JP6467850B2 - Method for manufacturing honeycomb core material - Google Patents

Description

  The present invention relates to a method for manufacturing a honeycomb core material useful as a constituent material of a honeycomb structure material that can be used for various applications such as building materials such as roofing materials and interior materials, and decorative materials such as signboards.

  A honeycomb core material, which is an aggregate of countless cells (small chambers) having various opening shapes such as a triangle, a quadrangle, and a hexagon, has a honeycomb sandwich structure sandwiched between two plates (skin layers), for example. It exhibits excellent properties such as light weight and high strength. Therefore, the honeycomb core material has been attracting attention as a constituent material used in various industries such as the construction industry, the automobile industry, and the aerospace industry.

  As a manufacturing method of such a honeycomb core material, conventionally, a sheet is formed from resin pellets, two sheets are stacked, and the sheets are bonded to each other at an appropriate interval, and the two sheets are respectively attached to both sides. By pulling, a sheet body in which a large number of cells are arranged is formed, and this is bonded with a liquid adhesive to form a honeycomb core material. There has been known a corrugation method in which a sheet body in which a large number of cells are arranged is formed, and this is bonded with a liquid adhesive material to form a honeycomb core material.

  As a special manufacturing method, for example, in Patent Document 1, after filling a void of the honeycomb core with a soft resin foam, the soft resin foam is impregnated with a liquid of a two-part curable resin, and then the honeycomb core is There is disclosed a method in which a face material and a honeycomb core are pressure-bonded by placing them between face materials, placing them on a mold and pressurizing them.

  Furthermore, in Patent Document 2, regarding a batch-type manufacturing method of a honeycomb core, a cage roller having a hexagonal bar is operated in association with a number of main hexagonal bars on a fixed base, A corrugated web is formed by the compression action of the hot thermoplastic web between the fixed base bars. The corrugated web thus made is assembled into a honeycomb structure by placing the first corrugated web on the main bar of the platform, followed by placing the secondary bar at the knot above the web. The second corrugated sheet is then placed so that its connection point is adjacent to the abdomen of the first web and another layer of secondary bars is placed on top. This procedure is repeated until the desired honeycomb thickness is reached. At this time, a method is disclosed in which the assembly is placed between a curl plate and a platen and heated to produce a final honeycomb product.

Japanese Patent Laid-Open No. 62-249732 U.S. Pat. No. 3,356,555

  The conventional method of continuously manufacturing honeycomb core material from resin pellet raw material or resin sheet is a problem that it is difficult to reduce the manufacturing cost of the honeycomb core material because the manufacturing line becomes long and the manufacturing equipment becomes large Was holding. In addition, since it is necessary to go through an adhesive application process, a liquid resin impregnation process, and the like, there is also a problem that production efficiency is lowered.

  Therefore, the present invention does not continuously manufacture the honeycomb core material from resin pellets or resin sheets, but can use a commercially available intermediate material as a raw material, thereby improving the production efficiency while reducing the manufacturing cost. Therefore, a new method for manufacturing a honeycomb core material is proposed.

  In the present invention, a wall portion that is long in one direction is disposed between two face plates at appropriate intervals in a direction perpendicular to the one direction, and a plurality of long pieces are provided between the two face plates. A hollow body provided with a simple cell is cut at an appropriate interval in the one direction so as to be divided into a plurality of cell row hollow bodies having a structure in which a large number of cells are arranged, and obtained in the dividing step. The formed cell row hollow bodies are arranged so that the face plate portions face each other, and a thermoplastic resin film is interposed between the face plate portions, and the thermoplastic resin film is heated to bond the face plate portions. A method for manufacturing a honeycomb core material comprising a cell row hollow body bonding step is proposed.

According to the method for manufacturing a honeycomb core material proposed by the present invention, since a commercially available hollow body can be used as a raw material, it is manufactured in comparison with a case where a honeycomb core material is continuously manufactured from resin pellets or resin sheets. The production line of the honeycomb core material can be reduced because the production line can be continuously produced with simple equipment without increasing the line length and the production equipment.
Moreover, since a material is bonded using a thermoplastic resin film, it is not necessary to use a liquid adhesive. As a result, work handling and work environment can be greatly improved.

