JP6840277B1 - 積層板の製造方法 - Google Patents
積層板の製造方法 Download PDFInfo
- Publication number
- JP6840277B1 JP6840277B1 JP2020029005A JP2020029005A JP6840277B1 JP 6840277 B1 JP6840277 B1 JP 6840277B1 JP 2020029005 A JP2020029005 A JP 2020029005A JP 2020029005 A JP2020029005 A JP 2020029005A JP 6840277 B1 JP6840277 B1 JP 6840277B1
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- JP
- Japan
- Prior art keywords
- foamed resin
- honeycomb structure
- plate
- fiber
- resin plate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/08—Dimensions, e.g. volume
- B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
- B32B2309/105—Thickness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2375/00—Polyureas; Polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract
Description
前記ハニカム構造体の厚み方向両側に繊維層をそれぞれ配置するに伴い、該繊維層のうちの少なくとも一方側の繊維層と前記ハニカム構造体との間に、硬化し且つ該ハニカム構造体の圧縮強度よりも低い圧縮強度とされる発泡樹脂板を介在させ、
前記両繊維層を前記ハニカム構造体に向けて圧縮するに伴い、その圧縮力を利用して前記発泡樹脂板を充填材料として前記ハニカム構造体の各貫通孔に押し込む構成とされている。
前記発泡樹脂板として、該発泡樹脂板の圧縮強度が前記ハニカム構造体の圧縮強度よりも小さく且つ該ハニカム構造体の圧縮強度よりも小さい所定の圧縮強度以上とされ、しかも、該発泡樹脂板の単位厚み当たりの伸び率が所定値以下とされたものを用いる構成とされている。
前記発泡樹脂板の単位厚み当たりの伸び率についての所定値を決定するに当たり、該発泡樹脂板の板厚と伸び率とに基づく、前記ハニカム構造体に対する該発泡樹脂板の挿入結果の良否を利用して、該発泡樹脂板の板厚と伸び率とを座標軸とする座標上において、該ハニカム構造体に対する該発泡樹脂板の挿入結果の良否を区画する境界線を作成し、該境界線の勾配を求める構成とされている。
前記発泡樹脂板として、発泡度合いが異なる複数種類のものを用意して、製造に当たって、該複数種類の発泡樹脂板の中から使用のための発泡樹脂板を選択する構成とされている。
前記発泡樹脂板が、板状の発泡ポリウレタンであり、
前記繊維層に供給する樹脂がポリウレタン生成混合物である構成とされている。
前記未硬化状態の樹脂として、未硬化状態の発泡樹脂を用い、
前記他方の繊維層として、前記未硬化状態の発泡樹脂に対する透過性に関し、該他方の繊維層の透過性が前記一方の繊維層の透過性よりも高いものを用い、
その上で、先ず、前記一方の繊維層に対する前記未硬化状態の発泡樹脂の付与により該未硬化状態の発泡樹脂を該一方の繊維層に含浸させ、
次に、前記他方の繊維層を前記一方の繊維層よりも上側配置となる姿勢状態とした上で、該他方の繊維層に対する前記未硬化状態の発泡樹脂の付与により該未硬化状態の発泡樹脂を該他方の繊維層を介して前記多孔体の各貫通孔内に供給する構成とされている。
前記多孔体がハニカム構造体をもって形成されている構成とされている。
(8)前記(1)〜(5)、(7)のいずれかの構成の下で、
前記ハニカム構造体が、紙材製のペーパーハニカム構造体である構成とされている。
各種発泡樹脂板(発泡ポリウレタン樹脂板)の試験片について、圧縮強度を測定した。試験は、JIS規格(JIS K 7220;2006)に基づき、各種試験片として50mm×50mmのものを試験速度1mm/minで圧縮し、元の板厚の10%変形時の荷重を測定した。また、各種試験片の取り出し材料である発泡樹脂板をペーパーハニカム構造体4上に載せて加圧し、ペーパーハニカム構造体4の各貫通孔5内に発泡樹脂板が充填材料として満たされた挿入(充填)状態になるか否かを判定した。このとき、ペーパーハニカム構造体4として、相当貫通孔径としてのセルサイズが6mm、板厚が18mm、圧縮強度(元の板厚の10%変形時の圧縮強度)が371.1kPaのものを用い、発泡樹脂板に対する加圧力を1000Nとした。
