JP4585723B2 - Method for manufacturing perforated honeycomb panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a laminate in which a planar member and a honeycomb member are laminated, and more particularly to a method for manufacturing a perforated honeycomb panel in which a plate-like member is a perforated member having a large number of holes.
[0002]
[Prior art]
Honeycomb panels are known as lightweight and high-strength structural materials. The honeycomb panel is configured such that a honeycomb-like honeycomb member is sandwiched between two plate-like members. Further, in the present specification, the cross section of the honeycomb member on the surface orthogonal to the surface constituting the honeycomb member is not limited to the honeycomb-shaped hexagon but also includes other polygons. When such a honeycomb panel is used as a sound absorbing member, a large number of holes in the plate-like member are drilled in order to improve sound absorbing characteristics.
[0003]
Conventionally, such a honeycomb panel has been manufactured by press-molding a plate-like material with a hole to obtain a plate-like member, and then bonding the plate-like member and the honeycomb material.
[0004]
[Problems to be solved by the invention]
As described above, in the conventional method for manufacturing a perforated honeycomb panel, the plate-shaped material is molded and the honeycomb material and the plate-shaped material are integrated separately by pressure molding, or a large number of holes are formed in the plate-shaped material. For this reason, when machining or drilling with a pin-type jig, it is difficult to remove from the curved surface of the jig, resulting in an increase in the number of manufacturing steps and high costs.
[0005]
The present invention has been made to solve the above-described problems, and an object thereof is to provide an inexpensive method for manufacturing a perforated honeycomb panel.
[Means for Solving the Problems]
In order to solve the above-described problem, a method for manufacturing a perforated honeycomb panel according to the present invention is the first before the curing in a state where the protrusion penetrates a forming jig in which a plurality of protrusions are erected on a flexible sheet. The first plate material is placed, the honeycomb material before being cured is laminated on the first plate material, and the second plate material is placed thereon. It is cured and integrally molded in a state integrated with the molding jig. After the integral molding, remove the molding jig. At this time, due to the flexibility of the sheet of the forming jig, the forming jig can be easily detached from the formed honeycomb panel.
[0006]
Further, before placing the honeycomb material, a cover sheet for smoothing the surface of the first plate-like material placed on the forming jig and preventing the protrusion tip of the forming jig from protruding is provided. The first plate-like material can be placed on top of each other and pressed together.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention (hereinafter referred to as embodiments) will be described with reference to the drawings. FIG. 1 is a diagram showing a schematic process of a method for manufacturing a perforated honeycomb panel of the present embodiment. The forming jig 10 is formed by embedding pins 14 made of a hard material such as metal in a plate-like sheet 12 having flexibility (FIG. 1a). The pin 14 protrudes from the surface of the sheet 12 and is a protrusion of the forming jig. On the surface of the forming jig 10 on which the protrusions are provided, a plate-like material 16 which is one of the plate-like members of the honeycomb panel and is a resin material before curing is placed (FIG. 1b). At this time, the portion embedded in the plate-like material 16 of the pin 14 has a substantially cylindrical shape, and the portion protruding from the plate-like material 16 has a substantially conical shape. Thereby, the diameter of the hole of the plate-like material 16 is made almost constant over the length thereof, and the hole for the plate-like material 16 can be made.
[0008]
Further, the cover sheet 18 is placed on the plate material 16 (FIG. 1c). The cover sheet 18 has flexibility and is disposed so as to cover the tips of the pins 14 protruding from the upper surface of the plate-like material 16. In a state where the forming jig 10, the plate-like material 16 and the cover sheet 18 are laminated, these are placed in the vacuum bag 20 and pressurized (FIG. 1d). By this pressurization, the surface of the plate-like material is smoothed.
[0009]
After the plate-like material 16 and the like are taken out from the vacuum bag 20, the cover sheet 18 is removed, and the honeycomb material 22 is placed on the plate-like material 16 (FIG. 1e). The cross-sectional shape of the honeycomb material 22 is literally a hexagonal honeycomb. However, the cross-sectional shape is not limited to this, and may be a shape combining other polygons.
[0010]
The second plate-like material 24 is further stacked on the honeycomb material 22 so that the honeycomb material 22 is sandwiched between the first and second plate-like materials 16 and 24 (FIG. 1f). In the laminated state, it is placed in the vacuum bag 26, and pressurized and heated to cure the resin constituting the first and second plate-like materials 16 and 24 (FIG. 1g). Then, the honeycomb panel 34 is obtained by sandwiching the honeycomb member 28 between the perforated plate member 30 and the plate member 32 without holes by taking out the vacuum bag 26 and removing the forming jig 10 by peeling off. (FIG. 1h). As described above, since the sheet 12 of the forming jig 10 has flexibility, it can be easily removed from the cured honeycomb panel 34.
[0011]
According to the above manufacturing method, the process of molding and hardening the material is only one process, and the manufacturing cost can be reduced.
[0012]
FIG. 2 is a diagram illustrating an example of a manufacturing process of the forming jig 10. A first die 40 made of metal or resin, which is composed of a frame 36 and a pin die 38 erected on the inside thereof, is prepared (FIG. 2a). A resin is poured into the mold 40 and cured (FIG. 2b). This resin is a flexible material even after curing. Using this flexibility, the flexible sheet 12 is removed from the mold 40 to obtain the flexible sheet 12 described above (FIG. 2c).
[0013]
Next, the sheet 12 is placed in the second mold 44 (FIG. 2d). The second die 44 is provided with a substantially conical hole 48 at a position corresponding to the hole 46 of the sheet 12 formed by the pin die 38. Therefore, when the sheet 12 is disposed in the second mold 44, the sheet hole 46 and the mold hole 48 become one continuous hole. There, the molten metal 50 is poured (FIG. 2d). The metal 50 is preferably poured in an amount sufficient to fill the hole 46 in the sheet and the hole 48 in the mold. The metal 50 is cured to become the above-described pin 14 and is removed from the second mold 44 to obtain the forming jig 10 (FIG. 2e).
[Brief description of the drawings]
FIG. 1 is a diagram showing a manufacturing process of a perforated honeycomb panel according to the present embodiment.
FIG. 2 is a diagram showing a manufacturing process of the forming jig 10;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Forming jig, 12 Flexible sheet, 14 Pin (projection), 16 1st plate-shaped material, 18 Cover sheet, 20 Vacuum bag, 22 Honeycomb material, 24 2nd plate-shaped material, 26 Vacuum bag, 28 honeycomb member, 30 perforated plate member, 32 plate member, 34 honeycomb panel.

Claims (2)

Placing a plate-like material in a state where the protrusion penetrates a forming jig in which a plurality of protrusions are erected on a flexible sheet; and
Pressurizing the first plate material together with the forming jig;
Placing a honeycomb material on the first plate-like material;
Placing a second plate-like material on the honeycomb material;
Curing and integrally molding the first and second plate-like materials and the honeycomb material in a state of being integrated with the forming jig;
Removing the forming jig from the integrally formed first and second plate-like materials and honeycomb material to obtain a perforated honeycomb panel;
A method for manufacturing a perforated honeycomb panel. 2. The method for manufacturing a perforated honeycomb panel according to claim 1, wherein a tip of a protrusion of the forming jig is not further protruded after the step of placing the first plate-like material on the forming jig. And a step of placing a cover sheet on the first plate-like material,
The step of pressurizing both the first plate-shaped material and the forming jig is a step of pressurizing including the cover sheet.
A method for manufacturing a perforated honeycomb panel.

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