It is the perspective view which showed an example of the hollow body. It is the perspective view which showed an example of the state which divided | segmented the said hollow body into the several cell row | line | column hollow body. (A) is the perspective view which showed an example of the state which interposed the thermoplastic resin film between two said cell row | line hollow bodies, (B) is a thermoplastic resin film between cell row | line hollow bodies It is the top view which showed an example of the state which made the cell row | line coupling | bonding hollow body bonded by interposing. (A) is the perspective view which showed an example of the state which interposed the thermoplastic resin film between two said cell row coupling | bonding hollow bodies, (B) is thermoplasticity between cell row coupling | bonding hollow bodies It is the top view which showed an example of the state which adhered and interposed the resin film. It is the perspective view which showed an example of the honeycomb core material. It is the front view which showed an example of the hollow body. (A) is a perspective view showing an example of a state in which a thermoplastic resin film is interposed between two hollow cell bodies and pressed by a pressing member, and (B) is a state of that state. It is a top view. It is the perspective view which showed an example of the press member.

  Next, an example of an embodiment (referred to as “this embodiment”) according to an example of the present invention will be described. However, the present invention is not limited to the embodiment described below.

<Honeycomb core material manufacturing method>
In the present embodiment, between the two face plates 2 and 2, wall portions 4, 4... Elongated in one direction are disposed at an appropriate interval in a direction orthogonal to the one direction, and the two sheets A hollow body 1 (see FIG. 1) having a plurality of long cells 5, 5,... Between the face plates 2, 2 is cut at an appropriate interval in the one direction as shown in FIG. , Dividing into a plurality of cell row hollow bodies 1A, 1A... Having a configuration in which a large number of cells 5A, 5A.
Next, as shown in FIGS. 3A and 3B, the cell array hollow bodies 1A and 1A obtained in the dividing step are arranged so that the face plate portions 2A and 2A face each other, and the face plate portion A thermoplastic resin film 6 is interposed between 2A and 2A, and the thermoplastic resin film 6 is heated to bond the face plate portions 2A and 2A to form a cell array coupled hollow body 1B (cell array hollow body). Bonding process),
Next, the cell row bonded hollow bodies 1B and 1B obtained by bonding in the cell row hollow body bonding step are bonded to each other using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step. Using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step, the cell row bonded hollow bodies 1C and 1C obtained by forming the row connection hollow body 1C and then bonding the cells in the above step are used. The honeycomb core material 10 can be manufactured by repeating the bonding process of the cell row bonded hollow bodies as necessary (honeycomb core material forming process).

  In the present invention, three or more cell row hollow bodies 1A, 1A,... Are arranged so that the adjacent face plate portions 2A, 2A face each other, and a thermoplastic resin film 6 is interposed between each face plate portion 2A, 2A. Thus, three or more cell row hollow bodies 1A, 1A,... Can be bonded at a time, and the honeycomb core material 10 can be manufactured in this way.

<Honeycomb core material>
The honeycomb core material 10 manufactured in the present embodiment is a member having a configuration in which a plurality of rows of cells opened in the same direction are arranged in parallel.
The cell is a room having a structure including a space penetrating in the thickness direction of the honeycomb core material, opening both end surfaces in the thickness direction and being surrounded by a wall portion.

Examples of the material of the honeycomb core material 10 include paper, resin, metal and fiber, and composite materials thereof. However, it is not limited to these.
Among these, from the viewpoint of easy adhesion with a thermoplastic resin film, the material of the honeycomb core material 10 is particularly preferably paper or resin, and among them, the one made of thermoplastic resin is particularly preferable.
The dimensions of the honeycomb core material 10 are preferably adjusted as appropriate according to the application. For example, a material having a thickness (height) of 1 mm to 100 mm, a wall thickness of 0.2 mm to 30 mm, and a cell space pitch of 2 mm to 40 mm can be formed.

