difficult. It was pointed out that control was not easy. That is, the ratio of the resin to the fiber base material in the fiber reinforced plastic is set to a target value of 40%, 35%, 30%, or the like according to the use of the honeycomb core C. However, it is not easy to control the amount of the resin as described above. For this reason, the tolerance / error has reached about plus or minus 3%, and as a result, a problem has been pointed out regarding the quality of the honeycomb core C made of fiber reinforced plastic to be manufactured.

Thirdly, the prepreg sheet 1 made of fiber reinforced plastic, which has been processed and prepared in advance as described above,
When forming into corrugated sheet 4 and manufacturing into honeycomb core C,
Although the material was cut into fixed-size dimensions, the material loss, stripping loss, and cutting removal loss were large. From this aspect, the honeycomb core C made of fiber-reinforced plastic was
Problems were pointed out in terms of cost. In particular, recently, higher rigidity and strength are required, and expensive glass fibers and the like are often used as the fiber base material of the fiber-reinforced plastic. In accordance with the amount necessary for the production of the honeycomb core C, it is suitable. There has been an increasing demand to use a minimum necessary amount of the prepreg sheet 1, that is, to eliminate waste of the prepreg sheet 1 that is cut and removed as unnecessary, that is, the fiber base material and the resin.

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, as a preliminary treatment, a band-shaped sheet of a fiber base material and a band-shaped sheet of a resin are prepared. After the upper and lower layers are integrally contacted, the laminated fiber base sheet and resin band sheet are heated and pressed to form a corrugated sheet, and at the same time, the resin adheres to and impregnates the fiber base. , Made of fiber reinforced plastic combined by mixing and the like. Accordingly, the present invention firstly requires no extra work, time, equipment, management, etc. for adhering, impregnating, mixing, etc. the resin to the fiber base material, and secondly, the resin amount can be easily controlled. Thirdly, it is an object of the present invention to propose a method for manufacturing a honeycomb core made of fiber-reinforced plastic, which is reliable and free of material loss.

[0007]

The technical means of the present invention for achieving this object is as follows. That is, in this method of manufacturing a honeycomb core made of fiber reinforced plastic, first, as a preliminary treatment, a separately prepared and supplied strip of fiber base material and a strip of resin are passed between pressure rolls. While being conveyed in the same direction, they are brought into contact with each other and heated, so that they are entirely and integrally laminated. The superposed band-shaped sheet of the fiber base and the band-shaped sheet of the resin are merely stacked up and down and are in contact with each other, and at this stage, the resin adheres to the fiber base, Not combined by impregnation, mixing, etc. Then, the layered sheet of the fibrous base material and the banded sheet of the resin are further conveyed, and supplied to a corrugating device such as a gear or a rack and heated and pressurized, so that the corrugations are continuously formed. A corrugated sheet made of a fiber-reinforced plastic, in which the resin is combined with the fibrous base material by being attached, impregnated, mixed, and the like at the same time as being bent, thereby integrating the fibrous base material and the resin. Molding. Thereafter, the plurality of corrugated sheets cut at predetermined lengths are stacked and joined in a positional relationship where the valleys and the tops are aligned, thereby forming a honeycomb core as a planar aggregate of hollow columnar cells. To obtain.

[0008]

The present invention comprises the above-mentioned means, and operates as follows. In this manufacturing method, first, as a preliminary treatment, a separately prepared and supplied strip of fiber base material and a strip of resin are heated and brought into pressure contact with each other while being conveyed, thereby being vertically stacked and integrated. Make contact. After such a preliminary treatment, the corrugated sheet is fed to a corrugating apparatus and heated and pressurized, so that the resin is adhered to, impregnated with, mixed with, etc. the fiber base material. Is molded. Then, the formed corrugated sheet is cut, stacked, and joined to produce a honeycomb core made of fiber reinforced plastic.

