JP4734967B2 - Method for manufacturing honeycomb sandwich panel with frequency selective plates laminated - Google Patents

Description

The present invention, instead or in the manufacturing method and the manufacturing method thereof of the honeycomb sandwich panel formed by laminating frequency selective plate (frequency selective Surface), more particularly ships for radome: frequency used (AEM / S Enclosed mast) such large honeycomb sandwich panel the vacuum resin transfer molding method by laminating a selection plate (VaRTM: vacuum-assisted resin transfer molding) by those about the method for manufacturing a honeycomb sandwich panel formed by laminating a frequency selective plate to be manufactured.

  Conventionally, when a resin molded product such as a fiber reinforced plastic (FRP) panel is manufactured, a resin transfer molding method (RTM) or a vacuum resin transfer molding method (VaRTM) is known. With the development of fiber reinforced plastic panels in the hull, there is a limit to molding large resin moldings in the autoclave method, so the development of fiber reinforced plastic panels by the vacuum resin transfer molding method (VaRTM) has been promoted. (For example, refer to Patent Document 1).

  Also, in recent years, ship radomes (AEM / S: Enclosed Mast) to which a frequency selective surface (FSS) is applied to stealth the ship's upper mast (to make it difficult to be captured by radar). ) Is also under development.

  However, the ship radome has a honeycomb core sandwich panel structure that uses GFRP (glass fiber reinforced plastic) as the skin material, and has a polyhedral structure that combines the panels, and cannot be molded by the autoclave curing equipment. Since it is a large size, it is difficult to manufacture, and it is a reality that a molding method in which the frequency selection plate as described above is incorporated in a ship radome has not yet been proposed.

Also, when molding large resin moldings, especially large flat plate moldings, using the vacuum resin transfer molding method (VaRTM), air is trapped on the tool surface side when the resin is injected during the resin suction process, and after curing There was a problem that the resin impregnation defective part occurred in the molded product of this and the product was defective.
JP 2001-96611 A

The present invention was devised by paying attention to such conventional problems. When manufacturing a large-sized flat plate molded product, the reaction resin material was uniformly impregnated into the laminate, and a frequency selection plate was incorporated. Manufacture of honeycomb sandwich panels that can easily produce large fiber reinforced plastic panels and laminate frequency-selection plates that can prevent resin impregnation failure and effectively prevent product failure after curing. It is intended to provide a method.

In order to achieve the above object, the present invention provides a method for manufacturing a honeycomb sandwich panel in which the frequency selection plates of the present invention are laminated, in which a rubber-like elastic sheet is laid on a metal base member provided with a tilting means. On the elastic sheet, a fiber reinforced base material, a honeycomb core made of a nonmetallic material having a frequency selection plate formed with a plurality of through holes bonded to the front and back surfaces, and a fiber reinforced base material are sequentially laminated at least one layer, The whole is covered with a film-like vacuum back, and the base member is laminated by the tilting means with the reactive resin material supply side on the bottom and the suction side on the top, with the laminate in the vacuum back being vacuumed The reaction resin material is supplied from one side of the body, and the reaction resin material is uniformly sucked from the other side of the laminate, so that the reaction resin material is uniformly distributed on the fiber reinforced substrate. Curing causes immersed is to summarized as.

Here, the size of the plurality of through holes formed in the frequency selection plate is set to a diameter of 0.5 mm to 3.0 mm, and the base member is inclined from 45 ° to 70 ° by the tilting means, whereby the vacuum back A spiral hose is disposed on the other side of the laminated body covered with, and a plurality of suction pipes are connected to the hose at a predetermined interval to uniformly suck the reaction resin material. The honeycomb core may be one selected from aromatic polyamide fiber, foam material, syntactic foam, and wood.

As the molding workbench for use in the method for manufacturing a honeycomb sandwich panel of the present invention, there is provided a molding workbench for use in the method for manufacturing a honeycomb sandwich panel, the molding work platform body, the base member on the support frame A support plate to be placed is installed, and one end side of the support plate in the longitudinal direction is connected to the support frame via a hinge so as to be swingable in the vertical direction, and between the other end side of the support plate and the support frame. a is a shaping worktable body which takes setting tilting means for tilting at an angle. Here, the tilting means is a lifting cylinder.

  With such a manufacturing method, when manufacturing a large flat molded product, a large fiber incorporating a frequency selection plate that can prevent resin impregnation failure and effectively prevent product failure in the molded product after curing. A reinforced plastic panel can be easily manufactured.