  The honeycomb core material 10 is useful as a constituent material of a honeycomb structure material that can be used for various applications such as building materials, decoration materials, and automobile parts. Since the honeycomb core material 10 can be formed from a transparent plastic, it is particularly useful for applications such as building materials and decorative materials.

<Hollow body>
In the hollow body 1 used as a raw material in the present embodiment, the wall portions 4, 4 which are long in one direction are appropriately spaced in a direction perpendicular to the one direction between the face plates 2 and 2 made of thermoplastic resin. And a plurality of long cells 5, 5... Are provided between the face plates 2 and 2.

In this embodiment, the honeycomb core material 10 can be manufactured efficiently and inexpensively by using such a hollow body 1 as a raw material.
The hollow body 1 may be manufactured by itself or purchased.
By appropriately selecting the opening size and thickness of the hollow body 1, the mechanical characteristics of the honeycomb core material 10 can be designed as appropriate.

Examples of the material of the face plates 2 and 2 of the hollow body 1 include paper, resin, metal and fiber, and composite materials thereof. Among these, from the viewpoint of easy adhesion with a thermoplastic resin film, paper or resin, and among them, those made of thermoplastic resin are particularly preferable. Examples thereof include thermoplastic resins such as polyethylene, polypropylene, polystyrene, polycarbonate, and polyethylene terephthalate (PET). Among these, polyethylene terephthalate (PET), polycarbonate and the like are particularly preferable from the viewpoint of transparency.
On the other hand, the material of the wall 4 provided between the face plates 2 and 2 in the hollow body 1 may be the same as or different from the face plates 2 and 2.

  The opening shape of the long cell 5 may be a triangle, a quadrangle (rectangle, square, trapezoid, etc.), a hexagon, an octagon, or the like. Further, as shown in FIG. It may be a complicated shape.

  As shown in FIG. 6, the hollow body 1 may be a hollow body 1 having three or more face plates 2. That is, three or more face plates 2,2. .. May be configured such that a plurality of wall portions 4, 4... Are disposed between two adjacent face plates 2, 2.

<Division process>
In the dividing step, as shown in FIG. 2, the hollow body 1 is cut at an appropriate interval in the length direction of the long cells, and a plurality of cells having a configuration in which a large number of cells are arranged in a row. What is necessary is just to divide into row | line | column hollow body 1A, 1A ....
At this time, as shown in FIG. 6, in the case of the hollow body 1 having three or more face plates 2, it can be divided into cell row hollow bodies 1A, 1A,.

  Since the interval at which the hollow body 1 is cut becomes the thickness of the honeycomb core material 10, the thickness of the honeycomb core material 10 to be finally formed is changed by changing the interval to be cut according to the use of the honeycomb core material 10 or the like. Can be changed as appropriate.

  Examples of a method for cutting the hollow body 1 include a hand cut method, a wire cut method, an NC cut method, and a laser cut method.

<Cell row hollow body adhesion process>
In the cell row hollow body bonding step, as shown in FIG. 3, the cell row hollow bodies 1A, 1A divided in the dividing step are arranged so that the face plate portions 2A, 2A face each other, and the face plate portion 2A, The thermoplastic resin film 6 is interposed between 2A, the thermoplastic resin film 6 is heated to bond the face plate portions 2A and 2A, and the cell array hollow bodies 1A and 1A are joined to each other to connect the cell array coupled hollow bodies. 1B is formed.

  In order to arrange the cell row hollow bodies 1A, 1A obtained in the dividing step so that the face plate portions face each other, the face plate portions 2A, 2A of the cell row hollow bodies 1A are erected and the cells 5A, 5A .., So that each cell row hollow body 1A is changed by 90 degrees such that the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A face each other. .

  Next, the thermoplastic resin film 6 is inserted and interposed between the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A.

(Thermoplastic resin film)
The thermoplastic resin film 6 is melted by heating, and has a glass transition temperature (Tg) lower than at least the glass transition temperature (Tg) of the face plate portions 2 and 2 of the hollow body 1 and the face plate portions 2 and 2. Any film may be used as long as it is made of a resin having good compatibility with the material constituting the material. For example, a film using a non-crystalline polyester such as glycol-modified polyester (PETG) or a resin such as poly (meth) acrylic acid alkyl ester such as polymethyl methacrylate can be cited as a preferred example.
The thermoplastic resin film 6 may contain a filler or a fiber from the viewpoint of strength.