Therefore, first, in this manufacturing method, the fiber base material and the resin are pressed and heated while being conveyed as a belt-shaped sheet, and are brought into contact with one another in an up-and-down direction, and then heated by a corrugating apparatus. A corrugated sheet made of fiber-reinforced plastic is obtained by applying pressure and combining resin by adhering, impregnating, mixing and the like to the fiber base material. In other words, in this manufacturing method,
As in this type of conventional example, a resin is first attached to a fiber base material, combined with impregnation, mixing, etc., and then a prepreg sheet made of fiber reinforced plastic is processed and prepared. Heat and pressurize,
It is not molded into a corrugated sheet. The corrugating device heats and presses the corrugated sheet from the fibrous base material and the resin, and at the same time, the resin adheres, impregnates, and mixes into the fibrous base material. Made of fiber reinforced plastic. As described above, in this manufacturing method, since the combination of the fiber base material and the resin is performed together with the formation of the corrugated sheet, the labor and time are reduced by that amount, and the dedicated high-temperature and high-pressure equipment, condition setting, and management become unnecessary. For example, a honeycomb core made of fiber-reinforced plastic can be easily and easily manufactured. Since resin is adhered to, impregnated with, and mixed with the fiber base material, special labor, time, equipment, management, and the like are not required separately, and the cost is excellent.

Second, the ratio of the resin in the fiber reinforced plastic is set to a predetermined target value depending on the application. This is realized by selectively using a resin strip having a thickness corresponding to the target value. Thus, in this production method, the amount of resin can be easily and reliably controlled. Third, in this manufacturing method, the resin is adhered, impregnated, mixed, and the like into the fiber base while the corrugated sheet is formed from the fiber base and the resin by heating and pressing. So,
Unlike this type of conventional example, there is no need to cut every fixed size in the middle, and no material loss, board removal loss, cutting removal loss occurs,
Waste of fiber base material and resin that is cut and removed as unnecessary
Be wiped out. Thus, according to this manufacturing method, only the necessary minimum amount of the fiber base material or the resin is used.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in the drawings. FIG. 1 is a front view for explaining an embodiment of the present invention. FIG. 1A shows a preparation step, a heating step, a corrugated sheet forming step, and the like, and FIG. The steps will be described. In this manufacturing method, first, a fiber-shaped strip-shaped sheet 5 and a resin strip-shaped sheet 6 are prepared.
Various fibers such as glass fiber, Kevlar fiber, carbon fiber, ceramic fiber, metal fiber, resin fiber, cotton cloth fiber, and other woven / non-woven composite fibers are used as the fiber base material of the belt-shaped sheet 5. As the resin of the belt-shaped sheet 6,
Epoxy resins, phenol resins, polyimide resins, polyester resins, other thermosetting resins and thermoplastic resins are used, and these are prepared as flat film-like ones. It should be noted that a type in which the resin is already slightly adhered, impregnated, or mixed with the resin in the belt-shaped sheet 5 of the fiber base material at this stage can also be used. Such a type is also referred to as a fiber in this specification. It is included in the belt-shaped sheet 5 of the base material.

In this manufacturing method, such a fiber base sheet 5 and a resin band sheet 6 are respectively wound around a reel 7 and unwound from a separately prepared state. The heat is supplied to the heating and pressurizing device 9 via the heating device. Then, while being conveyed in the direction indicated by the arrow in the figure, the heating and pressurizing device 9 is contacted and heated, and the entire belt-shaped sheet 10 is vertically stacked. That is, the fiber-based strip-shaped sheet 5 and the resin strip-shaped sheet 6
Is supplied to the heating and pressurizing device 9 and is passed between the pressure rolls 11 so that the belt-shaped sheet 10 is vertically stacked and contacted and heated, thereby forming a vertically integrated belt-like sheet 10. You.

After such a preliminary treatment, in this manufacturing method, the belt-shaped sheet 10 is further conveyed and the gear 1
2 and a rack 2, the corrugation molding device 3 is heated and pressurized, whereby the corrugated unevenness is continuously bent, and at the same time, the resin adheres, impregnates,
The fibers are combined by mixing or the like, whereby the corrugated sheet 13 made of fiber reinforced plastic is formed.