各種発泡樹脂板(発泡ポリウレタン樹脂板)の試験片について、伸び率を測定した。試験は、JIS規格(JIS K 6400-5;2012)に基づき、各種試験片について引張速度5mm/minで引張り、その際測定した測定値に基づき伸び率を求めた。この場合、各種試験片の試験に当たり、3つの同じ試験片の試験結果の平均値を各種試験片の試験結果とした。また、各種試験片が、図9において用いた試験片と同じものであるときには、試験結果を示す図10の「サンプルNo」において、先頭の数字を、図9に示す「サンプルNo」の数字と同じとした。さらに、発泡樹脂板からの各種試験片の取り出しに当たり、同じ発泡樹脂板(密度が同じ)の下で、その試験片の伸び方向の向きを90度異ならせたもの(発泡樹脂板の縦方向及び横方向のもの)をそれぞれ準備し、それら各方向のものを、後述の図10の密度欄において、密度(値)を同じにしつつも、「(縦)」「(横)」として区別して示し、そのことを、「サンプルNo」において、先頭数字に続く数字「−1」により「(縦)」方向のもの、先頭数字に続く数字「−2」により「(横)」方向のものとして示した。
(1)発泡樹脂板として、発泡ポリウレタン以外の発泡樹脂からなる発泡樹脂板を用いること。
(2)液状の発泡樹脂8C(8B)として、ウレタン樹脂以外のものを用いること。
2 コア層
3 繊維強化層
4 ペーパーハニカム構造体(多孔体)
5 貫通孔
6 発泡樹脂
6A 発泡樹脂板
7 繊維シート
7A 一方の繊維シート
7B 他方の繊維シート
8A 硬化後の熱硬化性樹脂
8B 未硬化状態の熱硬化性樹脂
8C 液状(未硬化状態)の発泡樹脂
10 積層体
B 境界線
Claims (8)
- 複数の各貫通孔が隣合うようにして形成される板状の多孔体としてのハニカム構造体を用意し、該ハニカム構造体の厚み方向両側に繊維層を配置し、該各繊維層に該各繊維層の外方側から未硬化状態の樹脂をそれぞれ供給した上で、該樹脂が供給された両繊維層を前記ハニカム構造体に向けて圧縮すると共に該圧縮状態の下で該樹脂を硬化させて、該ハニカム構造体の厚み方向両側に繊維強化層を形成する積層板の製造方法において、
前記ハニカム構造体の厚み方向両側に繊維層をそれぞれ配置するに伴い、該繊維層のうちの少なくとも一方側の繊維層と前記ハニカム構造体との間に、硬化し且つ該ハニカム構造体の圧縮強度よりも低い圧縮強度とされる発泡樹脂板を介在させ、
前記両繊維層を前記ハニカム構造体に向けて圧縮するに伴い、その圧縮力を利用して前記発泡樹脂板を充填材料として前記ハニカム構造体の各貫通孔に押し込む、
ことを特徴とする積層板の製造方法。 - 請求項1において、
前記発泡樹脂板として、該発泡樹脂板の圧縮強度が前記ハニカム構造体の圧縮強度よりも小さく且つ該ハニカム構造体の圧縮強度よりも小さい所定の圧縮強度以上とされ、しかも、該発泡樹脂板の単位厚み当たりの伸び率が所定値以下とされたものを用いる、
ことを特徴とする積層板の製造方法。 - 請求項2において、
前記発泡樹脂板の単位厚み当たりの伸び率についての所定値を決定するに当たり、該発泡樹脂板の板厚と伸び率とに基づく、前記ハニカム構造体に対する該発泡樹脂板の挿入結果の良否を利用して、該発泡樹脂板の板厚と伸び率とを座標軸とする座標上において、該ハニカム構造体に対する該発泡樹脂板の挿入結果の良否を区画する境界線を作成し、該境界線の勾配を求める、
ことを特徴とする積層板の製造方法。 - 請求項1〜3のいずれか1項において、
前記発泡樹脂板として、発泡度合いが異なる複数種類のものを用意して、製造に当たって、該複数種類の発泡樹脂板の中から使用のための発泡樹脂板を選択する、
ことを特徴とする積層板の製造方法。 - 請求項1〜4のいずれか1項において、
前記発泡樹脂板が、板状の発泡ポリウレタンであり、
前記繊維層に供給する樹脂がポリウレタン生成混合物である、
ことを特徴とする積層板の製造方法。 - 複数の各貫通孔が隣合うようにして形成される板状の多孔体を用意し、該多孔体の厚み方向両側に繊維層を配置し、該繊維層のうちの一方の繊維層及び他方の繊維層に未硬化状態の樹脂をそれぞれ付与した上で、該樹脂が付与された両繊維層を前記多孔体に向けて圧縮すると共に該圧縮状態の下で該樹脂を硬化させる積層板の製造方法において、
前記未硬化状態の樹脂として、未硬化状態の発泡樹脂を用い、
前記他方の繊維層として、前記未硬化状態の発泡樹脂に対する透過性に関し、該他方の繊維層の透過性が前記一方の繊維層の透過性よりも高いものを用い、
その上で、先ず、前記一方の繊維層に対する前記未硬化状態の発泡樹脂の付与により該未硬化状態の発泡樹脂を該一方の繊維層に含浸させ、
次に、前記他方の繊維層を前記一方の繊維層よりも上側配置となる姿勢状態とした上で、該他方の繊維層に対する前記未硬化状態の発泡樹脂の付与により該未硬化状態の発泡樹脂を該他方の繊維層を介して前記多孔体の各貫通孔内に供給する、
ことを特徴とする積層板の製造方法。 - 請求項6において、
前記多孔体がハニカム構造体をもって形成されている、
ことを特徴とする積層板の製造方法。 - 請求項1〜5,7のいずれか1項において、
前記ハニカム構造体が、紙材製のペーパーハニカム構造体である、
ことを特徴とする積層板の製造方法。
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