It is preferable that the glass transition temperature of the thermoplastic resin film 6 is lower than the glass transition temperature of the face plate portion of the hollow body. Especially, it is preferable that the glass transition temperature of the thermoplastic resin film 6 is 10 degreeC or more lower than the glass transition temperature of the faceplate parts 2 and 2 of the hollow body 1, and it is 15 degrees C or more especially, and it is more preferable that it is 20 degrees C or more especially low Even more preferred.
From such a viewpoint, the glass transition temperature (Tg) of the thermoplastic resin film 6 is preferably 30 ° C. to 130 ° C., more preferably 40 ° C. or more and 110 ° C. or less, particularly 50 ° C. or more or 90 ° C. or less. preferable.

The thermoplastic resin film 6 is preferably made of a material compatible with at least the face plate portion 2 of the hollow body 1.
From such a viewpoint, for example, if the face plate portion 2 of the hollow body 1 is polycarbonate, the material of the thermoplastic resin film 6 is poly (meth) acrylic acid alkyl ester such as polymethyl methacrylate, α-olefin and ( A copolymer of an alkyl methacrylate (meth), an amorphous polyester such as glycol-modified polyester (PETG), polyurethane, polyvinyl chloride, an acrylonitrile-butadiene-styrene copolymer, and the like are preferable.
If the face plate portion 2 of the hollow body 1 is a crystalline polyester such as polyethylene terephthalate, the thermoplastic resin film 6 is made of an amorphous polyester such as glycol-modified polyester (PETG), a polyester-based thermoplastic elastomer, or the like. Is preferred.
Moreover, when the face plate part 2 of the hollow body 1 is polymethylmethacrylate, the material of the thermoplastic resin film 6 is preferably an amorphous polyester such as polyvinyl chloride or glycol-modified polyester (PETG).

The short width and the long width of the thermoplastic resin film 6 are such that the film 6 does not protrude between the face plate portions 2A and 2A when interposed between the face plate portions 2A and 2A of the cell array hollow body 1A. The height or length of the portion 2A is preferably the same as or shorter than that. However, it may be long.
The thickness of the thermoplastic resin film 6 is preferably 20 μm to 150 μm, more preferably 30 μm or more or 100 μm or less, and particularly preferably 40 μm or more or 80 μm or less in consideration of adhesiveness, handling properties, economy, and the like.

When the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A of the adjacent cell row hollow bodies 1A and 1A, it is preferable to press the thermoplastic resin film 6 with the face plate portions 2A and 2A.
At this time, as a method of interposing the thermoplastic resin film 6 between the face plate portions 2A, 2A of the cell array hollow bodies 1A, 1A and pressing the thermoplastic resin film 6 between the face plate portions 2A, 2A, for example, As shown in FIGS. 7A and 7B, the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A of the cell row hollow bodies 1A and 1A, and the outer surface of each face plate portion 2, that is, the film 6 and The pressing member 7 may be brought into contact with the opposite surface, and the pressing plate 7 may press each face plate portion 2A toward the inside, that is, the film side.

The form of the pressing member 7A is arbitrary. For example, as shown in FIGS. 7 (A) and 7 (B), it is only necessary to have a portion that can be inserted into the cell 5A and that can press the face plate portion 2A from the inside of the cell 5A. Is optional.
For example, as shown in FIG. 8, each face plate portion 2A is inserted into a cell 5A by inserting a rod-like pressing portion of a pressing member 7A having a comb shape, that is, a shape in which a plurality of rod-like pressing portions are suspended from a horizontal shaft portion. What is necessary is just to make it press the outer surface of.