This step will be described in more detail. Although the corrugating apparatus 3 is composed of a pair of upper and lower gears 12 and a rack 2 in the illustrated example, it is also conceivable to use a pair of upper and lower gears 12 and further use various other pressing devices and belt-type dies. Is also possible. And the belt-shaped sheet 10
Is inserted between the gear 12 and the rack 2 of the corrugating apparatus 3 and sandwiched from both sides, and heated and pressurized to form a corrugated plate 13 in which corrugations are continuously bent.
Molded into The corrugated plate 13 has, in addition to the trapezoidal shape shown in the figure, a substantially triangular shape, a substantially square shape, and other various shapes of corrugations.
It is formed by bending at a predetermined pitch and height linearly and parallel to the short direction and continuously in the long direction. Along with this, the corrugated sheet 13 is formed by adding the resin constituting the band-shaped sheet 10 to the fiber base material forming the band-shaped sheet 10,
By heating, pressurizing, adhering, impregnating, mixing, and the like are combined and formed into a corrugated plate 13 made of fiber reinforced plastic in which both are integrated.

Then, in this manufacturing method, a plurality of fiber-reinforced plastic corrugated sheets 1 cut at predetermined lengths are used.
3 are stacked and joined in a positional relationship where the valley portion and the top portion are aligned, as shown in FIG.
The honeycomb core C which is a planar assembly of is manufactured.

This step will be described in more detail. That is, the corrugated plate 13 made of fiber-reinforced plastic molded as described above is coated with, for example, a node bond, that is, an adhesive agent 14 on the lower surface of the wave valley or the upper surface of the top of the corrugated plate, and dried. Be cut off. In the illustrated example, the adhesive 14 in the tray T is applied by a print roll 16 via a pickup roll 15, but the adhesive 1
4 can be applied by a coating stamp. After a while, a plurality of corrugated sheets 13 are shifted vertically by half a pitch of a wave, and a stacked block in which a space exists as a whole under the positional relationship of matching the valley and the top between the upper and lower sides. (See also FIG. 2 (4) described above). In the case where a flat plate (not shown) made of fiber-reinforced plastic obtained by pressing the prepreg-shaped band-shaped sheet 10 from above and below according to the above-described manner is further interposed between such corrugated plates 13. There is also. Thereafter, the corrugated sheets 13 stacked in this manner are further heated and pressurized, whereby the resin is cured, and the applied adhesive 14 is also cured, thereby bonding them together (as described above). In the case where a flat plate is further interposed, the corrugated plates 13 and the flat plate are also bonded. In the illustrated example, the joining method using the adhesive 14 was adopted, but the joining method using a brazing material or the melt hardening by heating the resin itself constituting the corrugated plate 13 was used regardless of this. Joining methods, etc. are also conceivable.

By following these steps, FIG.
The honeycomb core C made of fiber reinforced plastic shown in FIG. The honeycomb core C is formed of a number of hollow columnar cells B each formed in an independent space by using the corrugated plate 13 made of fiber-reinforced plastic (and the above-mentioned flat plate) stacked and joined as described above as a cell wall A. Consists of a planar assembly of The cross-sectional shape of the cell wall A and the cell B is typically a regular hexagonal shape as shown in the figure, but is not limited thereto, and a trapezoidal shape, a substantially triangular shape, a substantially square shape, and various other shapes are also possible. It is. The honeycomb core C made of fiber-reinforced plastic is excellent in weight ratio strength, is lightweight, has high rigidity and strength, and has a rectifying effect, flatness, heat insulation, and sound insulation, like the general one. It has excellent properties such as high surface area per unit volume and is widely used as various structural materials. When higher rigidity and strength are required for such a honeycomb core C made of fiber-reinforced plastic, as an after-treatment, reinforcement for further adhering and impregnating the outer surface of the cell wall A with a resin is performed. You.