Since the present invention is configured as described above, the following excellent effects can be obtained. (A). When manufacturing large flat molded products, it is possible to easily manufacture large fiber-reinforced plastic panels incorporating frequency selective plates by uniformly impregnating the laminate with the reactive resin material and molding after curing. It is possible to prevent defective resin impregnation in the product and effectively prevent the defective product.
(B). A large fiber-reinforced plastic panel incorporating a frequency selection plate can be easily manufactured by a vacuum resin transfer molding method (VaRTM).
(C). In the vacuum resin transfer molding method, an aromatic polyamide honeycomb core (Nomex (registered trademark) honeycomb core) that is cheaper and lighter than resin or wood can be used as the honeycomb core material.
(D). When manufacturing a honeycomb sandwich panel by the vacuum resin transfer molding method, the reaction resin material does not directly contact the metal base member having a large heat capacity. As a result, the reaction heat of the reaction resin material is applied to the metal base member. It is possible to effectively prevent poor curing of the resin molded product without absorbing heat.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is an exploded perspective view of a fiber reinforced plastic panel in which frequency selective plates according to the present invention are laminated, FIG. 2 is a front view of the frequency selective plate of the present invention, and FIG. 3 is a fiber reinforced plastic integrally laminated. The perspective view of the panel is shown, and the fiber reinforced plastic panel has a uniform liquid adhesive 2 made of a two-component epoxy resin on the front and back surfaces of the core material 1 selected from foam material, syntactic foam material, and wood. Further, a frequency selective surface 5 (FSS: frequency selective surface) having a plurality of through holes 4 is laminated.

  As the lamination method, a frequency selection plate 5 (a plurality of through holes 4 are formed between the patterns of the metal foil 3 as shown in FIG. 2 after the liquid adhesive 2 is applied to the front and back surfaces of the core material 1 ( FSS: frequency selective surface) is laminated and the whole is uniformly and uniformly formed with a spatula or the like. At this time, air bubbles (air traps) mixed between the core material 1 and the frequency selection plate 5 from the through-hole 4 formed in the frequency selection plate 5, the air emitted from the surface of the core material 1, etc. are liquid. It pushes to the opposite side of the bonding surface with the flow of the adhesive 2, thereby effectively removing the delamination of the frequency selection plate core panel later without generating an air trap between the frequency selection plate 5 and the core material 1 later. It can be prevented.

  In addition, the frequency selective plate 5 (FSS: frequency selective surface) is formed of a light metal plate, and in order to transmit or block a specific frequency, for example, a small piece of metal (referred to as a patch) having the same shape. Can be arranged in an array, or can be used by forming a structure in which holes having the same shape (called apertures) are cut out from a metal plate in an array.

  The size of the through holes 4 formed between the patterns of the metal foil 3 is preferably 0.5 mm to 3.0 mm in diameter. By setting the size of the through hole 4 to a diameter of 0.5 mm to 3.0 mm, it is possible to satisfy both the dischargeability and adhesiveness of the liquid adhesive at a higher level.

  In this way, a large laminate W formed by laminating at least one frequency selection plate 5 via the liquid adhesive 2 is formed by a vacuum resin transfer molding method (VaRTM) as shown in FIG. No. 5 and FIG. 6 are used to perform a molding operation.

  As shown in FIGS. 5 and 6, the forming work table body 10 of this forming work table has a metal support plate 13 on which a base member 12 is placed on a support frame 11 made of a light metal material or the like. At the same time, one end of the support plate 13 in the longitudinal direction is connected to the support frame 11 via a hinge 14 so as to be swingable in the vertical direction.

  Further, a tilting means composed of an elevating cylinder such as a fluid cylinder for tilting the forming worktable body 10 at a certain angle (for example, 45 ° to 70 °) between the other end side of the support plate 13 and the support frame 11. 15 is provided. The tilting means 15 is not limited to a fluid cylinder or the like, and a lifting device such as a crane can be used.

  Further, it is preferable to provide the supply side of the reaction resin material Q on the lower side of one end side of the support plate 13 and provide the suction side on the upper side. That is, the air accumulated on the tool surface side when the resin is injected moves upward as the support plate 13 tilts and can be easily exhausted on the suction side. Reference numeral 16 denotes a stopper member provided on the upper surface of one end side of the support plate 13.

  Next, a method of manufacturing a large honeycomb sandwich panel incorporating the frequency selection plate 3 as described above by a vacuum resin transfer molding method (VaRTM) will be described with reference to FIGS.

  First, a rubber-like elastic sheet 17 is laid on a metal base member 12 placed on the support frame 11, and a fiber-reinforced resin sheet 18 (fiber-reinforced base material), frequency is placed on the rubber-like elastic sheet 17. A core material 1 (aromatic polyamide honeycomb core) made of a non-metallic material in which a selection plate 3 is bonded to the front and back surfaces via an adhesive 2 is placed, and at least one fiber reinforced resin sheet 18 (fiber reinforced base material) is placed. The stacked body W is formed by sequentially stacking the layers.

  Thereafter, tapered dams 19 and 19 are disposed on the side surface of the laminated body W on the rubber-like elastic sheet 17, and a spiral hose 20 covered with an air weave is disposed on the suction side. The resin material inlet 21 and the peripheral portion of the suction pipe 22 connected to the hose 20 are covered with a film-like vacuum back 23 and the peripheral portion is sealed on the base member 12 with an adhesive tape 24 or the like.