(Heating means)
As a means for heating the thermoplastic resin film 6, for example, the cell array hollow bodies 1A and 1A are arranged so that the face plate portions 2A and 2A face each other, and the thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A. The thermoplastic resin film 6 may be heated in a heating furnace with the intervening state interposed therebetween, and the cell array hollow bodies 1A, 1A may be connected to each other with the face plate portions 2A, 2A. Are arranged so that they face each other, and a thermoplastic resin film 6 is interposed between the face plate portions 2A and 2A, and the pressing members 7 are brought into contact with the surfaces of the two face plate portions 2A and 2A that are not in contact with the film 6, respectively. The pressing member 7 may press the face plate portion 2 from both sides to the film side, and the thermoplastic resin film 6 may be heated by heat transfer from the pressing member 7.

  Under the present circumstances, the heating temperature of the thermoplastic resin film 6 should just be higher than the glass transition temperature of the thermoplastic resin film 6, and above all, it is 15 degreeC or more higher than the glass transition temperature of the thermoplastic resin film 6. Preferably, the temperature is higher than 30 ° C. In addition, the temperature is preferably lower than the glass transition temperature of the cell row hollow body 1A.

<Honeycomb core material forming process>
In this step, the cell row bonded hollow bodies 1B and 1B obtained by joining in the cell row hollow body bonding step are bonded using the thermoplastic resin film 6 in the same manner as in the cell row hollow body bonding step. Bonding to form a cell array coupled hollow body 1C.
Next, the cell array bonded hollow bodies 1C, 1C obtained by bonding in the above process are bonded using the thermoplastic resin film 6 in the same manner as the cell array hollow body bonding process, and if necessary, What is necessary is just to form the honeycomb core material 10 by repeating such an adhesion process.

A honeycomb core material having a desired size can be manufactured by appropriately repeating the bonding of the cell row-bonded hollow bodies.
The three or more cell row hollow bodies 1A, 1A,... Are arranged so that the adjacent face plate portions 2A, 2A face each other, and the thermoplastic resin film 6 is interposed between the face plate portions 2A, 2A. The honeycomb core material 10 having a desired size can be manufactured by bonding three or more cell row hollow bodies 1A, 1A,.

<Use of honeycomb core material>
The honeycomb core material 10 manufactured in this way can be used for various applications as it is, or a honeycomb sandwich structure can be manufactured by laminating skin layers on the upper and lower sides. It can also be used.

<Explanation of words>
In the present specification, when expressed as “X to Y” (X and Y are arbitrary numbers), unless otherwise specified, “X is preferably greater than X” or “preferably Y”. It also includes the meaning of “smaller”.
In addition, when expressed as “X or more” (X is an arbitrary number) or “Y or less” (Y is an arbitrary number), it is “preferably greater than X” or “preferably less than Y”. Includes intentions.

  In general, “sheet” is a thin product as defined by JIS and generally has a thickness that is small and flat instead of length and width. In general, “film” refers to length and width. A thin flat product having an extremely small thickness and an arbitrarily limited maximum thickness, usually supplied in the form of a roll (Japanese Industrial Standard JISK6900). For example, in terms of thickness, in the narrow sense, a film having a thickness of 100 μm or more is sometimes referred to as a sheet, and a film having a thickness of less than 100 μm is sometimes referred to as a film. However, since the boundary between the sheet and the film is not clear and it is not necessary to distinguish the two in terms of the present invention, in the present invention, even when the term “film” is used, the term “sheet” is included and the term “sheet” is used. In some cases, “film” is included.

  Next, examples of the present invention will be described.