The present invention has been described above. Then, it becomes as follows. That is, as shown in FIG. 1, in the method of manufacturing the honeycomb core C made of fiber-reinforced plastic, the separately prepared and supplied strips 5 of the fiber base material and the strips 6 of the resin are added while being conveyed. The resin is adhered to the fibrous base material, impregnated, and heated by applying pressure and heating to form the integrally laminated belt-shaped sheet 10 and further supplying the corrugated sheet 3 to the corrugating apparatus 3 for heating and pressing.
The corrugated plate 13 made of fiber reinforced plastic is integrally formed by mixing or the like. Then, the formed corrugated sheet 13 is cut, stacked, and joined to manufacture the honeycomb core C made of fiber reinforced plastic shown in FIG. Therefore, according to the method of manufacturing the honeycomb core C made of fiber reinforced plastic, the following first, second, and third cases are obtained.

First, in this manufacturing method, a fiber base material and a resin are contacted and heated while being conveyed as band-shaped sheets 5 and 6 to form a band-shaped sheet 10 that is integrally laminated.
Further, the corrugated sheet is heated and pressurized by the corrugating device 3 to form a corrugated plate 13 made of fiber reinforced plastic in which the resin is combined, impregnated, and mixed with the fiber base material.
In other words, in this manufacturing method, as in the above-described conventional example shown in FIG. 2, a prepreg sheet 1 of a fiber-reinforced plastic in which a resin is previously attached to a fiber base material by combining, impregnating, mixing, or the like in advance. The corrugated sheet 13 is formed from the fiber base material and the resin by heating and pressurizing the corrugated sheet forming apparatus 3 or the like, instead of forming the corrugated sheet 4 by heating and pressing the corrugated sheet forming apparatus 3. At the same time, the resin adheres, impregnates, and mixes with the fiber base material. As described above, in this manufacturing method, the combination of the fiber base material and the resin is performed together with the formation of the corrugated sheet 13, so that the labor and time are reduced by that amount, and it is not necessary to use dedicated high-temperature and high-pressure equipment, and to set and manage conditions. For example, the honeycomb core C made of fiber reinforced plastic can be easily and easily manufactured.

Second, the proportion of the resin in the fiber reinforced plastic depends on the use of the honeycomb core C, and may be 40%.
%, 35%, 30%, and the like. This is realized with a tolerance and error of about ± 1.5% by selectively using a resin strip 6 having a thickness corresponding to such a target value in the first step. In the method for manufacturing the honeycomb core C made of fiber-reinforced plastic, the amount of resin can be easily and reliably controlled.

Third, in this manufacturing method, as described above, while the corrugated sheet 13 is formed from the fiber base material and the resin by heating and pressing, the resin is adhered, impregnated, mixed, and the like to the fiber base material. . Therefore, as in the above-described conventional example of FIG.
A prepreg sheet 1 of a fiber-reinforced plastic in which a resin is previously attached, impregnated, mixed, or the like to a fiber base material is previously processed and prepared, and as in the case where the prepreg sheet 1 is formed into a corrugated sheet 4,
There is no need to cut every fixed size in the middle, no material loss, no board removal loss, no cutting and removing loss, and waste of the prepreg sheet 1 that is cut and removed as unnecessary, that is, waste of the fiber base material and resin. Be wiped out. As described above, according to this manufacturing method, only the necessary amount of the fiber base material or the resin corresponding to the amount required for manufacturing the honeycomb core C is used.

[0022]

As described above, in the method for manufacturing a fiber-reinforced plastic honeycomb core according to the present invention, first, as a preliminary treatment, a band-shaped sheet of a fiber base material and a band-shaped sheet of a resin are vertically stacked and integrated. And then heat and press the superposed fiber base sheet and resin band sheet to form a corrugated sheet, and at the same time, adhere, impregnate, mix, etc. the resin to the fiber base The following effects are exhibited by the combined use of the fiber reinforced plastic.