  Thereafter, the tilting means 15 causes the base member 12 to be placed on the reaction resin material supply side, that is, the resin material input port 21 on the lower side, and on the suction side, that is, the suction pipe 22 on the upper side, with a predetermined inclination angle, A resin material that is inclined at an angle of ° and is uniformly vacuumed by a vacuum pump P connected to a vacuum pipe 24 in the vacuum bag 23 and connected to the resin material supply tank 25 in a vacuum state. A normal temperature curable reactive resin material Q (for example, a thermoplastic material such as vinyl ester) is supplied from the inlet 21 to the fiber reinforced resin sheet 18 of the laminated body and uniformly impregnated, and impregnated by the reaction heat of the reactive resin material Q. Harden.

  When the reactive resin material Q is injected in this way, the air accumulated on the tool surface side moves upward as the support plate 13 tilts, and is sucked by the vacuum pump P and easily exhausted to the suction side. I can do it. Therefore, it is possible to prevent defective resin impregnation in the molded product after curing and effectively prevent defective products.

  As described above, since the reaction resin material Q is uniformly supplied at a uniform pressure to be impregnated and cured, the reaction resin material Q does not directly contact the metal base member 12 having a large heat capacity. The reaction heat generated by the molded product W is not absorbed by the metal base member 12 and curing failure can be effectively prevented, and a product with no unevenness can be manufactured.

  Further, since the rubber-like elastic sheet 17 also has a releasing effect on the resin material, it is not necessary to apply a release agent in advance, and the resin molded product W can be released or released smoothly from a metal mold or metal plate. I can do it. As a result, productivity can be improved.

  Furthermore, since the rubber-like elastic sheet 17 also has a mold release effect on the resin material, it is not necessary to apply a release agent in advance, and the resin molded product W can be smoothly released or peeled from the metal mold or metal plate. I can do it. As a result, productivity can be improved.

  Thus, when manufacturing a large fiber-reinforced resin molded product, the reaction resin material Q is extracted using the spiral hose 20 covered with the air weave as described above, so that the resin material is given a time difference. The reaction resin material Q can be uniformly impregnated.

In addition, as an Example of this invention, the magnitude | size (length x width x thickness) of the laminated body W which consists of a fiber reinforced resin molding, for example: 4 m x 7 m x 10 mm
Suction pressure by vacuum pump: 0.1Mpa
Amount of resin material supplied from the resin material supply tank 25 for the reactive resin material Q: 420 kg
It should be noted that the flow rate is initially high and gradually decreases.

FIG. 3 is an exploded perspective view of a honeycomb sandwich panel incorporating a frequency selection plate embodying the present invention. It is a perspective view of the honeycomb sandwich panel of this invention. It is a perspective view of the fiber reinforced plastic panel laminated | stacked integrally. FIG. 3 is a partially enlarged cross-sectional view of a vacuum resin transfer molding apparatus in which the method for manufacturing a honeycomb sandwich panel of the present invention is implemented. It is a front view of the shaping | molding worktable body before tilting. It is a front view of the forming worktable body after tilting.

DESCRIPTION OF SYMBOLS 1 Core material 2 Liquid adhesive 3 Metal foil 4 Through-hole 5 Frequency selection board 10 Molding worktable body 11 Support frame 12 Base member 13 Support plate 14 Hinge 15 Inclining means 16 Stopper member 17 Rubber-like elastic sheet 18 Fiber reinforced resin sheet 19 Tapered dam 20 Hose 21 Resin material inlet 22 Suction pipe 23 Vacuum back 24 Adhesive tape 25 Resin material supply tank Q Reaction resin material W laminate

Claims (5)

A rubber-like elastic sheet was laid on a metal base member provided with a tilting means, and a fiber-reinforced base material and a frequency selection plate having a plurality of through holes were adhered to the front and back surfaces on this rubber-like elastic sheet. After a honeycomb core made of a nonmetallic material and a fiber reinforced base material are sequentially laminated at least one layer, the whole is covered with a film-like vacuum back, and the base member is placed on the reaction resin material supply side downward by the tilting means. In the state where the suction side is on the upper side, the reaction resin material is supplied from one of the laminates while the laminate in the vacuum bag is vacuumed, and the reaction resin material is uniformly sucked from the other of the laminates, the method for manufacturing a honeycomb sandwich panel formed by laminating a frequency selective plate, characterized in that curing with uniformly impregnated with the reaction resin material into the fibrous reinforcement material. 2. The method for manufacturing a honeycomb sandwich panel in which frequency selection plates are laminated according to claim 1, wherein the size of the plurality of through holes formed in the frequency selection plate is set to a diameter of 0.5 mm to 3.0 mm. The manufacturing method of the honeycomb sandwich panel which laminated | stacked the frequency selection board of Claim 1 or 2 which inclines a base member to 45 degrees-70 degrees by the said inclination means. Wherein arranged spiral hose to the other of the laminate covered with a vacuum bag, according to claim 1 for uniformly withdrawing the reaction resin material by connecting a plurality of the suction pipe at a predetermined interval in the hose, 2 or A method for manufacturing a honeycomb sandwich panel in which the frequency selective plates according to 3 are laminated. A honeycomb sandwich panel in which the frequency selective plates according to claim 1, 2, 3, or 4 are laminated, wherein the honeycomb core is one selected from aromatic polyamide fiber, foam material, syntactic foam, and wood. Method.

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