<Example 1>
Between two face plates (8.8 mm) made of polycarbonate (Tg 153 ° C.) having a thickness of 0.6 mm, a long wall portion made of polycarbonate having a thickness of 0.5 mm is placed in a direction perpendicular to the one direction. A hollow body 1 (thickness 10.0 mm, width 1000 mm, length 2000 mm) provided with a plurality of long cells between the two face plates was prepared with an interval of 5 mm.
As shown in FIG. 2, this hollow body A was cut using an automatic hand-cutting machine at an interval of 8 mm, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells 5A were arranged.
Next, as shown in FIGS. 3 (A) and 3 (B), the direction of the cell row hollow bodies 1A obtained in the dividing step is changed by 90 degrees, and the face plate portions 2A and 2A are arranged to face each other. As shown in FIG. 8, a clip-type press is interposed between the face plate portions 2A and 2A with a thermoplastic resin film 6 made of polymethyl methacrylate (Tg 89 ° C.) having a thickness of 50 μm, a width of 8 mm, and a length of 1000 mm. Using the member 7A, the bar-shaped portion of the clip is brought into contact with the outer surface of the face plate portion 2, and each face plate portion 2A is mechanically pressed by the pressing member 7 so that the thermoplastic resin is interposed between the face plate portions 2A and 2A. The film 6 was clamped. In this state, it is placed in a heating furnace adjusted to a furnace temperature of 128 ° C., the thermoplastic resin film 6 is heated and melted, and the face plate portions 2A and 2A are bonded to produce a cell array coupled hollow body 1B. did.
Next, the thermoplastic resin film 6 is sandwiched between the two cell array coupling hollow bodies 1B produced in the same manner as described above, and the thermoplastic resin film 6 is heated in the heating furnace to heat the face plate portion 2A. 2A was adhered to produce a cell array coupled hollow body 1C. And this was repeated and the honeycomb core material 10 was manufactured.

<Example 2>
Between the two face plates (23.6 mm) made of polycarbonate (Tg 153 ° C.) having a thickness of 0.7 mm, a long wall part made of polycarbonate having a thickness of 0.5 mm is placed in a direction perpendicular to the one direction. A hollow body 1 (thickness 25 mm, width 500 mm, length 1000 mm) provided with a plurality of long cells between the two face plates was prepared with an interval of 5 mm.
As shown in FIG. 2, this hollow body A was cut using an automatic hand-cutting machine at intervals of 28 mm, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells 5A were arranged.
Using the thermoplastic resin film 6 made of polyurethane (Tg 50 ° C.) with a thickness of 70 μm, a width of 28 mm, and a length of 500 mm, the subsequent steps were the same as in Example 1 except that the furnace temperature was adjusted to 100 ° C. A honeycomb core material 10 was manufactured.

DESCRIPTION OF SYMBOLS 1 Hollow body 1A Cell row | line | column hollow body 2 Face plate 2A Face plate part 4 Wall part 5 Long cell 5A Cell 6 Thermoplastic resin film 10 Honeycomb core material

Claims (4)

A wall portion that is long in one direction is disposed between the two face plates at an appropriate interval in a direction perpendicular to the one direction, and a plurality of long cells are provided between the two face plates. The hollow body is cut at an appropriate interval in the one direction, and divided into a plurality of cell row hollow bodies having a configuration in which a large number of cells are arranged; and
The cell array hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, a thermoplastic resin film is interposed between the face plate portions, a pressing member is inserted into the cell, and the face plate the pressing member contacts the outer surface of the part, a face plate portion pressed onto the thermoplastic resin film side by the pressing member, the thermoplastic resin film cell column heated to bond between the surface plate portion hollow adhesin And a method for manufacturing a honeycomb core material. The cell array hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, a thermoplastic resin film is interposed between the face plate portions, a pressing member is inserted into the cell, and the face plate part of the pressing member abuts against the outer surface of the face plate portion by the pressing member placed in a heating furnace in a state of pressing to the thermoplastic resin film side, between said face plate portion by heating the thermoplastic resin film The method for manufacturing a honeycomb core material according to claim 1, wherein: In the cell row hollow body bonding step, the cell row hollow bodies obtained in the dividing step are arranged so that the face plate portions face each other, and a thermoplastic resin film is interposed between the face plate portions, by inserting a pressing member, the pressing member on the outer surface of the face plate section abuts the face plate pressed onto the thermoplastic resin film side by the pressing member, the thermoplastic resin film by heat transfer pressing member The method for manufacturing a honeycomb core material according to claim 1, wherein the face plate portions are bonded together by heating. The method for manufacturing a honeycomb core material according to any one of claims 1 to 3, wherein the pressing member has a shape in which a plurality of rod-shaped pressing portions are suspended from a horizontal shaft portion.

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