First, it takes time and effort to make a fiber reinforced plastic by adhering, impregnating, mixing, etc., a resin to the fiber base material.
Time, equipment, management, etc. are not required separately, and the cost is excellent. That is, in this manufacturing method, a prepreg sheet made of a fiber-reinforced plastic by previously adhering, impregnating, or mixing a resin into a fiber base material is not processed and prepared as in the above-described conventional example, but a corrugated sheet. These were performed while molding. Accordingly, labor and time are reduced by that much, and a dedicated high-temperature and high-pressure facility, condition setting, management and the like are not required. As a result, a honeycomb core made of fiber reinforced plastic can be manufactured more easily, easily and cost-effectively.

Second, the control of the amount of resin is made easy and reliable. In other words, this manufacturing method does not require complicated and delicate liquid temperature, viscosity, and heating temperature setting and management associated with the mixing and evaporation of the solvent, as in the above-described conventional example, and the resin used is not required. By selecting the thickness of the belt-shaped sheet,
The ratio of the resin in the fiber reinforced plastic can be set to the target value. Thus, the amount of resin is easily and reliably controlled, and a honeycomb core made of fiber-reinforced plastic having excellent quality can be obtained.

Third, waste of material loss is also eliminated. That is, according to this manufacturing method, as in the above-described conventional example, there is no material loss, board removal loss, and cutting and removing loss, and the waste of the fiber base material and the resin that is cut and removed as unnecessary is eliminated. In view of the situation where higher rigidity and strength are required and expensive glass fibers are frequently used as a fiber base material, it is significant that such loss and waste are eliminated.
As described above, the honeycomb core made of fiber reinforced plastic can be manufactured with excellent cost in this respect as well. 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]

FIG. 1 is a front view for explaining a method of manufacturing a honeycomb core made of a fiber-reinforced plastic according to the present invention, and FIG. 1A shows a preparation step, a heating step,
A corrugated sheet forming step and the like are shown, and FIG. 2B shows an adhesive applying step.

FIG. 2 is an explanatory front view for explaining a method for manufacturing a honeycomb core made of fiber-reinforced plastic according to a conventional example;
(1) Figure shows the prepared prepreg sheet, (2) Figure shows the corrugated sheet forming step, (3) Figure shows the formed corrugated sheet, and (4) Figure shows the corrugated sheet. And the joining process.

FIG. 3 is a perspective view of a honeycomb core.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 prepreg sheet 2 rack 3 corrugating device 4 corrugated sheet (conventional example) 5 strip sheet of fiber base material 6 strip sheet of resin 7 reel 8 guide roll 9 heating and pressurizing device 10 strip sheet of prepreg shape 11 pressure roll 12 Gear 13 Corrugated plate (of the present invention) 14 Adhesive 15 Pickup roll 16 Print roll A Cell wall B Cell C Honeycomb core T Tray

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B29B 11/16 B29B 15/08-15/14 C08J 5/04-5 / 10 C08J 5/24

Claims (1)

(57) [Claims] 1. First, as a preliminary treatment, a separately prepared and supplied fiber-based band-shaped sheet and resin band-shaped sheet are provided.
By passing between the pressure bonding rolls, they are brought into contact with each other while being conveyed in the same direction and heated, so that they are entirely and integrally stacked. At this stage, the resin is not combined with the fibrous base material by adhesion, impregnation, mixing or the like at this stage. The strip-shaped sheet and the strip-shaped resin sheet are further conveyed, and supplied to a corrugating device such as a gear or a rack and heated and pressurized, whereby the corrugated irregularities are continuously bent and formed at the same time. After forming the fiber reinforced plastic corrugated sheet in which the resin is combined with the fiber base material by adhesion, impregnation, mixing, etc., and thus the fiber base material and the resin are integrated, the corrugated sheet is formed at predetermined intervals. A plurality of cut corrugated sheets Intussusception in a positional relationship to match the valley and a top, by bonding, to obtain a honeycomb core is a planar assembly of hollow columnar cells, fiber-reinforced method for producing a plastic honeycomb core characterized by.